JeepCJ Automotive Repair Manual by Larry Warren
and John H Haynes
Member of the Guild of Motoring Writers
Models covered CJ-2A, CJ-3A, CJ-38, CJ-S, CJ-SA, CJ-6, CJ-7 Scrambler, Renegade , Laredo and Golden Eagle Automatic and manual transmissions
ISBN 1 56392 221 5
©
Haynes North America, Inc. 1996 Willi I*T'I'IIIOI'IIrom J H
~ ...
10 Co lid
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic: or mechanical, h:Iuding photocopying, IlKXlI'ding or by any information storage or retrieval system, -Mthout pemVssion in .....ntJng from the copyright holder.
Printed in the USA
i9Z2 - 50020) (412)
Haynes Publishing Group
Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc. BS1 Lawrence Drive Newbury Park California 91320 USA
97-70336
Acknowledgments Special thanks are due 10 American Motors Corporation for their supply of technical information BOO certain illustrations.
About this manual Its purpose The purpose of this manual is to help you get the besl value from your vehicle. It can do so in several ways. It can help you decide what work must be dona, even If you choose to have it done by a dealer ser-
vice department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it oHers diagnostic and repair procedures to follow when trouble occurs. It Is hoped that you will use the manuel to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than ,manging an appointment to get the vehicle into a shop and making the trips to lallve it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of sstisfaction and accomplishment that you feel after having done the job yourself.
Using the manual ' The msnual is divided into Chspters. Esch Chspter is divided into numbered Sections, which are headed in bold type between horizontsllines. Each Section consists of consecutively numbered paragraphs.
The two types of illustrations used (figures and photographsl. sre referenCed by a number preceding their caption. Figure reference numbers denote Chapter and numerical sequence within the Chspter; U.e. Fig. 3.4 means Chapter 3, figure number 4). Figure csptions are followed by a Section number which ties the figure to a specific portion of the text. All photogrephs apply to the Chapter in which they appear and the reference number pinpOints the pertinent Section and paragraph; i.l.l., 3.2 means Section 3, paragraph 2 . Procedures, once described in the text, are not normally repeated . When it is necessary to refer to another Chapter, the reference will be given ss Chapter and Section number i.e. Chapter 1/16). Cross references given without use of the word ' Chapter' apply to Sections and/or paragraphs in the same Chapter. For example, ' see Section B' means in the same Chapter. Reference to the left or right side of the vehicle is based on the assumption that one is sitting in the driver's seat. facing forward . Evan though extreme care has been taken during the preparation of this manual, neither the publisher nor the author can accept respon · sibility for any errors in, or omissions from. the information given.
Introduction to the Jeep CJ The Jeep CJ is available in an open utility body style with a folding windshield. Later models feature removable, folding tops or hsrdtops in both conventional and pick-up styles. Power from the engine is passed through the trsnsmission to a trsnsfar casa and then to tha front snd resr allies by driveshatts. Both msnual and sutomatic trsnsmissions ara available on these vehicles.
Esrly models used a csm snd lever type staering gear while later models featured a recirculating ball type steering gear with power assist as an option. Suspension is by semi-elliptic springs with tubular shock absorbers. Both four-wheel drum and front disC/rear drum brakes are used on these vehicles. with power assist as an option.
Contents
Page
Acknowledgements
0-2
About this manuel
0-2
Introduction to the Jeep CJ
0-2
General dimensions
0-6
Vehicle identification numbers
0-7
Buying perts
0-8
Maintenance techniques, tools end working facilities
0-9
Booster battery (jump) starting
0-15
Jacking end towing
0-15
Automotive chemicals and lubricants
0-16
Safety firstl
0-17
Troubleshooting
0-18
Chapter 1 Tune-up and routine maintenance
1-1
1
Chapter 2 Pert A General engine overhaul procedures
2A-l
2A
Chapter 2 Part B 151 cu in four-cylinder engine
26-'
28
Chapter 2 Part C 150 cu in four-cylinder and aJi in-line six-cylinder engines
2C-1
2C
Chepter 2 Part 0 VB engine
20-1
20
va engine
2E-l
2E
2F-O
2F
Chapter 2 Part E
Chapter 2 Part F L-and F-head four-<: ytinder engines Chapter
3 Cooling, heating and air-conditioning systems
3-1
3
Chapter 4 Fuel and exhaust systems
4-0
4
Chapter 5 Engine electrical systems
5- 1
5
Chapter 6 Emissions control systems
6-0
6
,
Chapter 7 Part A Manual transmission
7A-O
7A
Chapter 7 Part B Automatic transmission
78-1
78
Chapter 7 Part C Transfer case
7C-0
7C
Chapter 8 Driveline
8-1
8
Chapte r 9 Brakes
9-0
9
Chapter 10 Chassis electrical system
10-0
10
Chapter 11 Suspension and steering systems
11-0
11
Chapter 12 Body
12-1
12
Conversion factors Index
INO
, I
1• •
t
0-5
0-6
General dimensions Overall length CJ2 CJ·3 CJ·5
130 in 130 in 139 in
CJ6 CJ-7 1975 through 1981 1982 8nd 1983
15910 148 In
153.2 in
Height CJ-2 CJ-J CJ-5
CJ. CJ·'
66io
66.4,n 68 in 68.4 in 691n
Width CJ-2 CJ·3 CJ-5
CJ-S CJ-7
591n
59 in 59.9 in 59.9 in
59.9 in
Wheelbase CJ-2 and CJ-3 CJ5
80 1n
1954 Ihrough 1972
81 In
1973 through 1983
84 ,n
CJ-6 1959 through 1912
1973 through 1976 CJ·7
101 in 104 in
93.5 in
0-7
Vehicle identification numbers Modifications are a continuing and unpubticized process in vehicle manufacturing. Since spare parts manuals and lists £Ire compiled on 8 numerical basis, the individu81 vehicle numbers are essential to identify Ihe component required.
Vehicle Identification Number (VIM This very important identification numbor is stamped on a plate which is located on the firewall under the hood. On later models the VIN is also attached to the dashboard ned to the windshield on the driver's sida.
JEEP CORP. TOLEDO. OH USA
o
[ 5.1 ... Otde, No.
o
I
Vehicle Idenl,IoClilon IVINI Number
Safety certification label Later models carry this stickar which certifies that federal safety standards ere met. The sticker is located directly below the door opening on the driver's side. The label carries the VIN, gross vehicle weight and {:Iross vehicle a)(le ratings.
Engine identification numbers Important information such as build codes, serial numbers and identification numbers can be found on the engines. On F- and l-head engines. the serial number is stamped on the boss just behind the water
o
SSA&ONo
t"",
I
OplOon No
I
Model No
,~.
Typical vehicla idantiticatlon plate
150 cu in four-cylinder and aU In-line slx-cylinder engine build date code location
F- and l-head engine serial number location
0-8
Vehicle ident ification numbers
rrVB engine build d ate code 10<:811on
pump. On the ve, the code number is located on the right front face o f the engine block, adjaeent to the rocker IIrm cover. The in-line sile cylinder engine build date code is stamped on the machined surface between the number two and three cylinders on the right side. The
va
engine build date code is Itemped on I plete affixed to thll Iront surface of the right valve cover. The 151 cubic inch lour-cylinder engine 10 code is found on the front of the engine block 01 timing cover. In addition, engines bUilt lor use in Georgia have an additional two-digit num~r enclosed by 8sterisks. On six·cylinder engines the number is belOW the build date code, on engines it Is on the left side 01 the block next to the core plug and on lour-cylinder engines it is on the left side of the Ilywheel housing.
va
Manual transmission identification number The transmission identification tag, which dIsplays the vendor part and Jeep part number, is generally found on a tag attached to the upper left side 01 the transmission cover or shilt control.
Automatic transmission serial number The automatic transmission serial number Is found on a tag at tached to the right .ide 01 the transmission case..
15' cu In l our-cylinder engine Id,ntilication code location
Emissions control information label Later modelS have an emIssions contrOl information label which is located in Iront of the rsdiator. ThIS label contains informallon on engIne applicatIOn and tune·up specifications.
Transfer case identification number An identification tag featuring the vendor and Jeep numbers necessary to obtain the proper spare parts is affixed to the t.ansfer case. On the Quadro -T.ac transfel case. the tag IS attached to the real half of the case. On eally model 18 and 20 transfer cases, the identification tag is fastened to the case. while on later model 20 and 300 cases it is held in place by the intermediate shaft lockplate bolt
Buying parts Replacement parts are available from many sources, which general· 1'1 fall intO one 01 two categories - authorized dealer parts departments and independent retaileuto perts stores. Our advice concerning these parts is as follows : Aurhofized dea/af parts dapartlTlfln,; This is the best source fOI parts which are unique to your vehicle and not generally available elsewhere Ii,a. major engine parts, transmission parts. ttim pieces. etc.!. It is also the only place you should buy parts il your vehicle is still under warranty, as non-Iactory paru may invalidate the warranty. To be sure of obtaining the corract part., have your vehicle's engine and chassis numbers available ancl. it possible, takl! tha old parts along for positive
Identllication.
RetlJi/auto parts stores; Good auto parts stores will stock frequently needed componan ts which wear out relatively fast (i,a. clutch com· ponents, exhaust systems. brake parts. tune-up parts. etc. I. These stores often supply new Of reconditioned parts on an exchange basis, which can seve a considerable amount of money. Discount auto parIS stores are often very good places to buy materials and parts needed for general vehicle maintenance Ha oil, grease. filters, spark plugs, belts, touch· up paInt, bulbs. etc.l. They also usually sell tools and general ac· cessories, have convenient hOUfS, charge lower prices, and can often be found not far from '(Our home.
0-9
Maintenance techniques, tools and working facilities Maintenance techniques Thers afB II number of techniques involved in maintenance and repai r
Ih(ll will be refarred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organizad and capable of performing the veriaus tasks properly, which will ensure that the repair job is thorough end complete.
Fasteners Fasteners arB nuts. bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, either II lock washer, locknut, locking lab or thread adhesive. All thread· ed fasteners should be clean and straight, with undamaged threads and undamaged corners on the he)( head where the wrench filS. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber inserts can only be used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts and bolts should bo troated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpentine in a spout·type oil can, which works Quite well. After applying the rust penetrant, let it "work" for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores.
If a bolt or stud breaks off in an assembly, it can be drilled and re o moved with a spacial tool commonly available for this purpose. Most automotive machine shops can perform this task, as well as other rapair procedures Isuch as repair of threaded holes that have been stripped out). Flat washers and lock washers, when removed from an assembly, should always be replaced exactly as removed . Replace any damaged washers with new ones. Always use a flat washer between a lock washer and any soft metal surface Isuch as aluminum), thin sheet metal or plastic.
Fastener sizes For a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners . Therefore, it is important to be able to tell the difference between standard Isometimes called U.S., English or SAEJ and metric hardware, since they cannot be interchanged. All bolts, whether standard or metric, are sized according to diameter, thread pitch and length. For example. a standard 1/2 - 13)( 1 bolt is 1/2 inch In diameter, has 13 threads per inch and is 1 inch long. An M12 - 1.75 x 25 metric bolt is 12 mm in diameter, ha5 a thread pitch of 1.75 mm Ithe distance between thre&dsJand is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable.
T
T_ II _ I
~I
G-
O
~ L
I
Standard ISAE ) bolt dimens!onl/grade markl G L T
o
Grade marks (bolt srrength) Length (in inchesl Thread pitch (number of threads per inch) Nominal diameter (in inchesl
p -
O
L~
~
Metric bolt dimenl ions/grade marks
P - Property class (bolt strength) L - Length (in millimetersl T Thread pitch (distance between threads: in millimeters) D - Nominal diameter (in miffimeters)
0 -10
Maintenance technique s, tools and working facilit ies
In addition to the differences in diameter, thread pitch and length, metric and standard bolts can ,Iso be distinguished bV eXi:lmining Ihe boh heads. To begin with, Ihe distance acroSlS the lIats on II standard bolt need is melsured in inches, while the same dimension on II metric boh is measured In millimeters (lha same is true lor nutsl. As a result , 8 standard wrench should not be used on II metric bolt and II metric wrench should not be used on a stand ard bol t. AIIO, standard bolts have slashes fadie!ing out from the center o f the head to denote the grade or strength of the bolt Iwhieh is an indication ol lhe amount 01 torque the! can be applied to it). TI'Ie greater the number of slashes, the grellter the ,!rength 01 the bolt tgrades 0 through 5 are commonlv used on automobile.). Melric boilS have a property class Igrade) number, ralhar Ihan a sla5h, molded inl o their heads to indicate bolt strang th. In Ihie case, the higher the numbar, Ihe stronger the bolt (propertv cle .. numbers 8 .8, 9.8 and 10.9 are commonlv used on automobiles).
Grade 1 or 2
Gr ade
5
Strength markings can also be used to distinguish standard hex nuts from meuic hex nuts. Standard nuts halle dots stamped into one side, while metric nuts are marked with a number. The greater the number 01 dots, or the higher the number, the greater the strength 01 the nut. Metric studs are also marked on their ends according to property ciass Igrade). Larger .tuds are numberad (the same as metric bolts), while smaller studs carry a geometric co de to denote grade. It should be noted that many lasteners, especiallV Grades 0 through 2, have no distinguishing marks on them. When such Is the case. the onlv way to determine whether It is sUlndard or metric hi to measure the thread pitch or compare it to a known fastener 01 the same size. Slncelasteners 01 the same size lboth standard and metricl may have dillerent strengl h ralings. be sure to reinstall any bolts, studs or nuts removed from you r vehicle in their orlglnol locations. Also, when replacing a lastener wit h a new one, make sure Ihat the new one has a strenglh rating equal to or greater than tha original.
Grade 8
80lt strength markings (top -standar d/S AE , bottom - meltlc)
Maintenance techniques, tools and working facilities Tightenmg sequences and procedures Most threaded fasteners should be tighteoed to e specific torque value (torque is basically a twisting force l. Over-tightening the fasteoer can weaken it and cause it to break. while under-tightening can cause it to eventually come loose. Bolts, screws and studs, depending on the material they are made of and their thread diameters. have specific torque values tmany of which are noted In the Specifications at the beginning of each Chapterl. Be sure to follow the torque recommen dations closely. For fasteners not assigned a apecific torque. a general torque value chart is presented here as a guide. As waa previously mentioned. the slza and grade of a fastener determine the amount of torque that can safely be applied to it . The figures listed here are ep· proximate for Grade 2 and Grade 3 fasteners (htgher grades can tolerllte higher torque values). FaSteners la,d out In a pattern 11.8. cyhoder head bolts, oil pan bolts. dillerential cove. bolts. etc.) must be loosened or tightened In a se quence to aVOid warping the component. This sequence Will normally be shown In the appropriate Chapter. II a specifiC pallern is not given, the follOWing procedures can be used to prevent warping. Initially. the bolts or nuts should be assembled fingeHlght only. Next. they should be tightened one full turn each. In a crlss·cross or diagonal pattern. After each one has been tightened one full turn. return to the first ona and tlghten them all one-half turn. following the same pattern. Finally. tighten each of them one-quarter turn at a time until each fastener has been tightened to tile proper torque. 10 loosen and remove the fasteners. the plocedule would be leversed.
Component disassembly Component disassembly should be done with care aod purpose to Ilelp ensure that the parts go back together properly. Always keep track of the sequence in which parts are removed . Make note of speCial characteristics or marks on parts that can be installed more than one way (such as a grooved thrust washer on a shaft!. It is a good idea to lay the disassembled parts out on a clean surface In the order that they were removed . It may also be halpful 10 make sketches or take instanl photos of components before removal . When removing fasteners from a component, keep track of their locations. Sometimes threading a bolt back In a part. or putting the washers and nut back on a stud, cao prevent mix-ups later. " nuts and bolts caonot be ,elumed to Iheir original locations. they should be kept in a compartmented box 0' a series of small boxes. A cupcake or mullin tin IS Ideal for thiS purpose. since each cavity can hold the bolts and nuts from a parllcular area li.e. oil pan bolts. valve cover boits. engine mount boilS. etc.l. A pan of this type is especially helpful when work· ing on assemblies with very small parts. such as the carburetor. alter·
Metric thread sizes M·6 M·8
M·l0 .. M-12 M-14
Pipe thread sizes 1/8 1/' 318
... .. -.
1/2
U.s.
0-11
oator. valve train or interior dash and trim pieces. The cavllJea can be marked With paint or tape to identify the contents. Whenever wiring looml, harnesses or connectors are separatfld. it's a good idea to identify the tw<> halves wtth numbered pieces of masking tape so they can be easily raconnected .
Gaske t sealing surfaces Throughout any vehicle. gaskets are used to seal the mallng sur faces between two parts and keep lubricants. fluids. vacuum or pressure contained in an aSlembly. Many times these gaskets ara coated with a liquid or paste-type gasket sealing compound before assembly. Age, heat and pressure can sometimes cause the two parts to Slick together so tightly that they are very difficult to separale. Ollen. the assembly can be looseo&d by striking il with a soft-fec::ad hammer ne&l" the mating surfaces. A regular hammer can be used if a block of wood is placed between the hem· mar and the part. 00 not hammer on cast parts or parts that could be eaSily damaged. With any particularly stubborn part, always recheck to make sure that every fastener has been removed . Avoid using a screwdriver or bar to pry apart an assembly. as they can eesily mar the gasket sealing surfaces of the parts (which must remain smooth). If prying Is absolutely necessary. use an old broom handle. but keep in mind that exIra clean -up will be necessary if the wood splinters. After Ihe parts are separated, the old gasket must be carefully scraped off and the gasket surfaces claaned. Stubborn gasket mIIteriai can be soaked with rust peoe"ant or t,eated with a special chamical 10 501Ien it so it can be easily scraped off. A scraper can be lashjooed from a piece of copper tubing by lIatteoing and sharpening one end Copper is recommended because it ia usually softer than the surfaces to be scraped. which rflduces the chance of gouging the part. Some gaskets can be removed with a wire brush, but regardless of the method used, the mating surfaces must be left clean and smooth. If for some reason the gasket surface il gouged. then a gasket sealer thick enough to fill scratches will have to be usad during reassembly of the com· ponents. For most applications. a non-drying (or semi-drying) gasket sealer should be used.
Hose removal tips Caution: If rhf! "'flhiclfl is f/(juipped With ai' condirioning, do not disconnect any of the AIC hoses without first MVing tlHIsystem depMS$unzed by a deale, service department 0' an ai, conditioning specilllist. Hose removal precautions closely parallel gasket removal precau tions. Avoid scratching or gouging the lurface that the hosa mates against or the connection may leak. This Is especially Irue for radiator
Ft-Ib 6 to 9 14 to 21 28 to 40 50 to 71 80 to 140
Nm 9 to 12 19 to 28 38 to 54 68 to 96 109 to 154
5 to B 12 to 18 22 to 33 25 to 35
7 to 10 17 to 24 30 to 44 34 to 47
6 to 9 12 10 18 14 to 20 22 to 32 27 to 38 40 to 55 4010 60 55 10 80
9 to 12 11 to 24 19 to 27 30 to 43 37 to 51 55 to 74 55 to 81 75 to 108
thread sizes
1/4 - 20 5 /16 - 18
5116 3.8 318 7f16 7/16 112 -
24 16 24 14 20. 13
. . . .. . ... -
.. ..
0-12
Maintenance techniques, tools and working facilities
hosel. Because of various chemical reactlont, the rubber in hoses cln bond itself to the meliispigot that Ihe hose fiu over. To remove a hosa, lirst loosen the hal. clamps that securei! to Ihe spigot. Then, with .Iip-joint pilafs, grab the hose at the clamp and rotate it around the spigot. Work it back and forth until it i. completely free, then pull it off. Silicone or alh" lubricants will esse removel if they cen be applied between the hos8 and the outside of tha spigot. Apply the ume lubllcant to the Inlide of the hose and the Qutslde of the spigot to simplify installation. As 8 18st resort land If the hose is to be replaced with. new one anyway). the rubber clln be slit with II knife end the hOle peeled from the spigot. If thla must be done, be careful that the metal connection Is not damaged. If e hose clamp ia broken or damaged, do not reuse it. Wire·type ciampa usually weaken with aga, so it ia a good idea to replace them with screw·type ciampa whenever a hose ia removed.
penSIve, ale Invaluable because 01 their versatility (especially when various eKtensionland drives are available). We recommend the 112·inch drive ovel the 3lS·lnch drive. Although the larger drive is bulky and more expensive. It has the capacity of ecceptlng a very wide range of large sockets Udeally, the mechanic would have a 3lS'lnch dflve set and a 1 /2~inch drive sell. Socket set(sl Reversible mtchet Extension - '0 in UniV'8rsal joim Torque wrench (same size drive as sockets) Ball peen hemmer - B oz Soft·faced hemmer (plestic/rubber) Standard scnwdriver (1/4 in x 6 in) Stendard scnwdriver (stubby - 5/16 in) Phillips screwdriver (No. 3 x B m) Phillips screwdriver (stubby - No. 2) Pfief$ - vise grip Plief$ - linemen's Pliers - needle nose Pliers - snep·ring (internal and elCternalJ Cold chisel - 1/2 in Scriber Semper (made from flattened copper tubmg) Center purwh Pin punches (1116. 'IB, 3/16 in)' Steel ru/e/$'fflightadge - 12 in Allen wrench set (11B to 31B in or 4 mm to 10 mm) A selection of files Wire brush (large) Jackstands (second ser) Jack (scissor or hydfflu/ic type)
Tools A selection of good 1001. i. I basic requirement for anyone who plans to malnlain and repair his or her own vehicle. For Ihe owner who has few lools, if any, the Initlallnveslment might seem high, but when com· pered to the spil1lllng coati of professional auto mainteneoce and repelr, it i. a wise one. To help the owner decide which tools are needed to perform the tesks delailed in this manuel, the following toolli.l. are offered: M~ntenilflce and minor repair, Re".ir and Oll8rfuJul and SpM:iel. The newcomer to praclical mechanica .hould .tart off wilh the Malnttmance lind minor repllir 100/ kit, which I, adequale for the almpler joba performed on a vehicle. Then, as confidence end experience grow, the owner can tickle more difficult tasks, buying edditionalloolsls they ere needed . Eventually the basic kit will be expanded Inlo Ihe Repair snd oll8rheul tool set. Over a period of lime, the experienced do·it·yourselfer will aHambie a tool Ht complell enough for most repair and ovlrhaul procedures and will add toola from tha Sp«ial cltegory when it i. felt that the expense la justified by the frequency 01 use.
Maintenance and minor repair tool kit Tha tools in this liat should be considered the minimum required for performance 01 routine maintenance, servicing and minor repair work. We recommand the purchase of combinetlon wrenchas lbox·end and open·end combined In ani wrenchl; while marl expensive than open· ended ones, they offer the advantages 01 both types of wrench . Combination wrench set fI/4 in 10 , in or 6 mm to 19 mm) Adjustable wrench - B in Spark plug wrench (with rubber insertl Spark plug gap adjusting tool Feeler gauge set Braka bleedsr wrenCh Standard screwdriver (5/16 in x 6 in) Phillips sCfflwdriver (No. 2 x 6 in) Combination pliaf$ - 6 m Hacksaw and assortf1lflnt of blades Tire pressure gsuge Grease gun Oil can Fine emery cloth Wire brush Battsry post and cable clesning tool Oil filter wrench Funnel (medium SIZS) Safety goggles Jackstands (2) Dram pan Not.: If basic tune·ups ere going to be part of routine malmenence, it will ba necessery to purchese a good qUlllity stroboscopic timing light and combination IllchometerA:JweJl meter. Although they are included m the list of Speclel tools, it is f1IfIntioflild hare because they lire ab· solutely necessary for tuning most V'8hicles prop.,ly.
Repair and overhaul tool set These tools ere essential for anvene who plans to perform mejor repairs and are in addition to those in the Maintemmce and minor re".ir tool kit . Included is 8 comprehensive set of lockets which. though ex·
Note: Another tool which is often useful IS an electr;c dull motor (With chuck cllpeclty of 3/B·inchj and a set of good·quallty drill bits.
II
Special tools The tools in thililit Include those whIch are not used regularly. are expensive to buy, or'which need to be used in accordance WIth their manufacturer's instructions. Unless these tools will be used frequent · Iy, it is not very economical to purchase many 01 them. A conSldera· tion would be to .plit the cost and use between yoU/self and a friend or friends. In addition, most of these tools can be obtained from a tool rental shop on a temporary baSIS. This list primarily contains only those lools and instruments WIdely available to the public, and not those special tools produced by the vehi· cle manufacturer for distribution to deeler service departments. Occa· sionally, references to the manufacturer's special tools are Included in the text of this manual. Generally, an alternative method of dOing the job without the special tool is offered. However. sometimes Ihere is no elternative 10 their use. Where Ihil is Ihe case. and the 1001 cannot be purchased at borrowed, the work should be lurned ave. to the dealer service depanment or an automotive repair shop. Valve sprmg compressor Piston ring groove cleaning tool Piston ring compressor Piston ring ins tallation tool Cylinder compnssion gauge Cylinder ridge reamer Cylinder surfacing hone Cylmder bore gauge Micrometer(S}lmdkJr diel calipers Hydraulic lifte, removal tool Balljoint seperator Universal·type puller Impact screwdriver Dial indicator set Stroboscopic timing ligh t (inductillfl ptek·up) Hand·operated vacuum/prtlssure pump Tachomete,/rlwelf meter Universal elactrical multif1lflter Csble hoist Brake spring removal lind instl/illation tools Floor IBCk
0-13
Maintenance techniques, tools and working facilities
Piston ring groove cleening tool
Piston ring compre..or
Valve spring compreuor
Piston ring removal /installation tool
Cylinder ridge reamer
Telescoplng gauge set
Micrometer set
Cylinder surfacing hone
Dlel caliper
.;-......~~~ ,. , r:Universal-type puUer
Dial Indicator set
Hand-operlted vacuum pump
0-14
Maintenance techniques, tools and working facilities
Buying tools For the do-It-yourselfer who is jull starting to get Involved in lIohicle maintenance and repair. there are a number of option. available when purchaSing tool •• II maintenance and minor repslr i, the 8ICtani 01 the work to be done. the PUrches8 of individual tool. I, latislactory. If, on Ihe other hand, extensive work I. planned, it would be 8 good idea to purchase 8 modest 1001 set from one of the larva retail chain stores. A set can usuallv be bought 81 8 substantialssving. over I ha individual tool prices (and thev often come with 8 tool bo:.c). As additional tools are needed, add-on sets. individual tools and II larger tool boll can be purchased to expand the 1001 selection. Building a tool set gradually allows Ihe COli of Ihe lools 10 be spreed over e longer period of lime and gives Ihe mechanIc tha freedom 10 choose only Ihose tools thar will aCluslly be used. Tool stores witt often be the only source of some of I he specisl tools that are needed, but regardless of where tools are bought. Iry to avoid cheap ones lespec~"y when buying screwdrivelll and sockels) because lhey won'llast verv loog. The expense involved;n replacing cheap tools WiU eventually be grealer than the initial CO&l of quality tools.
Care and main tenance of tools Good tools are expensive. so it makes sense to treat them with respect, Keep them clean and in usable condition and store them property when not in use. Always wipe off any dirt, grease or metal chips before pUlting them away. Never leave tools lying around in the work area. Upon completion 01 a job, always check closely under the hood for tools that may have been left there (so they don't get lost during e test drivel. Some tools, such as screwdrivers, pliers. wrenches end sockets. can be hung on • panel mounted on the garege or workshop wall, while others should be kept in a tool box or tray. Measuring instruments. gauges. melers. etc. must be carefully stored where they cannot be damaged by weether or impact from other toola. When tools are used with care and stored properly. they Will last a
verv long time. Even With the best of care. tools will wear out If used frequently. When a tool is damaged or worn out. replace It; subsequent jobs Will be safer and more enjoyable il you do. Workjng facilities Not to be overlooked when discussing tools is the workshop. If anything more than rouline maintenance is to be carried out. some sort of suitable work area is essential. It is understood, and appreciated. that many home mechaniCS do not have a good workshop or garage available and end up removing an engine or doing major repairs outSide. It Is recommended. however, that the overhaul or repair be completed under the cover of a roof. A clean. flat workbench or table of comlortable working height is an absolute necessity. The workbench should be equipped With a vise that hal a jaw opening of at least four inches. AI mantiOfled previously, some cleen, dry Siorage space is also required for lools. as wella5 the lubricants. lIuids. cleaning salven". etc. which soon become necessarv. Sometimes waste Oil and flUIds. dreined from the engine or cooling system during normal maintenance or repairs, present a disposal problem. To avoid pouring them on the ground or into a sewage system, simply pour the used fluids Into large containers. seal them with caps and take them to an authorized disposal sile or recycling cenler. PlaSlic jugs Isuch as old antifreeze contalnersl are ideal for thiS purpose. Alwaya keep a supply 01 old newspapers and clean raga avsilable. Old towels are excellent lor mopping up spills. Many mechaniCS use rolls o f paper l ow els lor most work because they are readily available and disposable. To help keep the area under the vehicle clean, a large cardboard box can be cut open and flattened to protect the garage or shop lloor. Whenever working over a painted surface Isoch as when leaning over a lender to service something under the hood I. always cover it with an old blanket or bedspread 10 protectlhe linlsh. Vinyl covered pads. made especially for this purpose. are avaIlable al auto oarts stores.
•
0-15
Booster battery (jump) starting Certain precautions must be obserlled when using a booster battery to jump start a vehicle. a) BeforB connecting the booster battery, make sure that the ignition switch is in the Off position.
b) Turn off the lights, heater lind other IIlectrical loads. c) The ayes should be shielded. Safety goggles are II good idea. d) Make sure the booster battery is the same voltage as the dead one in the vehicle.
el The two vehicles must not louch each other. I) Make sure the tranSllxle is in Neutral (manual transaxle) or Park (automatic transell),,). g) If the booster battery is not II maintenance-free lyp6. remove the vent caps and lay II cloth over the vent holes.
Connect the fed jumper cable to the positive (+ I terminals of each bonary. Connect one end of the black. jumper cable to the negarive 1-) terminal of the booster battery. The other end of this cable should be connected to e good ground on the vehicle to be started, such as a bolt or brack.et on the engine block.. Use caution to insure that the cable will not come into contact with the ten, drivebelts or other moving pans of the engine. Start the engine using the booster battery, then, with the engine running et idle speed, disconnect the jumper cables in the reverse order of connection.
Make tha boo.ter banery cable connec:tlona In the numerical order shown Inote that the negative cable of the booater banery i. not attached to the negative tarmln.al of the daad battery)
Jacking and towing Jacking Two types of jack.s are used: a screw-type on ear1ier models and a scissors-type on later models. On ear1ier models the jack is located in a compartment under the passenger seat and on later models in the engine compartment below the battery or next to the driver's seat. The jack. should be used only for raising the vehicle for the purpose of changing a tire or placing jackstands under the frame . Cau· tlon: Never, under any circumsta,nces, perfonn worlc under the vehicle or start the engine while the jack is being used as the only means of w~.
The vehicle should be on level ground with the wheels blocked and the transmission in Park (automatic) or Reverse (manua~. Pry off the wheel cover (if so equipped) using the tapered end of the lug wrench. loosen the lug nuts one-half tum and leave them in place until the wheel is raised off the ground.
The jack should be placed under the spr1ng pivot
From the side of the vehicle, place the jack under either front or rear spring hanger, depending on the wheel to be lifted. Raise the vehicle with the jack, remove the lug nuts, pull off the wheel and replace it with the spare. With the beveled side in, replace the lug nuts and tighten them until snug. lower the vehicle, remove the jack and tighten the nuts in a crisscross pattern. Replace the wheel cover by placing it in position and using the heel of your hand or a rubber mallet to seat it.
Towing These vehicles can be towed at freeway speeds with all lour wheels on the ground and the ignition key in the Off position (if equipped with locking column) by using the following procedures. Manual transmission Shift the transmission and transfer case into Neutral on models built through 1979. On 1980 and later models, the transmission shOuld be placed in gear and the transfer case in Neutral. If equipped with locking hubs, they should be in the free-wheeling position on models built through 1976 and locked (to ensure axle lubrication) on 1977 and later models. On 1980 and later models, it wilt be necessary to stop every 200 miles, start the engine and run it for one minute with the transmission in gear and the transfer case in Neutral to circulate the transfer case oil. Automatic transmission On models equipped with Cuadra-Trac and an automatic transmissioo, but without the low range reduction unit, the vehicle can be towed with the transmission in Neutral and the front and fear driveshafts removed (Chapter 8). If equipped with the reduction unit, shift the transmission into Park and shift the reduction unit into Neutral. The Emergency Drive control located In the glovebox must be in the Normal position. If the engine was shut off with this control in the Emergency Drive position, restart It and rum the knob to Normal before towing the vehicle. On 1980 and later models, shift the transmission Into Park and the transfer case into Neutral. Stop every 200 miles, start the engine and run it for approximately one minute with the transmission in Park and the transfer case in Neutral to circulate the transfer case oil.
0-16
Automotive chemicals and lubricants• A number of automotive chemicals and lubricants are available fOf use during whlcls maintenance end repair. They include 8 wide variety of products fanglng trom cleaning solvents end degreasera to lubricants and protective spreys for rubber, plastic and vinyl. Contllct pointnpsrlc plug cleaner is II solvenl used to clean oily film end dirt from points, grime from electrical connectors and oil deposits from spark plugs. It i, oil fra. and leavel no residue. It can also be used to remove gum and V8foish from carburetor jets and other orifices. Carburetor cleaner is similar to contact point/tperk plug cleaner but it I, a.tronQ9r solvent end may leave 8 slight oily residue. It IlllOt recommer'lded for cleaning electrical components or connections. 8ftJke system clsaner I, used to remove grelse or brlke fluid from brake system components where clean .urlace. are absolutely necelSary and petroleum-based solvents cannot be used_ It al.o leeves no rl.idue. Silicone-lulsed lubricants Ire used to prollct rubber parts such as hOMS, weatherstripping and grommets, and Ire used IS lubricants fOf hingas Ind locks. Mulri-purpose grease I. In III-purpose lubricant used wherever grease I, more practical than a liquid lubricant such as oil. Some multi·purpose grease i, white and specially lormulated to be more resistant to water than ordinary grease. Baaring graase/wMM baafing graase Is I heavy grease used whare increased loads and friction are encountered liAL wheel bea~s, univer· sal joints, etc.t. High-temperature whfHI/ baaring grease Is designed to withstlnd the alltreme temperature. encountered by wheel bearings in disc-braka equipped vehicles. It usuelly conteins molybdenum disulfide, which Is e 'dry' type lubricant. Gaar 017 Isometimes callad geer lubel Is a apeclally designed oil uaed in dlfferentiels, manual transmissions and trlnsler cales, as well as other areas where hlgh·friction, hlgh·temperature lubrication is re quired . It il available in a number of viscosities (weights) for various applications. Motor oil, of course, is the lubrinnt specially lormulated lor use in engines. It nonmllily contain. a wide variety 01 edditives to prlMlnt cor· rosion and reduca foaming and weer. Motor o~ come. in various .....Ight. (viscosity ratings) of from 5 10 80. The recommended weighl 01 the 011 depends on the lelsonal temperature Ind the demlnds on the engine. Light oil is used In cold climatal and undar light load conditions; heavy oil II uled In hot climates Ind where high loads Ire encountered. Multi-viscosity oils are designed 10 h ..... characteristic. 01 both light and heavy oils and ale available in a number 01 _ights Irom 5W-20 to 20W-50. Oi/additives range from viscosity inda)( Improvers to slick chemical treatmants that purportedly reduce friction. It should be noted that most oil manufacturers Clution against using additives with their oils. Gas additives perfonn SlMlraliunctions, dapending on t heir chemical
makeup. They usually contain solvents thai help dissolve gum Ind var· nish thlt build up on carburetor and intaka parts. They also serve to break down carbon daposits that form on the inside surfaces 01 the combustion chambers. Some additives contain upper cylinder lubricanlS lor valves and piston rings. Bnke fluid is a .pecielly formulated hydraulic lIuid that cen With stand the heat and pressure encountered in breke systems. Cafe must be taken that this Iluid does not come in contact with painted surfaces or plastics. An opened container should alway' be resealed 10 prevent contamination by watar or dirt. Undercoating is a petroleum· based, tar· like substance IhaliS designed to prolect metal surlaees on the underside 01 a vehicle from corrosion. It also acts" a .ound-deadening agent by insulating the bottom of the vehicle.. 'Weatherstrip cement is used to bond ..... atherstripping around doors, windows and trunk lids_ It is sometimes used to attach trim pieces as we'l. {)egreastmi are ha8Y'y-duty so ....ents used to remove grease and gnme Ihat may eccumulate on engine and chassis components. They can be sprayed or brushed on and, depending on the type, ere rinsed off with either water or solvent. Solvents ere used atone or in combination with degreasers to clean parts and "sembli.. during repair and O\Ierhaul. The home mechenic should use only solvents that are non-flammable and that do not produce irritating fumes. Gasket suling compounds may ba used in conJUnction WIth gaskets, to improve their sealing capabilities, or alona, 10 seal metal·to -metal joints. Many gaskat sealers can withstand alltreme heat. soma are impervious to gasolina and lubricants, whila others are capable of filling and sealing large c8Y'ltles. Depending on the intended use. gasket sealers either dry hard or stay ralelively soft and pliable. They are usually applied by hand, with a brush, or are sprayed on the gasket seahng surfaces. Thread cement IS In adhesive locking COf'l'lPOUnd that prevents Ihreaded fastenars ftom loosening because of vibrat ion. It is available in a variety of types for differant applications. Moisture dispersants are usually sprays that can be usad to dry oul electrical componants such es the distributor. fuse block and wiring connectors. Some types can also be u'sed as treatment forrubbar and as e lubricant for hinges, cables and locks. W.JC8S and polishes are used to help protect painted and plated sur· faces from the weather. Different types 01 paint may require the use of differant types 01 wall polish. Some polishes ulili~e a chemIcal or abresive cleaner to halp remova the top laye' of oKldized (dulll palMt on oider vehicles. In recent years many f'IOn ·wax polishes that contalM e wide variety 01 chemicals such as polymers and silicones have been introduced. These non'well polishes are usually easier to apply and last longer Ihan conventional walles and polishes.
0-17
Safety first! Regardless of how enthusiastic you may be about getting on with the job at hand, take the time to ensure that your solely is not jeopardi~ed. A moment's lack of attention can result in an accident; so can failure to observe certain simple safety precautions. The possibility of an accident will always 8)(ist. end the following points should not be considered II comprehensive list of all dangers; rather, they are intended to mak.e you aware of the risks end to encourage II safety-conscious approach to all work you carry out on your vehicle.
Essential DOs and DON'Ts DON ' T filly on II jack when working under the vehicle. Always use approved jackstands to support the weight of the vehicle and place them under the recommended lift or support points. DON 'T anempt to loosen extremely tight fasteners H.e. wheel lug nuts! while the vahicle is on a jack; it may fall. DON' T start tha engine without first making sure tha t the transmission is in Nautral (or Park where applicable) and the parking brake is set, DON' T remove the radiator cap from a hot cooting system - let it cool or cover it with a cloth and relaase tha pressure gradually. DON' T attempt to drain the engina oil until you are sure it has coolad to tha poin t that it will not burn you. DON'T touch any part of tha anglne or axhaust system until it has cooled down sufficiently to avoid burns. ~ON 'T siphon toxic liquids such as gasoline. antlfraeza and braka fluid by mouth, or allow tham to remain on your skin. DON' T inhale brake lining dust - it is potentially hazardous. DON 'T allow spilled oil or graase to ramain on the floor - wipe it up before somaone slips on it. DON 'T use loose-fitting wrenc~es or other tools which may slip and cause injury. DON 'T push on wrenchas when loosening or tightening nuts or bolts. Always try to pull the wrench toward you. If the situation calls l or pushing the wrench away, push with an open hand to avoid scraped knuckles if the wrench should slip. ~ON ' T attempt to lift a heavy component alone - get someone to help you. DON' T rush or take unsafe shortcuts to finish a job. DON' T allow children or animals in or around the vehicle while you are working on it. DO waar eye protection when using power tools such as a drill, sander, bench grinder, etc. and when working under a vehicle. 00 keep loose clothing and long hair welt out of the way of moving parts. 00 make sure that any hoist used has a safe working load rating adequate for the job. DO get someone to check on you periodically when working alone on a vehicle. 00 carry out work in a logical sequenca and make sure that everything is correctly assembled and tightened. DO keep chemicals and fluids tightly capped and out of the reach of children and pets. 00 remember that your vehicle's safety affects that of yourself and others. If in doubt on any point, get professional advice.
Fire Remember at all times that gasoline is highly flammable. Never smoke or have any kind of open flame around when working on a vehicle. But the risk does not end there. A spark caused by an electrical short cir-
cuit, by two metal surfaces contacting each other, or even by static electricity built up in your body under certain conditions, can ignite gasoline vapors, which in a confined space are highly explosive. 00 not, under any circumstances, use gasoline for cleaning pans; use an approved se fety solvent. Always disconnect tha battery ground (-! cable before working on any part of the fuel systam or electrical system. Never risk spilling fuel on a hot anglne or exhaust component. It is strongly recommended thet a fire extinguisher suitable for use on fuel and electrical fires be kept handy in the garage or wo rkshop at all times. Never try to extinguish a fuel or electrical fire wit h water.
Fumes Certain fumes are highly toxic and can quickly cause un· consciousness and even death if inhalad to any extent. Gasoline vapor faUs into this category, as do the vapors from some cleaning solvents. Any draining or pouring of such volatile ftuids should ba done in a well ventilated area. When using cleaning fl uids and solvents, read the instructions on the container carefully. Naver use materials from unmarked containers. Nevar run tha engine in an enclosed space such as II garage; exhaust fumes contain carbon monoxide which is extremely poisonous. If you need to run the engine, always do so in the open air or It Ilast have the rea r of the vehicle outside t he work erel. tf you are fortunate enough to have the usa of an Inspection pit, never drain or pour gasoline and never run the engine while the vehicle is over the pit; the lumes, being heavier thin air, will concentrate in the pit with possibly lethal results.
The battery Naver create a sperk or allow a bare light bulb near the vehicle's bat · tery. It will normally be giving off a cenain amount of hydrogen gas, which is highly explosive. Always disconnect the battery ground (-I cable before working on the fuel or electrical systems. If possible, loosen the finer caps or cover when charging the bit· tery from an externat source, Do not charge at en excessive rate or the battery may burst. Take care when adding wate r and when carrying a battery. Theelectrolyte, even when diluted, is very corrosive and should not be allowed to contact clothing or skin. Always wear eye protection when cleaning the battery to prevent the caustic deposits from entering your eyes.
Household current When using an electric power tOOl, inspection light, etc., which oparates on household current, always make sure that the tool II correctly connected to its plug and that, where necessary, it Is properly grounded, Do not use Buch items in damp conditions and, Igain, do not create a spark or apply excessive heat in the vicinity of fuel or fuel vapor.
Secondary ignition system voltage A severe electric shock can result from touching canain Plrts of the ignition system (such as the spark plug wiresl when the engine Is running or being cranked, plnicularly if components are dlmp or the insulation is defective. In the case of an electronic ignition system, the secondary system voltage is much higher and could prove fatal.
0-18
Troubleshooting Contents
Applicable Section
Symptom
Engine mechanical Engine beckfires . • . . • • . .
. •.....•.••..
Engine 'diesels' [cootinues to runl aher ,wilehlng off
13 15 4
Engine herd to start when cold ....... .
Engine hard to start when hot .......... . .... . laeks power. . . . . . . . . . . . . . . . . . .. . ..... . lopes white idling or [diu erratically .......•. misses at idle speed .•......•.••.•.•. missal throughout driving speed ,ange ..... .... . . Engine rotate. but will not start .. . . . . . . . . •..... Engine stall • ...... ...... . . ..•.. .... •....•..••.... Engine ,tart. but SlOpS immediately . . . . . . . . ....... . Engine will not rotate when 'Hemptiog to start ...... . Pinging or knocking engine sounds during acceleration or uphill •.•..•.•...•....•.•. Statter motor noisy or excasslvely rough in engagement Statter motor operates without roteting engine
Engine Engine Engine Engine
5
'2 8
•
'0
2
", 7
14
• 3
Engine electrical Battery will not hold a charge . . . • . . . .•.•.•. .•.. . . Charge light fails to come on whan key is turned on . . • . • .. Charge light fails to go out .. .. .. .. .. .•. .•.•. .. . • . •..
,6 18 17
Fuel system Excessive fuel consumption ..• •• • ..•..• • ••• • • • • • Fuel leakage and/or fuel odor ••.••.••• ••••........•
19 20
Cooling system External coolant laakage . . . • . • . . . . • . . . . • . • . . . . • . . . .. Intarnal coolant laakage . •••.••.. . • . . . . • . • . • • . • . . . .• Qvercooling •• •....•.•.•.• • •.••.•.. • .••.• • .•. Overheating . • . • • . • . • • • • • • • • • . . . . • . . • • . . . • . . • .. • Poor coolant circulation .• .. ...... . ...•.•.•... Coolant loss . • . . . . . . . . . . . . . . • • . . . . . . . • . . . . . • • .
23 24 22 21 26 25
Clutch Clutch slips (engine speed increases with no increase in vehicle speed! . . . . . . . . . . . . . . . . . . • . • . . . Clutch pedal stays on floor when disengaged •.••.•.•.•• Feils to release (p edal prassed to the floor - .hift lever does not move Ireely in and out of Reverse) . • • • . • . . Grabbing (chattaring) as clutch Is engaged ••.••• . .. . Squeal or rumble with clutch fully disengaged (pedal depressed) . •• . . . . . . • . . . . . . . . . . . . . Squeal or rumble with clutch lully engaged (padal released! ..
28 32
.•.•.•.. •. .•. .. . running . .•.... .... .. . .. . .. .
•.••.•. . . ... . ...... . . .. ..•. . . .. .•.••.. .
31 30 37 34 33 35 38 36
Automatic transmission Engine will Itan in gears other than Park or Neutral . . . . Fluid leakaga .•. . . . . . . . . . . • . . . . . . . . • . . . General shilt mechanism probleml .. . .. .. .. . Transmission slips, shifts rough, il noisy or has no drive in forward or reverse gears .•••••..•....•.••.•.•••• Transmission w ill not downlhjft with accelerator pedal pressed to the floor . • • • • • • . • . . . . . . . . . • . • .
42 39 40 43 41
Transfer case Lubricant leakl from th e vent or output shaft seals
Applicable Section
Noisy Of jumps out of 4 ·wheel drive UlW range .•... Rasping, pulsaling noise. particularly at low speeds (Quadra -Trac! ..•. Transfer case difficult to shill into Ihe deSired range Transfer case noisy in all gears
46 47 44 45
Driveshaft Knock or clunk when the transmission is under initial load Hust after transmission is put into gear) . .......•.••.. leakage of fluid at front of drivesha!t . . . •• • • Metallic grating sound consistent With vehicle speed . . Vibration .•...... .•.. . ....•.•..
50 49 51 52
Axles Noise (same when in drive as when vehicle is coasting) . Oil leakage . . Vibration
53 55 54
Brakes Brake pedal feels spongy when depressed .. Brake pedal pulsates during brake application Excessive brake pedal travel . . ..•..... . . . Excessive effort required to atop vehic le •. Noise (high -pitched squeal without brake applied) Pedal travels to floor With little resistance Vehicle pu"' to one side during braking .
59 62
5'
60 57 6' 56
Suspension and ~teering Vehicle pull s to one side ..•.. .... .. Excessive pitching and /or rolling around corners or during braking . .. ..•. . . Excessive play in steering Excessive tire wear (not lpecilic to one areal Excessive tire wear on inside edge Excessive tire wear on outsida edge Excessively stiff steering ... Lack of power assistance. . Shimmy. shske or vibration Tire tread worn in one place
63 65 67
6. 71
70 66
•• 64
72
27 29
Manual transmission Difficulty in engaging gears . Noisy in all gears . . . . • • • • Noisy in Neutral with engine Noisy in one particular gear Oil leakage . . • . . . . . . . . . . Slips out of high gear . . . . .
Symptom
46
This section provides an easy-reference guide to the more common problems which may occur during the operation 01 your vahlCle. These problams and possible causes are grouped under vanous components or systems1.e. Engine. Cooling system. elc.. and also reler to the Olaptef and/or Section which deals with the problem. Remember that success lui troubleshooting is not a mysterious 'black art' practicll'd only by professional mechanics. it's simply the reSult of a bit 01 knowledge combined with an intelligent. systematic approach to the problem. Always work by a process of elimination. staning with Ihe simplest solution and worlting through 10 the most complex - and nevar overlook Ihe obvious. Anyone can forgello fill Iha gas tank or leave Iha lights on overnight. so don't assume Ihat you ara above such oversights. Finally, always get clear In your mind why a problem has occurred and lake steps to ensure that it doesn't happen again. If the electrical system fails because 01. poor connection. check all other connections in Ihe system to make lure that they don't fait as well; if a particular fuse continues to blow. find oul why - don' t just go on replecing fuses. Remember, failura of a small component can often ba Indica live of potantial failure or incorreCI functioning 0 1 a more important compo nent or system.
Troubleshooting
0-19
Engine mechanical Engine will not rotete when Ittemptlng to start Battery term inal connections loose or corroded. Check the cable term inals at the battery; tighten the cable or remove corrosion as necessary. 2 Battery discharged or faulty. If the cable connections are clean and tight on the battery posts, turn the key to the On position and switch on the headlights and lor windshield wipers. If they fail to function, the battery is discharged. 3 Automatic transmission not fully engaged in Park. 4 Broken. loose or disconnected wiring in the starting circuit. Inspect all w iring and connectors at the battery, starter solenoid and ignition switch. 5 Startar motor pinion jammed on flywheel ring gear. If manual transmission, place in gear and rock the vehicle to manually turn the engine. Remove starter (Chapter 5) and inspect pinion and flywheel at earliest convenience. 6 Starter solenoid faulty (Chapter 5). 7 Starter motor faulty (Chapter 5). B Ignition switch faulty (Chapter 10).
2
Engine rotatel but will not stlrt
1 Fuel tank empty. 2 Battery discharged (engine rotates slowly). Check the operation of electrical components as described in previous Section IChapter 5). 3 Battery terminal connections loose or corroded. See previous Section. 4 Carburetor flooded andlor fuel level in carburetor incorrect. This will usually be accompanied by e strong fuel odor from under the hood. Wait a few minutes, depress the accelerator pedal all the way to the floo r and attempt to start the engine. 5 Choke control inoperative (Chapter 4). 6 Fuel not reaching carburetor. With ignition switch in Off position, open hood, remove the top plate of air cleaner assembly and observe the top of the carburetor (manually move choke plate back if necessary). Have an assistant depress accelerator pedal fully and check that fuel spurts into carburetor. If not, check fuel filter (Chapter 11. fuel lines and fuel pump (Chapter 4). 7 Excessive moisture on. or damage to. ignition components (Chapter 5). B Worn, faulty or incorrectly Adjusted breaker points or spark plugs (Chapter 1). 9 Broken, toose or disconnected wiring in the starting circuit (lee previous Section). 10 Distributor loosa (which changes ignition timing). Turn the distributor as necessary to start the engine, then set ignition timing as soon as possible (Chapter 1). 11 Ignition condenser faulty (Chapter 1). 12 Broken, loose or disconnected wires at the Ignition coil or distributor or faulty coil (Chapter 5).
5
Engine hard to Itart wh en hot
1 2 3 4
Choke sticking in the closed position (Chapter 1). Carburetor flooded {see Section2). Ai r filter clogged (Chapter 1). Fue!' not reaching the carburetor (see Section 41.
e
Sta"er motor nollY or excelilvaly rough In engagement
Pinion or flywheel gear teeth worn or broken. Aemove the inspec ' tion cover at the rear 01 the engine [if so equipped) and Inspect. 2 Starter motor mounting bolts loose or missing.
7
Loose or faulty electrical connections at distributor, coil or alternator. 2 Insufficient fuel reaching the carburetor. Disconnect the fuel line at the carburetor and remove the filter (Chapter I ). Place a container under the disconnected fuel line. Observe the flow of fuel from the line. If little Of none at all, check for blockage in the lines and lor replace the fuel pump (Chapter 4). 3 Vacuum leak at the gasket surfaces of the Inteke manifold and/or carburetor. Check that all mounting bolts (nuts) are tightened secu rely and that all vacuum hoses conencted to the carburetor and manifold are positioned properly and in good condition. 4 Faulty ignition ballast resistor (Chaptet 5 ).
8
Stllrter motor operates without rotllting anglne
1 Starter pinion sticking. Remove the starter (Chapter 5) and inspect. 2 Starter pinion or engine flywheel teeth worn or broken. Remove the inspection cover at the rear of the engine (if so equippedl and inspect.
4
Englnl hard to stllrt when cold
1 2 3 4 5
Battery discharged or low. Check as described in Section 1. Choke control inoperative or out of adjustment (Chapter 1). Carburetor flooded (sae Section 2). Fuel supply not reaching the carburetor (see Section 4). Carburetor worn and in need of repair [Chapter 41.
Engine lopes while Idling or Idlel errlllically Vacuum leakage. Check mounting bolts Inutsl at the carburet or
and intake manifold for tightness. Check that all vacuum hoses are con-
nected and in good condition. Use a doctor's stethoscope or a length of fuel hosa held against your eer to listen for \lacuum leaks while the engine is running. A hissing sound will be heard. A soapy water solu· tion will also detect leaks. Check the carburetor and intake manifold gasket surfaces. 2 leaking EGA valve or plugged PCV valve (see Chapter 6 ). 3 Air cleaner clogged and in need of replacement (Chapter 1). 4 Fuel pump not delivering sufficient fuel to the carburetor [ see Section 7). 5 Carburetor out of adjustment (Chapter 4). 6 leaking head gasket. If this is suspected, take the vehicle to a repair shop or dealer where it can be pressure checked without the need to remove the head!s). 7 Timing chain and /or gears worn (Chapter 2). B Camshaft lobes worn, necessitating the removal of the cam shaft for inspection (Chepter 2).
9
3
Engine starta but Itopa Immediately
Engine ml"el at Idle Ipeed
I Spark plugs faulty or not gapped properly (Chapter 1). 2 Faulty spark plug wires [Chapter I). 3 Carburetor choke not operating properly (Chapter I I. 4 Sticking or faulty emissions system components [Chapter 6). 5 Clogged fuel filter and/or foreign matter in fuel. Remove the fuel filter {Chapter I I and inspect . 6 Vacuum leeks at carburetor, intake manifold or at hose connec· tions. Check as described in Section 8. 7 Incorrect idle speed or Idle mixture (Chapter 1). 8 Incorrect ignition timing (Chapter 11. 9 Uneven or low cylinder compression. Check compression as described in Chapter 1.
10
Engine ml ..es throughout drlvlng speed range Fuel filter clogged and/or imputities in the fuel system (Chap -
0-20
Troubleshooting
ler 11. Also check fual output 8t the carburetor (see Section 7). 2 Faulty or incorrectly gapped spark plug. (Ch8pler 1). 3 Incorrect ignItion liming {Chapter H. 4 Check for cricked distributor cap, disconnected distributor wires or damage to the ignition system componentl (Chapter 5L 5 Leaking spark plug wires (Chapter 11. 6 FaullV emission. -VItam components (Chapter 6). 7 lDw or uneven cylindlSf compression pressures. Check 8S descnbed in Chapter 1. 8 Fauhy breaker pOints or condenser (Chapter H. 9 Vacuum leaks at carburetor, intake manifold or vacuum hoses (see Section 8).
15
Engine 'dlaHI,' (conllnues to fun) eftaf switching off
1
Idle speed 100 high (Chapter 11. Electrical solenoid at side of carburetor not functioning properly Inol all models, see Chapter 4). 3 Ignition timing incorrectly adjusted (Chapter 11. 4 Air cleaner heat valve not operating properly (Chapter 1). 5 E;IIcesslve engine operating temperature. Probable causes 01 this are malfunctioning thermostat, clogged radiator, faulty water pump (Chapter 3).
2
Engine electrical "
Engine staH,
1 Carburetor idle speed incorrectly set (Chapter 11. 2 Fuel filter clogged endlor water and impurities in the fuel system (Chapter 11. 3 Choke improperly adjusted or sticking (Chapler 11. 4 Distribulor COmpooeols damp. poinll OUI of adjuslmenl or damage 10 dlslribulor cap. rOlor etc. (Chapter 5). 5 Fauhy emissions lYstem components IChapter 61. 6 Fauhy or incorrectly gapped spark plugs. Also check spark plug wires IChapter 11. 7 Vacuum leak at the carburetor, intake manifold or vacuum hoses. Check as described in Section 8. 6 Valve clearance incorr&etly set IChaptsr 11.
16 Blttlry will not hold a charge 1 2 3
4 5 6 7
17 1
2
lB
1 2
Incorrect ignition timing IChapter 11. Exxcessive play in distributor shalt. At the same time. check lor worn or out-of-adjustment points, faulty distributor cap, wires, etc. ,Chapter 11. 3 Faulty or incorreclly gapped spark plugs (Chapter 1). 4 Carburetor not adjusted properly or exceSllvely worn (Chapler 4). 5 Weak condenser (Chapter 51. 6 Faulty coil (Chapter 51. 7 Srakes binding (Chapter 11. 8 Automatic transmission lIuid level incorre ct, causing slippage (Chapter 11. 9 Manual IransmlSSlon clutch slipping IChapter 8). 10 Fuel filter clogged and/or impurities in the fuel system (Chapter 1). 11 Emissions control system not lunctlonlng properly ,Chapter 6). 12 Use of sub-standard fuel . Fill tank with proper octane fuel. 13 Low or uneven cylinder compression pressures. Check as described in Chapter 1.
1 Emission system not functioning properly (Chapter 61. 2 Ignition timing incorrect (Chapter 11. 3 Carburetor in need of adjustment or worn e;llcessively (Chapter 4). 4 Vacuum leak 81 carburetor, intake manifold or vacuum hoses Check as described in Section B. 5 Valve clearance Incorrectly set, andior valves Slicking (Chapter 11.
14
Pinging or knocking englna sounds during acceleration or uphill
1 Incorr&et grade 01 fuel. Fill tank with fuel of the proper octan-e rating. 2 Ignition timing Incorrect (Chapter 11. 3 Carburetor in need of adjustmant (Chapter 41. 4 Improper spafk plugs. Check plug type with that sp&eifted on label located inside engine compartment. Also check plugs and wires for damage (Chapter 1I. 5 Worn or damaged distributor components tChapter 51. 6 Faulty emissions system (Chapter 61. 7 Vecuum leak. Check as described in Section 8.
1
2
3
Alternator drivebell defective or rlOt adjusted properly IChapter 11. Electrolyte level low or electrolyte too weak (Chapter 11. Ballery terminals loose or corroded (Chapter 1). Alternator nOt charging proparly (Chapter 5). LDose. broken or laulty wiring in the cha rging circuit (Chepter 5). Short in vehicle circuitry caullng a conlinuai drain on battery. Battery defective internally
Cherge light falls to go OUI Fault in alternator or charging Circuit IChapter 51. Alternator drivebelt dafeclive or nOI properly adjusted IChapter 11.
Charge lighl faU, to come on when key i. turned on Warning hght bulb faulty (Chapter 10). Alternator fautty (Chapter 5). Fault in tha printed cirCUli, dash wiring or bulb holder (Chaptsr 101.
Fuel system 19
Excessive luel consumption
Clogged air filter element (Chaptel 1) Incorr&et Ignition timing (Chapter 1) 3 Choke sticking or improperly adjusted IChapter 11. 4 Emissions system not functioning properlv (not all vehicles. see Chapter 61. 5 Carburetor Idle speed and/or mixture not adjusted properly (Chapler 1). 6 Carburetor Internal parts excesSively worn or damaged (Chepter 4). 7 LDw lire pressure or incorrecl Ille size (Chapter 11. 1 2
20 1 2 3 4 5
Fuel leakege andlor fuel odor Leak In a fuel feed or vent line (Chapter 4). Tank overlilled. Fill only to automatic shut·off. Emissions s,!,Slem liller in need of replacement (Chapler 6 1. Vapor leaks Irom system lines {Chapter 4 ). CarburetOf internal parts excessively worn or damaged (Chapter 4).
Cooling system 21
Overheating
1 Insufficient coolant in system (Chapler 1). 2 Fan bell defective or not adjustad properl,!, (Chapter 1). 3 Radiator core blocked Of radiator grille dlny and restricted (Chapter 31. 4 Thermostat laulty (Chapter 3). 5 Fan blades broken or cracked IChapter 3). 6 Radiator cap not mainlainlng proper pressure. Have cap pressure
Troubleshooting
0-21
telled by gss station or fepair shop. 7 Ignition timing Incorrect (Chapter 1).
3 Clutch disc not .eated. It may taka 30 or 40 normal .tart. for a new disc to saat.
22 Overcooling
29 Gr.bbinV (ch.tt.rlnv) a. clutch Is InVltliJed
1
Oil on clutch disc. Ramove disc (Chapt.r 8) and inspect. Corraci any leakaga souree. 2 Worn or 100 .. angine or transmission mounts. Thel8 units mo.... slightly when clutch I, releasad. Inspect mounts .nd bolts. 3 Worn spline. on clutCh disc. Remova clutch componants (Chap, tar 8) and inspect. 4 Warp.ed preasure pllt. or flywheel. Remove clutch components and inspect.
2
23
Thermostat faulty (Chaptar 3). Inaccurste tamperature gauge (Chapter 10)
Ext.mal coolant I.akag.
O.teriorated or damaged hosas. LDosen clamps at hose connection. (Chapter 11. 2 Water pump seals defective. If this i. tha can. wster will drip from the 'weep' hola in the watar pump body (on .ome models) (Chapter 3). 3 Laskege from radialor core or heBder tank. This will requlra the radiator to be professionally rapairad (see Chaptar 3 lor ramoval proceduresl. 4 Engine drain plugs or water Jacket core plug. lesking (see Chapters 2 snd 3).
Nota: Inttlm81 cool8nt Itl8k$ can usu8/ty be detected by 8xtlmining thtl oil. Check the dipsticlr. 8nd inside of rhtl roclr.e, 8rm cOVBr(s} for w8ter deposifs and 8n oil consistency lik.e thet of a mifk.shake. 1 FaUlty cylinder head gasket. Have the sy.tem pressure-tested or remove the cylinder head(.) (Chapter 2) and Inspect. 2 Cracked cylinder bore or eyHnder head. Oi.mantle engine and inspect (Chapter 2). #
26 1 2 3 4
26
30
Inproper adjustm.nt; no free play (Chapt.r 1). Release bearing binding on transmission bearing retainar. Remoll8 clutch componanll (Chapter 8) and Check balrlnv. Remova any burrs or nicks. clean and relubricala befora reinstallation. 3 Weak linkaliJfl or p.dll return .pring. R.place tha sprlnv. 1
2
Squ.aI or rumble "",lth clutch fully dl•• nveved (ped.' d.pr.lnd)
31
1 Worn. faulty or brok.n release bearinV (Chaptar 8). 2 Worn or brokan pressure plate sprln"a (or diaphragm fingaral (Chaptar 8). 3 Crankshaft pilot bushing worn. Replac. twlhing (Chapter 8).
32
Coolant 10" Overlilling system (Chaplar 1). Coolanl boiling away due to overheating (.ee Section 211. Internal or external leakaga (see Sectionl 23 and 24). Faulty radiator cap. H....e the cap pressure tested.
Squ••1 or rumble with clutch funy .ngBliJed (pedal r.I.IMd)
Clutch ped.1 lie.,. on floor when di••nv.ved
Bind In linkage or r.lea58 bearing. In.peclllnkage or remove clUlCh components as n.c.ssary. 2 Linkage springs being over-traveled. Adjust linkaga for proper frea play. Make sur. proper oedal stop (bumperl i. installed.
Manual transmission
Poor coolant circulation
Note: All the foffowing references are to Chapter 7, unless noted. Inoperative water pump. A quick last I, to pinch the t op radiator hose closed with your hand while tha engina i. idling, than lal it loose. '!bu .hould leel the surge 01 coolant if tha pump Is working properly (Chapler 3). 2 Aallriction in cooling .yltam. Orain, lIush and relill the syltem (Chepler 11. II it appee~ necessary. relTlO\le the redi.tor (Chaptar 3) and h ....8 it reverse·llushed or professionally cleaned. 3 Fan drivebalt defactive or not adjustad properly (Chapter 11. 4 Thermostat sticking (Chapter 31.
33
Noi.y In N.utrll with .ngln. runnlnv
, 2 3 4
Input shefl b.arinv worn. Damaged main drivegaar bearinv. Worn counterg.er bearings. Worn or demavad countergear anli ·lash pllll.
1 2
Any of tha above causes. and/or: InsuHicient lubric.nt (saa checking proceduras in Chaptar 1).
Clutch 27 Fall. to release (pedal pr••• ad to the floor not mov. fr ••ly In Ind out of A.ve,...)
. hlh I ....ar doe.
, improper linkaga fraa play adjustment (Chaplar II. 2 Clutch fork off ball "ud. LDok under the vehicle, on the leh side of Ifsnsmission. 3 Clutch disc wsrped or damaged (Chapt.r 81.
36
28 Clutch .Iip. (.nvln. 'PHd lncr.es•• "",lth no Incrae.. In .... hlcl••peedl
36
, linkaga in need of adjustment (Chapter 1). 2 Clulch disc oil soakad or facing worn. Remove disc (Chapter 81 and Inspect.
1 2
1 2 3 4
NoilY In on. plnlcular g ••r Worn. damaged or chipped Vear teeth for that particular gear. Worn or damaved synchronizer lor that particular vear.
SUp. out of hlVh VH' TrsnsmisaiOfl mounting bolts loose. Shift rods interfering with engine mounts or clutch lever. Shift fads not working fraely. Damaged maln'haft pilot baaring.
0-22
Troubleshooting
5 Dirt between transmission case and engine or misalignment of tlansmisslOn. 6
37
1 2
Worn or improperly adjusted linkage.
Difficulty In engaging gear.
Clutch not releasing completely (see clutch adjustment, Chapter 11. Loose, damaged or maladjusted shift linkage. Make II thorough in-
spection, replacing parts as 1l8C8Ssary. Adjust &s described in Chapter 7.
38
Oil leakage
E~C8ssiv8 amoun! of lubricant in transmission (see Chapter 1 for correct checking procedures; drain lubricant as requi redl. 2 Side cover loose or gasket damaged. 3 Rear oil seal Of speedometer all seal In need of replacement.
Automatic transmission Note: Due /0 the complexity of the eutotmltic t ransmission, it is dif-
ficult for the home mechanic to properly diagnose and service this component. For problems other than the fol/owing. the Vf1hic/e should be taken to 8 reputable mechanic. 39
Fluid leakage
Automatic transmission fluid is a deep red color and fluid leaks should not be confused with engine oil. which can easily be blown by an flow to the transmission. 2 To pinpoint a leak, first remove all built-up dirt and grime from around the transmission. Degreasing agents and/or steam cleaning will achieve this. With the underside clean, drive the vehicle at low speeds so air flow will not blow the leak far from its source. Raise t he vehicle and determine where the leak is coming from. Common areas of leaka ge
43 Tranlml Slion I lipI, I hlhl rough, is noisy o r hal no drive In forward or revarle gearl There are many probable causes lor the above problems, but the home mechanic should concern himself with only one possibility: fluid level. 2 Before taking the vehicle to a repair shop, check the level and condition of th e fluid as described in Chapter 1. Correct fluid level as necessary or change the fluid and filter if needed. If problem persists, have a pro fessional diagnose the probable cause.
Transfer case 44
Transfer case diffic ult to shih into the desired ran ge
Speed may be too great to permit engagement. Stop the vehicle and shift into the desired range. 2 Shift linkage loose, bent Of binding. Check the linkage for damage or wear and replace or lubricate as necessary (Chapter 7). 3 If the vehicle has been driven on a paved surface for some time. the driveline torque can make shifting difficult. Stop and shift into 2-wheel drive on paved or hard surfaces. 4 Insufficient or incorrect grade or lubriC8nt. Drain and refill the trans fer c ase wit h the specified lub ~cant (Chapter 11. 5 Worn or dam aged internal components. Disassembly and overhaul of the transler case may be necessary (Chapter 71.
45
Transfer case noisy In all gearl
Insufficient or incorrect grade of lubricant. Drain and refill (Chapter 1) .
46
Noisy or jumps out of 4 -wheel drive Lo w range
,lte: 011 b) c) d) e) f)
40
FlUid pan: tighten mounting bolts and/or replace pan gasket as necessary (see Chapter 7). Rear extension: tighten bOlts and/or replace oil seal as necessary (Chapter 7). F~ler pipe: replace the rubber seal whme pipe enters transmission case. Transmission oil tines: tighten connectors where lines en ter transmission case and/or replace lines. Vent pipe: transmission over· fitled and/or water in fluid (see checking procedures. Chapter 1). Speedometer connector: replece t he O-r ing where speedometer cable enters transmission case.
General I hift mechanism problem.
Chapter 7 deals with checking and adjusting the shift linkage on 8utomatic transmissions. Common problems which may be attributed to poorly 8dJusted linkage are: a) Engine starting in gears othar than Park or Neutral. bl Indicator on Quadf8nt pointing to a gear other than the one actually being selected. cl Vehicle will not hold firm when in Park position. 2 Refer to Chapter 7 to adjust the manual linkage.
1 Transfer case not fully engaged. Stop the vehicle, shift into Neutral and then en gage 4L. 2 Shift linkage loose, worn or binding. Tighten. lepan or lubricate linkage as necessary. 3 Shift fork cracked, inserts worn or fork binding on the rail. Disassemble and repair as necessary [Chapter 7l.
47 Rasping. pul. ating noise. particularly at low speeds (Quadre·Trac) Quadra-Trac stick-slip condition caused by improper lubrication or mismatched tire sizes. Drain and refill the transfer case [Chapter 1) and check the tire size and inflation.
48
Lubricant leaks from the vent or output shaft leel s
1
Transfer case is overfilled. Drain to the proper level (Chapter 1). Vent is clogged or iammed closed. Clear 01 replace the vent. 3 Ou tput shaft seal incorrectly installed or damaged. Replace the seal and check the seal contact surfaces for nicks and scoring.
2
Driveshaft 4' Tranl mission will not downlh lh with accalerator pedal prass ad to the floor
49
Chapter 7 deals with adjusting the downshift cable or downshift SWitch to enable the transmission to downShift properly.
Defective transmission or transfer case oil seal. See Ch8pter 1 lor replacement procedures.
42
50 Knock or clunk when tran l minion is under initial load Uust aher transmisalon il put Into gaar)
Engine w ill start in gearl other than Park or Neutral
Chapter 7 deals with adjusting the various linkages used with 3utomatlc transmissions.
Leakage of fluid at front of dr!veshaft
Loose or disconnect ed re ar suspension components. Check all
Troubleshooting mounting bolts and bushings (Chapter 111. 2 Loose drivashaft bolts. Inspect all bolll and nuts and tighten to the specified torque (Chapter 8). 3 Worn or damaged universal joint bearings. Test fOl' wear [Chaptar 8).
51
Matallic grating sound conilitent with vehicle I peed
Pronounced wear in the universal joint bearings. Test for weer (Chapter 8).
0-23
one side. Inspect as descflDed in Chapter 1. 2 Excessive weer of brake shoe pad material or drumfdisc on one .ide. Inspect and correct as necessary, 3 Loose or disconnected front suspension components. Inspect and tighten all bolts to the specified torque (Chapter 11. 4 Defective wheel cylinder or caliper assembly. Aemove and inspect for stuck piston or damage [Chapter 9).
57
Noise {high-pitched _queal without brake applledl
Front brake pads worn out_ The noise comes from t he wear sensor rubbing against the disc (does not apply to aU vehicles), Replace pads with new ones immediately [Chapter 91. Note: Bafo'-& it can be assumed that the driveshllft is lit fllult. mllka sure tha I,res are perfectly balanced and perlorm Ihe folfowing lest. 1 Install a techometer inside the vehicle to monitor engine speed as the vehicle is driven. Drive the vehicle and note the engine speed et which the vibration [roughness) is most pronounced. Now shift the transmission to a different gear end bring the engine speed to the same point . 2 If the vibration occurs at the same engine speed [rpm) regardless of which gear the transmission is in, the dnveshaft is NOT at fault since the drlveshalt speed varies. 3 If the vibration decreases or is eliminated when the transmission is in a different gfIar at tha same engine speed, refer to the following probable ceuses. 4 Bent or dented driveshaft. Inspect and replace as necessary [Chapter 8). 5 Undercoating or bUild -up din. etc. on the dflveshalt. Clean the shaft thoroughly and recheck. 6 Worn universal joint bearings. Remove and i" spec t [ChClp ler 8). 7 Driveshaft andlor companion flange out of belance. Check for missing weights on the shaft. Remove driveshaft [Chapter 8) and reinstall 180" from original position. Aetest. Heve driveshaft professionally balanced If problem persists.
Axles 53
Nolae [lame when in dri .... al when vehicle II coaSling)
1 2 3
Road noise. No corrective procedures available. Tire noise. Inspect tires and tire pressures [Chapter II. Front wheel bearings loose. ,worn or damaged [Chapter 11.
58 ExcelllVtl brake pedal travel Partial brake system failure. Inspect entire system (Chapter 9) and correc t as required . 2 Insuff icient fluid in master cyllnder. Check (Chapler 11. add fluid and bleed system if necessary. 3 Rear brakes oot adjusting properly. Make a senas of starts and stop. while the vehicle is in Reverse. If this does not correct the situation, remove drums and inspect self-adjusters (Chapter 9). 4 On early models, adjust the brakes {Chapter 91.
59 Brake pedal teel. spongy when depra"ed 1 Air in hydraulic lines. Bleed the brake system (Chapter 91. 2 Faulty flexible hoses. Inspect all system hoses and lines. Aeplace parts IS necessary. 3 Master cylinder mounting nuts loose. Inspect master cylinder [nuts) and tighten to specified torque. 4 Master cylinder faulty [Chapter 9).
60
54
Vib ration
See probable causes under Drill8shaft, Proceed under the guidelines listed lor the driveshalt. If the problem persist •• check the rear wheel bearings by raising the rear of the vehicle and 5pinning the wheels by hand. Listen for evidence of rough {nolsyl bearings. Remove and inspect (Chapter 8).
1 Power break servo not oparating properly (Chapter 9). 2 Excessively worn shoes or pads. Inspect and replace if necessary IChapter 9). 3 One or more caliper pistons or wheel cylinders seized or sticking. Inspect and rebuild as required (Chapter 9). 4 Brake shoes or pads contaminated with oil or grellSe. Inspect and replace as required (Chepter 91. 5 New pads or shoes installad and not yet seated. It will take awhile for the new material to seat against the drum [or rotOl') .
61
1 Pinion seal damaged [Chaptar 8). 2 Axle shalt oil seals damaged [Chapter SI. 3 Differentiel inspection cover leaking. TIghten mounting bolts or replace the gasket a5 required [Chapter 81.
Elllce"iva affon required to stop ....hlcle
P.dal trayell 10 floor wilh Iltlle resistance
Little or no fluid in the master cylinder reservoir (caused by leaking wheel cyl inder{s). leaking caliper piston[s). loose. damaged or dlscon· nected brake linesl. Inspect entire system and correct as necessary.
62
Brake pedal pul.at•• during brake appllcallon
Brakes Nota: Before assuming that a bfllke probkm alCists. make sure that the tires lire in good condition lind infillted properly (see Chllpter 11, the front end alignment is correct lind IfIlII Ihe vehicle is not loaded with weight in an unequal manner. 56
Vehicle pull. to one side during breklng Defective. damaged or oil contaminated brake shoes or pads on
1 Wheel bearings not adjusted properiy or in need of replacement (Chapter 11 ). 2 Caliper nOI sliding properly due to improper installation or obstructions. Remove and inspect [Chapter 9 1. 3 Aotor not within specifications. Remove the rotor (Chapter 9) and check lor excessive lateral runout and parallelism. Have the rotor machined or replace it with a new one. 4 Out·of-round brake drums. Aemove the drums and have them resurfa ced or replace them with new ones.
0-24
Troubleshooting
Suspension and steering 63
,
2 3
VehIcle pulls to on. ,Id.
nre pressures uneven !Chapter
1).
2 Defective tire (Chapter 1). 3 Excessive weal in suspension or steering components {Chapter 11. 4 Front end in need of alignment. Take vehicle to 8 qualified specialist. S Front brakes dragging. Inspect brake. 815 described In Chepler 1.
64
1 Steering pump drivebeh taulty or not adjusted properly (Chaptar 1). 2 Fluid lavel low (Chapler 11. 3 Hoses or lines restricting the flow. Inspect and replace parts as necessary. 4 Air In power steering system. Bleed system (Chapler 11).
Shimmy. shlke or vlbretion 69
Tire or wheel oUl-al-balance or out-of-round. Have professionally belanced. 2 L0058, worn or out-ol-adjustment wheel bearings (Chapter 11. 3 Shock absorbers end /or suspension components worn or demo aged (Chepter 11.
65 bee.siva plcchlng Ind/or roiling around corner. or during brlklng 1 Datective shock absorbers. Replace as a sat ICheptar 11). 2 Broken or weak springs end/or suspension components. Inspect as dascribed in Chapter 11 .
66
1 2 3 4
70
b:casslva tlra _ar Inot spaclflc to ona er(8) Incorrect tire pressures (Chapter 1) r lfes out of balance. Have professionelly balanced . Wheels damaged. Inspect and replace as necessary. Suspension or steering components excessively worn ,Chapter 1).
Excessive tlra _ar on ouu.lda edge
1 Inflation pre8lures not correct !Chapter 11. 2 Excessive speed on turns. 3 Front ernlalignment incorrect (excessive toe-in I. Have professionally aligned. 4 Suspension arm bent or twistad.
bceulvely stiff steering
Lack of lubricant In steering box (manual) or power steering fluid reservoir IChapter 1). 2 Incorrect tire pra8lures (Chapter 1). 3 Lack of lubrication al sleering joints (Chapter 1). 4 Front end out of alignmenl. S See also Section 68, Lscl( of power assistanca.
, 2 3
72 67
Excessive weer in suspension 01 steering components (Chapter 1). Steering g8el Oul of adjustment (Chapter 111.
bcauiva play In st-'ng loose wheel bearings (Chapter').
1 2 3
Inflation pres.ures incorrect (Chepler 11. Front end alignment incorrect (toe-out). Have professionally aligned. loose or damaged steering components (Chapter "I.
Twa traad worn In one place TIres out o f balance. Damaged or buckled wheel. Inspect and replace ., necessary Defectiva tire.
1-1
Chapter 1 Tune-up and routine maintenance Content. Air filter end PCV filler replacement .......•........... Automatic: transmission fluid change ..•..•.....
17 27
Battery - check .nd maintenance
....... .
38
Brake check .. .. .. .. .. . .. .. .. . .. . . •. • .. .. C.rburetor choke check (late models onlyl ............. . Carburetor mounting torque check ................... . Chassis lubric8Iion • . • • . • . . . .•..•.•.•• • •.•.•. CIUICh pedal tree pie.,. check •..•.•.•..•.•...••••.•. Cooling svstem check. . . . . . ............... .
31 I.
Cooling system servicing (draining, flushing and refilling) ............. . Contact points and condenser - replacement and adjustment (1953 through 1974 models) ................... .. . Cylinder compression check •..•......•.•.•..•....... Differendel lubricant change ...•.•......•... Drivebelt check and adjustment ..•..... Engine idle speed adjustment ....•....•.•••.•..•... Engine oil and filter change. . . . . ..•.•.••••.•.••.•.. Evaporative Control System (ECSllitter repl.cement ....•.• bhausl Gas Recirculation I EGRI valve check ...... . bhaust svstem check E~haust heat valve check ........•.••••.•...••
20 7
24 8
3. 34 37 30 11 21
5
3. 23
•
22
Fluid level checks ..........•.•...••.•••••••.••.• Fuel filter replacement .......••...••....... Fuel system check . . . . . . . • . • . • • . • • • . • • . . . . • . • •. • Ignhion timing check and adjustment •.•....•.•..• • ... Introduction to routine maintenance ......•..••... . • Manusl transmission lubricant chan.ge •••..•.•.........• Oil bath·type air cleaner service •.•.••••.•.•.•..• Positive Crankcase Ventilation (PCVI valve reptacement Routine maintenance schedule ....••..•.•...... Spark plug replacement •.•......•.•...•...... Spark plug wires, distributor cap and rotor - check and replecement .......•...... Suspension and steering check ....•....... Thermo·controlled Air Cleaner IT ACI check .... Tire and tire prassure checks •. . . . • .• •• Tire fotation . . • . • . . • . • . • . • . . • . • . • . •. .. . •..•... Transfer case lubricant chanoe •. . •.•............. Tune·up sequence .......•.• •. . ••.............. Underhood hoses - check and replacement . • ••••••.•• Valve ctearance adjustment (F- and L·head en.gines onlyl •• Wheel bearing check ••.•.•.••••.•.•. . ..••.•• Windshield wipers - Inspection and blade replacement .
. Specifications Not.: Additional specifications can be found in the appropriate Chapters.
Recommended lubricants and fluids Engine oil type Single viscosity Above +4O"F (150 C) .... .......................... . ..... . Above O"F (-I8"C) ....................... . . ........... . Below O"F (- 18" C) . .. . .................. . Multi-viscosity Above +4O"F (150 C) ........... . Above 0" (-18" C) . . . ' . ............ .......... .
Below 0" F (- 18" C) . ......... . °Do not operata at speeds above 5S mph with SAE JOW oil Engine coolant type . .... . .....•..•....•. . .•..•.. •... Automatic trat\$mission fluid type .......... . ....... ... . Manual transmission lubricant type T·5 (5-speed) ••.••.•••..••••..•.••••.••• • •• o • • o. Allothilrs ..................................... . Transl.. case lubricant type and viscosity $pic8f 18 and 20 .... .... ............................... . Model 300 ..... .. . .... ................. .. ............. . Quadra-Trac ..•. . .•..• .... Front and rear differential lubricant type and viscosity Conventional .. .. .. .......... Trac· l oc •..•... . ........•.... Brake fluid type . • . . . . ......•... Steering gear lubricant POWIlf steering system fluid .•....•.• Suspension and steering component grea58 .. . Wheel bearing grease ......................... .
API SF rating
SAE 30 01' 40W SAE 20W SAE lOW
SAE 10W-JO. 20W-30 or 10W-40 SAE 10W-JO or 10W-40 SAE 5W-20 01' 5W-JO
50150 mix 01 water and ethytene glycol based antifreeze OEXRON II Jeep Manual Transmission lubricant (part No. 4874464) SAE 75W·90 API Gl-5 gear lubricant API Gl-5, SAE SOW-90 API Gl-5, SAE S5W-90 Jeep Ouadra-Trac lubricant 01' SAE JOW non-detergent motor oil API Gl-5. SAE BOW-90 API Gl-5, SAE BOW-90 limited slip lubricant DOT type 3 (SAE J1703) LHhlum based chassis lube
OEXRON II NlGI No.2 lithium based grease NlGI No.2 lithium based grease
Capacities Engine oil (With filter change) F- and l-head four-cylinder engine ••...•. • .•. Sj~·cyljnder engine ...•.•..•.... V6 engine. . . . .• . . . . ...••....•.. VB engine ..•..•... 151 cu in lour-cylinder engine. 150 cu in four-cylinder engine.
5 US qts
6 USqts 5 USqts 5 USqts 3 USqts /I US qts
4 14
13 35
,. 1
28
15 3 32 33
10 18
•
25
2'2 12 40 2• 41
1
Chapter 1 Tune-up and routine maintenance
1-2 Capacities (continued) Cooling system
F- and l-head four-cylinderengil"l9 ............. . Six-cylinder ellQine ....•..•.••.••. V6 engine ................ . VB engine 1972 through 1976 ............. .. .. . ... , .. , .... .
1977 through 1981 ......................... . ......... . 151 cu in lour-cylinder engine .•. '50 cu in four-cylinder engine Standard ........ . ........ . With air-conditioning or heavy duly system Automatic transmission Through 1979 1980 through 1986 Manual transmission 3-speed (F- and l-head and V6 engines) 4-speed (F- and L-head and V6 engines) .................... . 3-speed (six-cylinder engine) 1972 through 1975 ... . . . 1976 through 1979 .•. 3-speed (V8) •.•..•.••.••. 4-speed 1972 through 1979 1980 through 1986 SR-4 ........ . •..•.••. . ~176 ................................ . T-55-speed ........... . . . Transfer case Model 18 ..................•..• . ..•..•..•..•. Model 20 . . ............................ . Model 300 ................. . Cuadra-Trac (1976 only) With reduction unit . ........ . All others .............. . Cuadra-Trac (1977lhrough 1979) With reduction unit . All others ............. .... . Differential ThrOU9h 1971 (fron t and rear) 1972 through 1975 Front ...................... . Rear 1976 and 1977 Front Rear ...... . 19781hrou9h 19B6 Fronl. . ............................... . Rear
12USqts 10.5 US qts 10 US qts 14 US qls 12 US qts 7.8 US qls 11 USqts 14 US qts 5 US qts 4.25 US q l s 2.5 US pIs 6.75 US pIS 2.5 US pis 2.8 US pIs 2.75 US pIs 6.5 US pIs 3.0 US pIs 3.5 US pIs 4.0 US pIs 3.25 US pIs 3.25 US pIs 4 US pIs 4.5 US pIs 3.5 US pIs 2.5 US pIS 2.0 US pIs 2.5 US pIs 2.5 US pIs 3.0 US pIs 2.5 US pts 4 US pIS 2.5 US pIs 4.8 US pIs
Spark plug type (Check the Emissions Control Information label Specifications for your vehicle) F-head four-cylinder engine L-head four-cylinder engine In-line six-cylinder engine . V6 engine ......... V8 engine .......... 151 cu in four-cylinder engine 150 co in four-cylinder engine
...
. .. • ..•. • ...•. • ... •
AC-45 or Champion J·8 Champion J-B N12Y. RN12Y. N13L or RN13L AC-44S or Champion UJ12Y N12Y or RN13L ACR44TSX Champion RFN14LY
Spark plug gap F-head four-cylinder engine .. L-head four-cylinder engine .. In-line six-cylinder engine V6 engine .. VB engine . .. ........ . 151 cu in four-cylinder engine 150 cu in four-cylinder engine
0.030 in 0.030 in 0.03310 0.037 in 0.035 in 0.033 to 0.038 in 0.060 in 0.035 in
Spark plug firing order All four cylinder engines .... Six-cylinder in-line engine .. V6 engine VB engine
1-3-4-2 1-5-3-6-2-4 1-6-5-4-3-2 1-8-4-3-6-5-7-2
1-3
Chapter 1 Tune-up and routine maintenance Distributor direction of rotation F- and L·head four cylinder engines. All others
Counterclockwise Clockwise FIRINC OROER 1.3.4.2
Battery specific gravity · (fully charged) F- and l -hesd lour-cylinder and V6 anginas All others ... . . _ . .
1.260 1.265
Distributor point gap l -head engine Autohte distributor Oelco-Aemy distributor F-hesd engine (Prestolite distributod _ ___ . All sill -cylinder and V8 engines
0.020 in 0.022 in 0.020 in 0 .016
F- and L-head four-cylinder engine (1953-1971)
Dwell angle l -head engine . F-head engine In-line sill-cylinder engines V-6 engine PreSlolite distributor Oelco-Remy distributor V8 engine
25 to 34°
42' 31 to 34°
32' 30' 29 to 3 , 0 fiRING ORDER
Ignition timing F- and l -head non-emission controlled engines . ..... . F-head emission controlled engines. V6 engine Oelco-Remy distributor Prestolite distributor In-hne SllC -cylind9f engines 1973 and 1974 232 cu in engille 258 cu in engine 1975 232 cu in engine (Without EGRI 258 cu in engine (with EGR) . '976 232 and 258 cu in engine (manual transmisSiOn) 258 cu in engina 'automatic transmission) . 1977 232 cu in engine With 49 -state emission tYF carbure torl 232 cu in engine with almGde compensator (YF carburetorl Above 4000 It Below 4000 It 25S cu III engine (YF carburetor) Manual transmiSSion and 49-state emissions Manual transmission and altitude compensator ___ _ . Manual transmission and California emissions Automatic transmission and 49-5tate emissions . . .. . Automatic transmission and California emissions . _ .. . 258 cu in IInglne (BBO carburetor) 1978 232 cu in engine tYF carburetorl Manual transmission and 49-slale emissions Manual transmission and altil ude compensator Above 4000 ft Below 4000 It 258 cu In engine (YF carburetor) Manual transmISsion and 49-state emissions Manual transmission and California emissions _. Automatic transmiSSion and 49 -sta te emissions. Automatic transmission and Californis emissions 258 cu in engine (BSO carburlltor - all) . 1979 258 cu In (YF carburetod Manual transmission Automatic transmission 258 cu in (BBD carbOietor) Manual tranSmISSiOn Automatic transmiSSion
1+~4-)'2
1
5° BTDC 0° (TDC I 5° 8TDC
0"
(TOC)
5" BTDC
V6 engine (1953-1971)
3° BTDC 3" to 7° BTDC ,0 to 5° BTDC 6° to , 0" BTOC 4° to 8° BTDC 5° BTDC
. ®®0®®CD
10'
S' ," 8" 4" 8° 6° 4°
to to to to to to
5° BTOC '2° BTDC 8° BTDC 12° STDC 10" BTDC 8° BlOC
3° to 7° 8l0C 80 to 12° BTDC 5" BTOC 1° 6° 8° 6° 40
to to to to to
Inlina sIll-cylinder engIne (1972-1974)
. ®®0®®CD
5° STDC 10· BlOC 10· BTOC 10" BlOC 8° BTDC Inline-silt·cylinder engine (1975-1986)
4° to 8" BTDC 2° to 6" BlOC 6° to S" BTOC So to , 0" BTDC
Cylinder location and distributor rotation
1-4
Chapter 1 Tune-up and routine maintenance
Ignition timing ( continued) VB engme
4° to 5° BlOC to 7" BlOC
1973 and 1974 . .. . . 1975 (manual transmission)
UFT aANI!
3°
1976 Automatic transmission and 49-state emissions . . ... • .... • •. Manual transmission and 49-state emissions ............. . . Manual and automatic transmission and California emissions
1977 49 state emissions ...
8" to 12" BlOC 3" to 7" BlOC 3" to 7" BlDC 8" to 12'" BlOC
3" to 7" BlOC
California emissions . .
1978 Manual transmission
Automatic transmission
...• • ..•
Automatic transmission and California emissions ..... _ ..... .
3" to 7" BlOC 8° to 12" BlDC 3° to 7" BlOC
1979 Manual transmission .. . . •. . • .• ..• . .•..• . .•..• . .• .. • . Automatic transmission . ••.•..•.•..• . •• .. • . •• .....
3" to 7" BlOC 6" 10 10" BlOC
CLOCKWISE ROTATION ,,,·4·3 ·1-6·7 ·' RIGHT
IlAN~
CD CD CD FRONT!)
V8 engine (1972-1983)
1980 Manuallransmission and 49-state emissions ... .. .. . . Manuallransmissioo and California emissions . .. ....... .. . . Manual transmission hilly terrain operation ... Automatic transmission and 49-state emissions Automatic transmission and Califomia emissions . • _ ... . . , . .. 1961 Manual transmission and 49-state emissions ., .. , .. , .. • .. , _ Manual transmission hilly terra in operation , .. , .. , ..•.. , .. • _ Automatic transmission and 49-state emissions . • .... .. •. .•. 151 cu in four-cylinder in-line engine 1960 and 1961 (with vacuum advance hose disconnected) Manual transmission and 49-state emissions •.. • . . •. . •..• . . Manual transmission and California emissions . • , .. , . • ,. Automatic transmission and 49-state emissions , , . Automatic transmission and California emissions 1962 (with vacuum advance hose disconnected) Manual transmission and 49-state emissions Manual transmission and Califomia emissions Manual transmission high altitude operation (above 4000 tt) . , . 1963 (with vacuum advance hose disconnected) (all) •.. • ..•..• , . 150 cu in four-cylinder engine 50 state .......... , High altitude ..... , .. . .. . _ . • • . . _ .• ..• _ .•..• , . .
6" 10 10" BlOC 3" to 7" BlOC 10" to 14° BlDC 8" 1012" BlOC 3° to 7" BlOC 8" BlOC 12" BlDC 10" BlDC 10" BlOC 12'" BlOC 12° BlOC 10" BlDC
12" BlDC 6"BlDC 17° BlOC 12'" BTDC 12" BlOC 19" BTDC
Valve clearances F-head engine Intake .. . " .•• . •... .. , . Exhaust , . . . •..•....•. . •. ... L-head engine Ontake and exhaust) •.•. . , . . . .
0.016 in 0,018 in 0.016 in
Curb idle speed settings L-head engine ..•. , .. , .. , . F-head engine YF-938-SD carburetor . , . YF-4002-S carburetor .. . .... , YF-4366-S. YF-4941-S and YF-5115-S carburetors With distributor IAY-4401A . With distributor IAY-4401 B . V6 engine (all models) ... . ..... , In-line six-cylinder engines 1972 and 1973 Automatic transmission . , .. , . . •..•. Manual transmission wi th EGR .... . , .. • . . •..•.. . ..•. . •. Manual transmission without EGR. . . ... • .. • .. • . • _ .. _ .. _ . 1974 Automatic transmission Manualtransmission . . 1975 232 and 258 cu in engine without EGR 258 cu in engine with EGR Manual transmission Automatic transmission ... ... . ...•.• . ..•. .... • ... 232 and 258 cu in California engines , . . •. . •. . , .. . . 1976 232 cu in engine (manual transmission) . . 258 cu in engine Automatic transmission .• .. _ . ... _ .•... _ .• _ .••.• _ .••.
0@00
600 rpm 600 rpm 650 to 700 rpm 650 to 700 rpm 700 to 750 rpm 650 to 750 rpm
550 rpm 600 rpm 700 rpm 550 rpm 600 rpm 700 rpm 450 to 650 rpm 550 to 750 rpm 500 10 700 rpm 500 10 700 rpm 450 to 650 rpm
151 cu in four-cylinder en9ine (1980-1983)
FRONT
G
(0000)
~ 150 cu in four-cylinder (1984-1986)
Cylinder location and distributor rotation
Chapter 1 Tune-up and routine maintenance Autom.tic transmission and Caillornia emissions Manual transm ission Manual transmission and California emissions 1977 without altitude compensation device Manual transmiSSion Automatic transmission 1977 with altitude compensation davice Manual transmission Automatic transmission Manual transmission and Calilorn,a emission! __ Automatic transmission and Cahlornla emissions 1978 232 cu In engine Manual trensmission AutOm.IIC transmlsslon/ahllude comp60&a llon device_ 258 cu in engine Manual transmission Manual transmission/altitude compensation device __ Automatic transmission _ _. .. . 1979 and 1980 Manual transmiSSion Automatic lIansmission 1981 and 1982 Manual transmiSSion Automatic lIansmlssion 1983 Manual transmission and 49-stalll amissions. Automatic t"nsmission and 49-sl8le emissions Manual lIansmission and California emissions Automatic tlllnsmission and California emissions.. .. _ . Manual transmission and altitude compensation device .. Automatic transmission and altitude compensation device V8 engine ' 1972 through 1974 '975 and 1976 Manual transmission Automatic transmission 1977 Manual transmission Automatic transmiSSion 1978 Manual transmission Autom.tic lIansmlSSlon 1979 Manual transmission Manual transmission and California amissions ...... _ .. Automatic transmission 1980 Manual transmission Automatic transmission and 49-stale emissions Automatic transmiSSion and California emissions. 1981 Manual lIansmission and 49-state amissions Manual transmission and hilly terrain operation AutomatiC lIansmiSSIon 15' cu In lour-cylinder engine '980 and '98' Manual transmission Automatic "ansmission , 982 and 1983 (all models) 150 cu in lour-cylinder engine
600 to 800 'pm 500 to 700 'pm 500 to 700 rpm 850 rpm 550 rpm 600 550 850 700
rpm rpm 'pm rpm
750 to 950 rpm 500 to 700 rpm 750 to 950 'pm 500 to 700 'pm 450 to 650 rpm 600 to 800 rpm 500 to 700 rpm 650 rpm 550 rpm 600 500 650 550 700 650
,pm rpm rpm rpm rpm rpm
700 to 800 ' pm 650 to 850 rpm 600 to 800 rpm 700 to 750 'pm 700 rpm 650 to 950 rpm 600 to 800 rpm 600 to 800 rpm 650 to 850 rpm 550 to 750 rpm 600 10 800 'pm 550 to 750 rpm 500 to 700 rpm 500 to 700 rpm 700 'pm 550 to 650 rpm
900 rpm 700 rpm 900 rpm 750 rpm
Compres sion pressure F- and L-head four-cylinder engines
V6 engine In-hne six-cylinder engines 232 cu in engine 258 cu In engine V8 engll'\e 151 cu In fOUl-cylinder engine 150 cu in lour-cylinder engine
120 to 130 psi lowest reading cyl, must ba at least 7596 of highest reading cyl. '40 psi 150 psi 140 psi 140 pSi 155to185psl
Clutch pedal free pia V 1953 through 1972 1973 through' 975
1-5
3/410'-'/4In 1/2 to 3/ 4 in
1
1-6
Chapter 1 Tune-up and routine maintenance
Clutch Dedal free plav (continued) 1976 and 1977 ...... .
3/4 101 in 1 to 1·1/4 in
1978 through 1986 ....... .
Brakes Disc brake pad lining service limit . ......•. Drum brake shoe lining service limit Bonded . ... . . . . . . ........ . . ... . . Riveted . .. ....•.•......•
When worn to approximately the thickness of the pad backing plate
Torque specifications
Ft-Ib
Nm
Automatic transmission oil pan bolts . . . ... . . . Manual transmission drain and fill plugs .......• Transfer case drain and fill plugs. . .......... . .. . Axle housing drain and fill plugs. . . . . . ..... . .... . •. . Spark plugs F- and L-head lour-cylinder engines V6 engine .......•........•. All others
12 15t020
16 20 to 27 20 to 34 20 to 34
1116 in 1132 in above rivet head
15 to 25
15 to 25 25 to 33 25 to 35 22 to 33
1 Introductio n to routine ma inte nance This Chapter was designed to help t he home mechanic maintain his lor I'H;If) vehicle for peak performence, economy, safety and long life. On Ihe following pages you will find a maintenance schedule along with Sections which deal specifically wilh eech item on the schedule. Included are visuel checks, edjustments and item replacements. Servicing your vehicle using the tim&/mileage maintenance schedule ,tnd Ihe sequenced Sections will give you e pl anned program of maintenance. Keep in mind that it is a compre hensive plan; maintaining only a few itams althe specified intervals will not produce Ihe same results . As you service your vehicle you will find Ihat, due 10 the neture of the job, many of the procedures can and shoul d be grouped logether. Examples of this ere: If the vehicle is reised for chessis lubrication, it is an ideal time for the manual transmission oil, exhaust syslem. suspension. sleering and fuel system checks. If the tires and Wh86ls ere removed, es during e routine lire rotation, go ahead and check the brekes and wheel bearings al the same time. If you must borrow or nmt a torque wnmch, it is 8 good idea to replace the spark plugs and/or repack (or replace)lhe wheel Dearings all in the same day to save time end money. The first slep in this or any mainlenance plan is to prepare yourself before the actual wo rk begins. Read through the appropriate Sec tions for all work that is to be performed before you begin. Gather together all necessary parts and 10015. If it appears that you coutd have a problem during a particular job, don't hesitata to ask advice from you r local parts man or dealer service department .
M inor tune·up
•
Clean, inspect and test battery ISec 38) Check all engine-related fluids ISec 41 Check cylinder compression (Sec 371 Check and adjust drivebelts ISec 11) Replace spark plugs (Sec 32) Inspect distributor cap and rotor (Sec 32) Check andlor replaca breaker points and adjust dwell angle (Sec 341 Inspect andlor replace spark plug and coil wires (Sec 331 Change oil and filter (Sec 5) Check and adjust idle speed ISec 211 Check and adjust timing (Sec 35) Check and adjuJt fue1/air mixture (Chapter 41 Replace fuel filte r ISec 141 Replace PCV valve (Sec 15) Adjust valve clearances ISec 401 Check cooling system (Sec 8)
Major tune-up Perform all operations listed under Minor tune-up Check ignition advance systems (Chapter 51 Check EG A system (Chapter 6) Test alternetor end regulator (Chapter 5) Test igni tion system (Chapter 5) Test cha rging 5Y5tem (Chapler 5) Check fuel system (Chapter 4)
3 2
34 to 44 34 to 45 17 to 44
Routine maintenance schedule
Tune-up . equ ence
The term 'Iune-up' is loosaly applied to any general operation thaI puts the engine back into proper running condi tion. A tune -up is nol a specific operation, but rather a combination of individual operations, such as replacing the spark plugs, adjusting the idle speed, selting the ignilion timing, etc. If. from tha time the vehicle is new, the routine maintenance schedule ISection 3) is followed closely and frequent checks are made 01 fluid levets and high wear items. as suggested throughout this manual, the engine will be kept in relatively good running condition and the need for all inclusive tune-ups will be minimized. More likely than not, however, there will be times when the engine is running poorly due to lack of regular maintenance. This is even more likely if a used vehicle which has not received regular and f requent maintenance checks is bought. In such ceses an engine tune-up will be needed outside of the regular routine maintenance intervals. The following serias of oparations are those most often needed to bring a generally poor running angina back into a proper state of tune.
This maintenance schedule covers all of the service procedures recommended by the manufacturer. In some instances the intervals have been altered where additional or more frequent checks are advisable. Note: Not ell maintenance checks or operations are appliceble to every
model.
Every 250 miles, _ ekly or before a long trip Check the tife pressures (when cold) Inspect the tires for wear and damage (Sec 6) Check the steering for smooth and accurate operation (Sec 10) Check the power steering fluid level, refilling as necessary ISec 41 Check the brake fluid level and , if it has dropped noticeably, inspect the system lor leaks (edd fluid if necessary) ISec 41 Check the operation of the brakes ISec 311 Check the automatic transmission fluid level (Sec 4)
~)
Fig . 1.1 , Blltt.,')' 2 Hell t., hOSIlS
3 Air cltum.r IIsstHnbly 4 Air Injection systllm
"""
5 C.rbur.tor 6 Br.kII boost.,
engine comp.nment compon8ntl (typklillat. model in-lin. slx-cyllnder)
,
~
0>
----.
,
Fig. 1.2 Engine compartment components (typical late model VB)
Battery 2 Heater hose 3 Air cleaner essembly
6 Windshield washer
4 Fuel filter
8 Radiator 9 Distributor
5 Brake master cylinder reservoir
reservoi, 7 Powel steering pump
10 Rlldistor cap
"
Oil filler cap
12 Upper fadiafor hose , 3 Emissions Control Information label 14 Ignition coil
Ag. 1.3 Englntl comp.lt"",nt undersKle compOflent. Uvplc.lI I 2 3 4 5 6
Spring Spring bU$hin9 Sway bar Grease lirr;ng Steering geer Steeflng arm
7 Grea$e fitting 8 Steering damper 9 Steering knuckle 10 Braka calipar /I Brake line 12 A)lle hOU$l·n9
'3 Engine oN drein plug 14 Drive$haft 15 Front dflveshalt univarsal iomt 16 Differentiel housmg
17 Differential housing cover 18 Shock absorber 19 Grea$e fitting 20 Graase fitring ~
~
'"
1-10
•
~~
~.s: :!:! ,~~
"'" 'O! ~
E c: &.Q ~ !!.c: o.'b
'i;.!"§ ~ ~ ...::,"tt .. ~
~
E
---
•••
..
• 0
~
~
0 u
2:
~
.if ~
•• ••
~
••
~
~
0,0-,...
-
""'a!. ~ .. . ~~ ~
~.-
~ .s ~ S t;
~
\(')1Q .....
ctI
't:;
t}cft5~
1-11
Chapter 1 Tune-up and routine mainten ance Check the operation of all tights Check the operation of tha windshield wipers and washers Check the wiper mechenism and blades lSac 41) Fill the washer reservoir as necessary (Sec 4) Check the horn operation Check the operation of ali gau.ges and instruments Check the radiator coolant level ,Sec 4) Check tha battery electrolyte level fSec 4)
Every 5000 mllea or 6 months, wh ichever comas flrat Lubricate the auspenaion and steering components (Sec 7) Check the PCV valve lor proper operatIOn (Sec 15) Change the engine oil and filtel {Sec 5) Check and lubricate the clutCh lever and linkage (Sec 7) Check the tlansfer ca" lubricant 18vel (Sec 4) Check and adjust the engine idle speed (Sec 21) Check the manual transmission lubricant level (Sec 4) Lubricate the rear wheel bearings on 1953 /hrough 1971 modals with grease finingl (Sec 7) Check the Iront and rear axle lubricant level (Sac 4) Inspect the 8xhaust system (Sec 9) Check and adjuS! the F· and l-head valve clearances (Sec 40) Inspect tha brake line. and hose. (Chapter 9) 'napect the m.ke discs and peds (Sec 311 Check the ste8l'in9 box lubrican1 level (Sec 7)
Evary 3000 mUes or 3 mont ha, wh lchev8r comea flrat Change engine oil and liltel (heavy-duty operation) (Sec 5) Check and service the 011 bath-type air cleanel (Sec 16) lubficate the clutch lever and linkage (heavy-duty operation) (Sec 71 Lubflcate the suspension and steering components {heavy-duty operation) {Sec 7)
1
®
~
FOUR·CY LINDER ENGI NE
®
NOT APPLICABLE
SIX-CYlINDER ENGINE
NOT APPLICABLE
va ENGINE
,
Fig. 1.5 1S71 through 1986 model enSine compartment chacks
Engine oi/level
2 Oil filler 3 Oil filter 4 Automatic transmission fluid level
5 Battery alec/lolytB level 6 Braktt master cylinder fluid levttl 7 Coofant level and condition
8 Power steering Iluid HJvel 9 Dn"vebelt tension 10 FUlIf filter
12 Air cleaner fifter element 13 PCV filrer
"
15 Spark plug replilcement
Exhaust heat valve check and lubricatIOn
14 PCV valva and hose connections
1-12--------------------------------------------------~
)
Fig. 1.6
'953 through 1971 ch.I.I, lu bricat io n a nd check points
Ch~ssis
belJring grease fittings 2 Spring sheckle lind
pivot bushings 3 UnivfI(SlJ1 joints [md
•
o
driveshllh Front axle bearings
5 Steering
g88( housing 6 Reef wheel bfJllrings
7 8 9 10
Front wheel billrings Tnlnsmission Transfer elise Front differrmti/JI
"
Rallr differe~tilll
12 Distributor 13 V6 engine distributor
I. Ai, cfellner 15 Engine oil
cv-Co
LUBR ICAT ION PO INTS
Fig. 1.7 1972 through 1986 cnassis lubrication and check points Front lind rear differentials 2 Front wheel be8fings end manuel locking hub 3 Brake operation end ffuid level
•
Clutch leve' and linkege
5 Exhaust system ch.ck 6 Manuel st08rin9 gear 7 Driveshefr
BRAKES
Chapter 1 Tune-up and routine maintenance Check the dellection 01 all drivebelts (Sec 11 f Check the operation 01 the brake booster (Chepter 9) Check the steering wheel lor excessive free play (more than an inchf (Chapter 11) Inspect and lubricate the exhaust manifold heat valve (Sec 22) Drain and replace the transfer 08se lubricant (neavy-duty operation) (Sec 29) Lubricate the F· and L·head engine distributor (Sec 34) Check and replace (il necessary) the air cleener 'ilter element (Sec 17) Inspect the distributor cap and rotor (Sec 33) Lubricate Ihe drivesha!t universal joints (Sec 71
Every 10 000 mile. or 10 month., whichever come. flnl Replace the automotic transmission fluid and filter Iheavy·duly operation (Sec 27) Inspect the brake linings and drums (Sec 31) Check Ihe emissions system air injection hoses (Chaptar 6f Replace the fuel IiIter (Sec 14) Check the radiator hoses for cracks and leaka (Sec 12) Check the shock ab.orberl, bushings and mounts for wear and damage (replace components as necessary) (Sec 10) lubricate the rear wheel bearings on early model CJ·2 with full · lIoating axleshahs (Chapter 11 )
1-13
Check the tightness of the cylinder head bOlts (Chapter 2) Drain and refill the transfer case (Sec 29) Lubricate the locking front hubs (Chapter 8) H.evy·duty Opeqitlon Heavy-duty operation i. defined as Off-fO ad operation 'lee below), extended idling, towing heavy trailers (2000 lb.), operating in dusty conditions or excellive .hon run use (6 to 8 mile trips constituting 30 percent of the vehicle'. use). Shaner maintenance intervals ara recommended In these Instances.
Off·road opel'atlon After driving off fOad through mud, sand or water, check the foUowlng daily: Bl1Jke discs and pads Bl1Jke drums tJnd shoes Brake lines and hoses Tl1Jnsmission, transfer case and differential oil Air filter Alia, lubricate the following daily or a. loon al practical: Steering linkll(le lind knuckles Driveshaft unfverslll joints
1
Every 15000 mile. or 15 months, whichev.r come. firat 4 Check and adjust the automatic transmission linkage (Chapter 7f lubricate all latches. hinges, seat tracks and 10ck cylinders (Chapter 12) Check and adjust, if necessary, the clutch pedal haight (Chapter S) Have Ihe front end alignment checked and adjusted as necessary Replace the spark plugs (Sec 32f Perform a minor or major tune·up as necessary (Sec 2) Check the choke linkage for free movement, lubricating as necessary (Sec 19f Inspect all vacuum hoses and connections (Sec 12 ) Inspect the ECS charcoal canister and replace the lilter, if so equipped (Sec 36) lubllcate the fronl wheel baarings (Chapter 11) Replace the distributor cam lubricator, if so equipped (Chapter 5) Check the EGA system (Sec ~3f Check the PCV valve and hoses (Sec 15) Check the Thermo·controlled Air Cleaner (TAC) system (Sec 1Sf Check the Transmission Controlled Spark (TCS) system (Chapter 6) Inspect the fuel system hoses, connections, fuel tank and cap ISec 13) Check and adjust. as necessary, the transler case shift linkage (Chapter 7)
Every 20 000 miles or 20 month •• whlchlllYer come. first Check the operation 01 the high·altitude compensation system, if so equipped (Chapter 41
E....ry 25 000 mUel or 25 months, whichever camel first Drain and retilt the automatic transmission (Sec 271 Replace ilil drivebelts (Sec 11) Drain and refill th e cooling system With the specilied coolant (Sec 391
Every 30 000 milu or 30 monthl, whlchlllY.r eomel first Drain and refill the differentials (Sec 301 Drain and reti!! the manual !ransmiSlion (Sec 28)
Fluid level chlMlu
There are a number 01 componentl on a vehicle which rely on the use of fluidl to perform their job. During the normal operation of the vehicle. the fluids are uled up and must be replenished before damage occurs. See the Reco~nd~ lubricllnts lind fluids Section at the lront of this Chapter for the specific fluid to be used when additions are reo quired. When checking lIuid levels It Is important to heve the vehIcle on a level surface.
Engine oil 2 The engine oil Javel is checked with a dipstick which I. located at the .ide of tha engine block. The dipstick extends through a lUbe and into the oil pan al tha bottom of tha engine. 3 Preferably, the all level should be checked before the vehicle has been driven, or about 15 minutes after the engine has been shut off. If the oil is checked immediately after driving the vehicle, some of the oil will remain In the upper engine componentl, resulting In an inac· curate reading on Ihe dipltick. 4 Pull the dipstick from the tube and wipe all the oil from the end with a clean reg (photo). Insert the clean dipltlck all the way back into the oil pan and pullt out again. Observe the 01 at the end 01 the dipstick. At its highest point, tha IlIIY8lshould be between the Add and Full markS (photoL 5 It takel approximately one III quart of ojl to raise the level from tha Add mark to the Full mark on the dipstick. 00 not allow the level to drop below the Add mark since engine damage due to oil starvation may result. On the other hand, do not overfill Ihe engine by adding ojl above the Fuft mark al o~·fouled spark plugl, o~ leaks or oil seal fduras may occur. 6 Oil is added to th. engine after removing a twisl-off cap located either on the rocker arm cover or e ra ised tube near the front 01 the engine. The cap Ihould be marked Engintl oN or lomething Ilmilar (photo). An 0;1 cen lpout or funnel will reduce .plill as the o~ is poured in. 7 Checking the 011 Javel can also be an important preventative maintenance lIep. If you lind the oilllllYel dropping abnormally, It I. an indication 01 oil leakage or Intamal engine wear, whiCh should ba cor· rected. If there are water dropletl in the oil, or If it is milky looking, thil also indicatee component failure tthe engine should be checked immediately), The condition of the all Ihould also be checked along with the level. With the dipllick removed Irom the engine. w ipe your thumb and index linger up the dipstick, looking for smatl dirt and metal partIcles, which will cling to the dipstick. Their presence is an Indica· tion that the oil should be c hanged (Sec 5).
1-14
Chapter 1 Tune-up and routine maintenance
Engine coolant 8 Many vehicle •• re equipped with. pressurized coolant recovery system which make. coolant level checks very A clear or white
ee,.,..
coolant reservoir attached to the inner fender panel hi connected by It hose to the radiator neck. At the engine heat. up during operation, coolant i, IOfCed from the radi.etor through the connecting tube and into the felervalr. AI the engina cools, coolan! i, automatically drawn back into the radiator 10 maintain the correct level. 9 The coolant lev1tI,hould be checked when the engine Is cold. MereIV observe the level of fluid in the fe.ervoir. which should be al or near the Full cold mark on the ,Ide of the reservoir. If the Iystem i, completely cooled, ,1'0 check the level in the radiator by removing the cap.. Some systems also heve It Full hot mark to cneck tne level wnen tne engine is not. 10 If your particular venicle i. not aquipped witn a coolant recovery system, tna level snould be cnecked by removing tne radiator cap. Warning: The cap should not, undar any circumstances, ba remolllBd whita the system is hot as escaping steam could cause san"ous injury.
4.4A Witl'ldrawing tne 011 dipstick (VB engine snown)
Wait until tha angine has compf8taly coolad, then WftJp a thick cloth around the cap and tum it to its first stop. fI any steam escapes from tM caA tIIIow t"- engine to cool fUrTher, then remolo'l'l the cap and check the1eve1 in the ftJdietof. It should be ebout one inch below the bot· tom of the filfer neck (photoJ. 11 II only a small emount of coolant is required to bring Ine system up to tne proper level, regular waler can be used. However, to maintain tne proper antifraaze/water millture in tne system, both should be mi ..ed together to repleni.h e low level. High-quality antifreeze ollering protection to - 2O"F .hould be milled with water in tne proportion specified on tne container. Do not allow antifraeze to come in contact witi'! your skin or painted suriaces 01 the venicla.. Flusi'! conU!cted areas immedietely witn plenty of water. Caution: Antifreeze can be flltal to childrtln end pets. They like it because It is sweet. Just a few drops can cause death. Wipe up garage floor end drip pan coolant spills immedia tely. 12 On syatems with a recovery tank., coolant should be added to the reservoir aher removing the reservoir cap. Coolant should be added
4 .48 The level on the dipllick must be between the Add end Full marks (arrow.)
"J
4 .6 Remove the engine o~ filler cap by rotating it and lilting it away from the rocker erm cover (latar model in·line sillcylinder shownl
•
4 .10 Cnecklng tne coolant level in me radiator {in tnla ellample the level i. low)
4 .18 Removing tne cap. to check tne banery electrolyte level
4 . 24 Cnecklng tna brake master cylinder fluid level
4.43 Dana Model 300 transfer case filler plug location (arrow)
4.19 Carefully add distilled water to the benery cells to avoid splattering electrolyte
Fig . 1.8 Quadr.-Trac tran.fer ca •• fill and drain plugs ISec 4 and 291
Chapter 1 Tune-up and routine m aintenance
1-1 5
directly to the radiator on systems without a coolant recovery tank. 13 As the coolant level is checked. note the condition of the coolant. It should be relatively clear. If it is brown or a rust color, tne system should be drained. flushed and refilled ISec 391. 14 If the cooling system reqUires repeated additions to maintain the proper level. nave tne radiator cap cnecked for proper sealing ability. Also. check for leaks in the system (crackad hoaes, loose hose connections. leaking gaskets. etc.) (Sec 12).
the proper level. it is an indication olleakege in the brake sy5lem which should be corrected immediately. Check all brake ~nes and connections. along with the wheel cylinders and booster Isee Chapter 9 for more informetionl. 29 If upon checking the mester cylinder fluid level you discover one or both reservoirs empty or nearly empty. the system should be bled (Chapter 91. When tne fluid level gelS low, air can enter the system and should be removed by bleeding the brakes.
Windshield washer fluid
Manual transmission lubricant
15 Tne flukl for tne windshield wnner system Is located in s plastic reservoir_ TheJ.eve1 inside the reservoir should be mainteined st the Full mark. 16 A good quality washer solvent should be added to the reservoir whenever replenishing is required. Do not u.e plain water alone in thi. -vltem, e.pecially in cold climates wnara tne water could freezl.
30 Manuel transmissions do not heve • dip5tick. The oil level is checked by removing a plug in the aide of the transmission case.lDcate the plug and use a reg to clean the plug and the area around It. 31 With the engine cold, remove the plug. If oil immediately stans leaking out, thread the plug back Into the transmission becllusa Ine levell. all right. If there is no oil flow. completely remove the plug and place your little finger inskle the hole. The oil level should be just at the bottom of the plug hole. 32 If the transmission requires more oil. usa a syringe 10 squeeze Ihe eppropriate lubricant into the plug hole to bring the oil up to the proper level. 33 Thread Ihe plug beck into the transmillion and tighlen it secureIy. Drive the vehicle and check for leaks around the plug.
Battery electrolyte Nota: There are certain precautions to be taken when working on or near the battery: al never exposa a battery to open flame or sparks which could Ignite the hydrogen gas gillfJn off by tha betteIY; bl wear protective clothing end eye protection to ~uce tha possibility of the corrosiWJ suffuric acid solution inside the battery harming you (if tha fluid is splashed or spilled, flush the contacted area immediately with plenty of weter); cl fllmolll!l' ell metal jewelry which could contact the positive termina/and enother grounded mete/ source, causing a short circuit; dJ a/ways keep batteri8s and bsttery acid out of the ffllJCh of children. 17 Venicles equipped witn maintenance-hee battaries require no maintenance because tne b8ttery case is sealed and nas no removeable caps for adding water_ 18 If a maintenance-type battery is installed, tna caps on tne top of ma battery should be removed periodically to cneck for a low electrolyte level (photo). This cneck will be more critical during tne warm summer montns. 19 Remova eacn of Ihe caps and add distilled waler to bring tne level 01 each cell 10 Ine split ring in the liller opening Ipnotol. 20 Allhe same lime the battery electrolyte level is Checked. the overall condition of the battery and its releted components should be inspected. II corrosion is present on the cable endS or battery terminels, remove the cebles and clean away all corrosion using a baking soda/watel' solution or a wire brush cleaning tool designed for this purpose. See Section 38 for complete battery cere and servicing procedures.
Brake fluid 21 The brake master cylinder is ~ocated on the leh side of the engine compertment firewilll and nes a cap which must be removed to check tne fluid level. 22 Before removing the cap, use a rag to clean all dirt, grease, etc. from around the cap area. If any foreign metter enters the master cylinder with the cap removed. blockage of the brake system lines can occur. Also. make sure all painted surfaces around the master cylinder are covered, as brake fluid will ruin paint. 23 Release the cliplsl securing Ihe cap to Ihe top of the master cylinder. In most cases, a screwdriver can be used to pry the wire clip(s ) free. 24 Carefully lift the cap ott the cylinder and note the flukllevel (photol. h snould be approximately 1/ 4-lnch below the top edge of each reser voir (photo). 25 If additional fluid is necessary to bring Ine level up to the proper height. carefully pour the specified brake fluid Into the mester cylinder. Be careful not to spill the fluid on painted surfeces. Be sure the specified fluid is used. es mixing different types of breke fluid can cause damllge to the system. See Recommended lubricants and fluids or your owner's manual. 28 At th is lime tne fluid ilnd mlllter cy~nder can be inspected for contaminatIOn. Normally. me hydraulic system wI. not require periodic draining and refilling. bot if rust depoSits. dirt panicles or weter droplets .re seen in Ihe fluid. the system should be drained lind refilled with fresh fluid . 27 Reinstell the master cylinder cap end secure it with the cliplsl. Make sure the cap is properly seated to prevent flukl loss. 28 The breke fluid level in the master cylinder will drop slightly as the brake shoes or pads at lIilch wheel wear down during normal operation. If the mlllter cylinder requires repeated replenishing to keep it at
Automatic transmission fluid 34 The fluid inside the tfansmillion must be at normal operating tempereture to get en accurale reading on the dipstick. This is done by driving the vehicle for severe! miles. making frequent sterts and stops to allow the transmission to shih through all gears. 35 Park the vehicle on a level surface. place Ihe selector in Park and leave Ihe engine running al an idle. 36 Remove the transmission dipstick and wipe all tne fluid from tha end with a clean rag. 37 PUSh the dipstick back into the transmillion until the cap seetl firmly on tne dipstick tuba. Now relTlOlle the dipstick egain and observe the fluid on the end. The highest point 01 fluklshould be between the Full mark and 14 -inch below the Full mark. 38 11 the fluid level is at or below the Add mark on tne dipstick, add sufficient fluid to raise the level to the Full mark. One pint of lIuid will raise the level from Add to FuU. Fluklshoolcl be added directly Into the dipstick guide tube, using a funnel to prevent spills. 39 It Is important that the transm lllion 's not overfilled. Under no circumstances shoukl the fluId level be above the Full mark on the dipstick, as this could cause tntemll damage to tne transmission. The best wey to prevent overfilling Is to add lIuld a little at a time. driving the vehicle and checking the level between additions. 40 Use only trensmlssion lIuid specified by the manufacturer. This Information can be found in Ihe RlICOmmended lubricants lind fluids Section. 41 The condition of the fluklshould also be checked along with the level. If the fluid at the end of the dipltick is e dark reddish-brown col O!', or if it hes a 'bumt' smell. Ihe fluid should bl changed. " you are in doubt about the condition of the fluid. purchllse lOme new fluid and compare the two for color and smell.
Transfer case lubdcant 42 The Iransfer case lubricant level ahould be checked at the same time es the manual transmission and differentials. 43 Remove the filler plug and delermlne whether or not Ihe lubricant level Is even with the bottom of the filler hole (photo). On Cuadra-Trec transfer cases with reduction units. the reduction units nave a seperete lubricant supply which must be checked also.. 44 Fill the transfer case and, if so equipped, the reduction unit to tne proper level with the specified lubricant. Replace the filler plugs, drive the vehicle and check for leaks.
Differential lubricant 45 Uke the manual transmission and transfer case. lhe front and rear differentials have an inspection and fill plug whICh must be removed to check the level. 46 Remove the plug. which is located either 'n the removable cover plete or on the skle of the ditterential carrier. Use your linle finger to reacn Inside the nousing to feel tha level of the oii. It should be at the bottom of Ine plug nole (photos). 47 If such Is not Ihe case, add the proper lubricant to the cerrier
1
1-16
Chapter 1 Tune-up and routine maintenance
TvpiCal .xla differential fill plug
4 .46A (arrow)
4.468 Some models nllve the fm plug (arrow) in the removable differential
4 . 54 Checking the power steering pump fluid level
cover through the plug hole. A syringe or a ameli funnel can be used for this. 48 Make certain the correct lubricant is used, 8S regular and TreklDk rear axles require different lubricants. A Trak-l.ok ule with the wrong lubricant will make 8 ehsnarlng noile and must be drained and refilled with the proper lubricant. • 49 TIghten the plug securely and check for leaks after the first few miles of drilling.
REDUCTION UN IT FILL HOLE PLUG
Power steering fluid TRANSFER CASE ORAtN PLUG
REOUCTION UNIT HOUSING BOLT CHAIN TENSION INSPECTION PLUG
Fig. 1.9
Ouadtll- Trac with reduction unit ISec 4 and 29)
50 Unlike manual steering. the power sleering system reliel on fluid which may, Oller a period 01 time, require replenishing . 51 The reservoir for the power steering pump will be located near Ihe front of the engine, and cen be mounted on either the leh or right side. 52 The power steering fluid level should be checked only after the lIehicle hes been driven, with the fluid et operating temperature. The front wheets should be pointed straight ahead. 53 With the engineJlhut off, use a rag to clean the feservoir cap and the areas around the cap. This will help prellent foreign material hom failing into the reservoir when the cap is removed. 54 Twist ott the reservo ir cap. which has a built-in dipstick a!lached to h. Pull off the cap and remove the fluid at the bottom of the dipstick wllh a clean rag . Now relnstaU the dipstick/cap assembly to get a fluid level reading. Remove the dlpsticklcap and note the lIuid level. It should be at the Full hot mark on the dipstick (photo). 55 If additional fluid is required, pour the specified type directly in· to the reservoir using a funnel to prellent spills. 56 If the reservoir requires frequent fluid additions. ell power steering hoses, hose connections, the power steering pump and Ihe steering 00)( should be checked carefully for leeks.
5
5.3
Tvpical oil change toots
I
Or.in pan
2 Funnel 3 Oil can spout .,
Rubber glove's)
5
Filter wrench
6 ell" O/Hntllf 7 hake, be' 8 Socket (6-point)
Engine 011 and filter change
Frequent oil changes may be the besl lonn of preventalive maintenance 8Vailable to the home mechanic. When engine oil is old. it gets diluted end conteminated, which ultimately leeds to premature engine wear. 2 Although some sources recommend oil filter changes every othar oil change, we feel that the minimal coat of an oil lilter and the relative aase with which it is installed dictate that a new fllter be used whenever Ihe oil Is changed. 3 The tools necessary for a normal 011 and filter change ere a wrench to tit the drain plug al the bottom of the oil pan, an oil filter wrench to remove the old filter, a container with a sl)(-quart capacity to drain the old oil into and a funnel Of 011 can spout to help pour fresh oil into the engine (photo). 4 In addition, you should hlrlle plenty of clean rags and newspapers handy to mop up any spills. Access to the underside of the vehicle is greatly improved if it can be lifted on a hoist. driven onto ramps Of sup· ported by jackstands. Ceutlon: Do nOt work under a Vf!Ihicle which is supported only by e bumper, hydraulic or scissors-type jeck. 5 If this is your first oil chenge on Ihe lIehicle, it is a good Idea to crawl underneath and famlliarlza yourself with the locetione of the oil
Chapter 1
5.9 Typical oil drain plug location (arrow)
Tune~up
and routine maintenance
5.20 The oil liltar should be handtighrttMd only
drain plug and the olifilllr. Since the engine and eKhaust components will be warm during the actual work, it is a good idea to figure out any potential problems before the engine and eKhauS! pipes are hot. 6 Allow the engine to warm up to normal operating temperature. If new oil or any tools are needad, use the werm-up time to locate everything necessary for the job. The correct type of oil to buy for your application can be lound in Recommended lubricllnrs lind fluids near the front of this Chapter. 7 With the engine oil warm (warm engine oil will drain bener and more built-up sludge will be removed with the oill, raise the vehicle for access beneath it. Make sure the vehicle il firmly supported. If jackstands ere used, they should be placed toward the front of the frame railS which run the length of the vehicle. 8 Move all necesSlry toOll, rags end newspapers under the vehicle. Position the drein pan under the drain plug. Keep in mind that the oil will initially flow from the pan with some force, so posi tion the pan eccordingly. 9 Use the wrench to remove the drain plug near the bottom of the oil pan but be careful not to touch eny of I he hot exhaust pipe componan ... Depending on how hot the oil hes become, you may want to wear gloves while unacrewlng the plug Ihe finel few turns (photo). 10 Allow the old 0" to drain into the pan. h may be necessary to move the pan farther under the engine as the oil flow reduces to a trickle.. 11 After all the oil has drained, clean the drain plug thoroughly with a clean reg. Small metal particles may cfing to the plug and immediataly • contaminate the new oil. 12 Clean the erea around the drain plug opening and reinslall the plug. Tighten It securely. 13 Move the drain pan into position under the oil filter. 14 Now use the lilter wranch to loosen the oil filter. Chain or metal bend-type filter wrenches may distort the filter can iller. but don't worry about it because the filter will be discarded. 15 Sometimes the oil filter is on so light it cannot be loosened, or it is positioned in an araa which IS inaccessible with a filter wrench. As a lall reson, you can punch a metel bar or long screwdriver directly through the bonom of the canister and use it as a T·bar to turn the filter. If this must be done, be prepared for oil to spurt out of the canister as it is punctured. 16 Completely unscrew the old filter. Be careful. It is full of oiL EmpIy the old oil inside the filter into the drain pan. n Compare the old liltar with the new one to make sure they ara the same type. 18 Use a clean rag to remove all oil, dirt and sludge from the area where the oit filter mounts to the engine. Check the old filter to make sure the rubber gasket is not stuck to the engine mounting surface. If the gasket is stuck to the engine (use a flashlight to checkl. remove It. 19 Open one of the cans of new oil and fill the new filter about half full of oil. Also apply a light coet of fresh oil 10 the rubber gasket of the new oil filter. 20 Auach the new filter to the engine following the tightening direc tions printed on the filter canister or packing Dox (photo). Most filter manufaclurers I&commend against using a filter wrench due to the possibility 01 ovartightaning and damaging the canister. 21 Remove all tools. rags, etc. from under the vehicle. being careful not to spill the oil in the dlain pan. lower the vehicle.
1-17
5.24 Pouring 011 into the filler opening (V8 engine shown)
22 Move to the engine compartment and locate the oil filler ca p on the engine. In most cases there will be a screw-off cap on the rocker arm cover or a cap at the end of a fill tube at the Itont of the eng.ne. In any case, the cap will most likely be labeled Engine 011 or something similar. 23 If an oil can spout is used, push the spout into the top of the oil can and pour the fresh oil through tha filler opening. A funnel placed in t he opening may also be used. 24 Pour aDout threa (3) quarts of I resh 011 Into the engine (pho to). Wait a lew minutes to allow the oil to drain to the pan, then check the level on the oil dipstick (lie Sec 4 if necessary). 11 the oil level is above the Add mark, start the engine and allow the new oil to cirCUlate. 25 Aun the engine for only aDout a m inute and then shut it off. Immediately look under the vehicle and check for leaks at the oil pan drain plug and around the o~ filter. If either is leaking, tighten w ith a bit mOle force. 26 With the new 011 circulated and the filter now co mpletely full, recheCk the level and add enough oil to bring the level to the Full mark on the dipstick. 27 During the first few trips aher an oil change. make it a POint to check frequently for leaks and correct oil level. 26 The old oil drained from the engine cannot be reused In Its prasent state and should be disposed of. Oil reclamalion centers, auto repair shops and gas stations wiH noml8lly aocapt the oil, which can be relined and used again. Afler the oil has cooled, it can be drained into a SUitable container (capped plastic jugs, topped bottles, milk cartons, etc.! for transportation to a disposal site.
e
llre and tlr. pressure checks
Periodically inspecting the tires may not only prevent you from baing stranded with a flat ti.... but can also give you clues as to possi· ble problems with the steering and suspension systems before major damage occurs. 2 Proper tire inflation edds miles to the lifespan of the mes, allows the vehicle to achieve maximum miles per gallon flgutes and contributes to overall ride quality. 3 When inspecting the tires, first check the wear of the treed. Ir· regularities in the tread pattern Icupping, flet spots, more wear on one side than tha other) are indications of front end alignment and/or balance problems. If any 01 thele conditions are noted, take the vehicle to a reputable repair shop to correct the problem. 4 Also check the tread area for cuts and puncture s.. Many times a nail or tac k will embed Itself into the tire tread end yet the tire will hold its air pressure for a short tithe. In most casas, e repair shop or gas station can repelr the punctured tire. 5 It is also importent to check the sidewslls of the tires, both InSIde and outside. Check for deteriorated rubber, CUll, and punctures A lso inspect the inboard side 01 the tire for ligns of brake fluid leakage. in· dicating that a thorough brake inspection is needed immediately. 6 Incorrect tire pressure cannot be determined merely by looking at the tire. This Is especially true for radial tires. A tire pressure gauge must be used. If you do not already have a reliable gauge. it il a good
1
1-18
6.8
Chapter 1 Tune-up and routine maintenance
The tire pressure placard is located on the glovebox door
idea to purchase one end keep it in the glove box. Built-in pressure gauges at gas stations are often unreliable. 7 Always chec;k tire inflation when the tires are cold. Cold, in this case. means Ihe vehicle has not boon driven more than one mile after sitting for three houl'8 or mora It is normal for the pressure to increase 4 to B pounds or more when the tires are hot. 8 Unscrew the valve cap protruding from the wheel or hubcap and firmly press the gauge onto the valve stem. Observe the reading on the gauge and compare the figure to the recommended tire pressure listed on the tire placard. The tire placard is usually attached to the glove bOl( door {photo). 9 Check all tiras and add air as necessary to bring them up to the recommended pressure levals. Do not forgat the spere tire. Be sura to reinstall the valva caps (which will koop dirt and moisture out of the valva stem mechanism).
7.1
Tools required for chassis lubrication , 2
3 4
Grease gun end flexibla nozzle Grease cartridge Multi-purpose spray lubricant Oil can
7 Challl, lubrlcetion A grease gun and a cartridge filled with the propar grease (see Recommended lubricants and fluids) are necessary to lubricate most chassis components (photo). 2 Using the accompanying illustrations, locata the various greasa fitings (photo). 3 For easier access under the vehicle, raise it with a jack and place jackstands under the frame. Make sure the vehicle Is firmly supported by the stends. 4 Before proceeding, force II little of the grease out of the nozzle to remove IIny dirt from the end of the gun. Wipe the nozzle clean with a rag. S Wipe tha grease fitting clean and push tha grease gun nozzle firmly over it. Squeeze the trigger on the greasa gun to force grease into the component. The tie-rods and balljoints should be lubricated until the rubber reservoir is firm to the touch. 00 not pump too much grease into the fittings as it could rupture the reservoir. II the grellse seeps out around the grease gun nozzle. the fitting is clog gad or the nozzle is not fully seated on the fitting. Resecure the gun nozzle to the fitting and try again. If necessary, replace the litting with a new one. 6 Wipe any e:o:cess grease from the components and the grease fitting. 7 Early models feature different types of rear wheel bearing lubricstion. On models with grease fittings. carefully lubricllte the fitting with wheel bearing grease until the grease flows from the vent opening. Make sure this vent is kept open or the grease will eventually bac~ up onto the brake shoes. On models without grease fittings. it will be necessary to remove the reer wheel bearings and lubricete them as described in Chapter 8. 8 On later models, the clutch lever shaft should be carefully lubricated using chassis grease (photo). 9 While you ere under the vehicle. clean and lubricate the brake cable. 10 Lower tha vehicle to the ground for the remaining lubricetion procedures. 11 Open the hood and smur a little chassis grease on the Illtch mechanism.
LUBRICANT
Fig . 1.10 Manuallteering gear lubrication check (Sec 7)
Chapter 1 Tune-up and routine maintenan ce
7.2
Steering erm grease titting location (arrow!
7.8
1-19
Clut ch lever shaft grease fitting location (arrow(
1
8.4 Squeezing the radiator hose to check for crecks and deterioration
9 .2 Check the area around the exhaust pipe connections (arrow( lor cracks and evidence of leaks
12 Remove the bolt opposite the steering gear adjuster and check the lubricant level. " it is not even with the bottom of the bolt hole, add chassis lubricant to the proper level and replace the bolt. 13 Lubricate all hinges (door, glove box door, hood and lift gate! with light engine oil, multi-purpose oil or spray lubricant, which is available at auto pans stores. 14 Finally, the key lock cylinders should be lubricated with spray graphite or silicone. also available at auto parts stores.
cooling system will usually show up as white or rust colored deposits on the areas adjoining the leak. 8 Use compressed air or a soft brush to remove bugs, le.ves. etc. from the front of the radiator or air-conditioning condenser. Be careful not to damage the delicate cooling fins or cut yourself on them. 7 Finally, have tha cap end system pressure tested. If you do not have a pressure tester. most gas stations and repair shops will do this for a minimal charge.
8
Cooling .y.tem check
Many major engine failures can be attributed to a faulty cooling system. Illhe vehicle is equipped with an automatic transmission, the cooling system also plays an imponant role in prolonging transmission life. 2 The cooling system should be checked with the engine cold. Do this before the vehicle is driven for the day or .her il has been shut off for at leastlhree hours. 3 Remove the radiator cap and thoroughly cleen the cap (inside and out) with clean water. Also clean the tiller neck on the radiator. All traces 01 cOlrosion should be removed . 4 Carelully check the upper and lower radiator hoses elong With the smaller diameter heater hoses. Inspect each hose along its entire length. replacing any hose which is cracked, swollen or shows signs of deterioration (photo!. 5 Also make sure that all hose connections ere tight. A leak in the
With the engine cold (at least three hours after the vehicle has been driven), check the complete exhaust system from its starting point at the engine to the end of the tailpipe. This should be done on a hoist whera unrestricted access is available. 2 Chack the pipes and connections for signs of leakage and/or corrosion indicating a potential failure. Make sure that all brackets and hangers are tight and in good condition (photo!. 3 At the same time. inspect the underside of Ihe body for holes. corrosion, open seam •• etc. which may allow exhaust ga$8s to enter the passenger compartment. Seal ell body openings with silicone or body putty. 4 Rattles and other noises can often be traced to the exhaust system. especially t he mounts and hangers. Try to move the pipes. muffler and catalytic converter (if so equipped). If the components come into contact with the body or drivellne parts. secure the exhausl system with
1-20
Chapter 1 Tune-up and routine maintenance REPLACE FILTER'\,. ~ASKET
~~\I»LVJ~ CARBURETOR
, 1.3
Twist the drivebelt to check the
underside " rrow l for cracks and deterioration
14 .5 Removing the fuel filter screwtype clamp with a screwdriver tin-line
six-cylinde r engine shownl
new mounts. 5 This is also an ideal time to check the funning condition of the engine by Inspecting inside the very end of the teilpipe. The exhaust deposits here are an indication of engine state-aI-tune. If the pipe is black and sooty or coated with white deposits, the anglne is in need of 8 tune-up !including 8 thorough carburetor inspection and adjustment).
10 Su,penllon and ,teerlng che<:k Whenever the front of the vehicle is faised for service. it is a good idea to visU!llly check the suspension and steering components for wear. 2 Indications of II fault in these syltems are excessive play in the steering wheel before the front wheels react, excessive sway around comers, body movement over rough roads or binding at some point IiIS the steering wheel is turned. 3 Before the vehicle Is raised for inspection, test the shock absorbers by pushing down to rock the vehicle at each comer. If you push the vehicle down and it does not come back to a level position Within one or two bounces, the shocks are worn end must be replaced. As this is dona check for SQueaks and strenge noises from the suspension components. Information on shock absorber end suspension components can be found in Chapter 11. 4 Now raise the front end of the vehicle and suppon it firmly on jackstands placed under the fl1lme l1Ii1s. Because of the work to be done. make sure the vehicle cannot fall from the stands. S Grab the top and bottom of the front tire with your hands and rock the tire/wheel on the spindle. If there is movement of more than O.OOS-inch, the wheel besrings should be serviced (see Chepter 111. 6 Crawl under the vehicle end check for loose bolts, broken or disconnected parts end deteriorated rubber bushings on all suspen sion and steering components. Look for grease or fluid leaking from around the steering box. Check the power steering hoses and connections for leaks. Check the balljoints for wear. 7 Have an assistant turn the steering wheel from slde-to-side and check the steering components for free movement, chafing and binding. If the steering does not react with the movemant o f the steering wheel. try to datermine where the slack is located.
11
FUEL LINE
Drlvebelt check end edjullment
The drivebelts, or V-belts as they are sometimes called, are located at the front of the engine and play an imponant role in the overall operation of the vehicle and its components. Due to their function and material make-up, the belts are prone to failure after a period of time and should be Inspected and adjusted periodically 10 prevent major eng Ina damage. 2 The number of belts used on a psnicular vehicle depends on the accessories installed. Drivebelts are used to turn the generatorfalternator, smog pump, power steering pump, wllter pump. flln and air conditioning compressor. A single bell mey be used for more than one of these co mponents and the wide ribbed serpentine belt is used for all
FIg.l .11
Csrburetor mounted fuel filter exploded view {Sec 141
of them. 3 With the engine off, open the hood end locate the various belts at the front of the engine. Using your fingers (and a flashlight if necessary), move along the belts checking for cracks and separation of the belt plies. Also check lor fraying and glazing, which gives the belt a shiny appearance. Both sides of the belts should be inspected, which means you will have to twist the belt to check the underside (photol. 4 The tension of each belt is checked by pushing on the belt at a distance halfway between the pulleys. A special tension gauge is required to check the serpentine belt. On standard belts, push firmly with your thumb and see how much the belt moves down (deflects). Generally, if the distance (pulley center-to-puttey center) Is between 7 and 11 inches, the belt should deflect % -inch. If the belt is longer and travels between pulleys spaced 12 to 16 inches apart, the belt should deflect Yo-inch. On the serpentine belt, the gauge should read between 180 and 200 Ibs on a new belt and 140 and 160 Ibs on a used bell. S If it is necessary to adjust the belt tension, either to make the belt tighter or looser, it is done by moving the belt-driven accessory on the bracket. 6 For each component there will be an adjustment or strap bolt and a pivot bolt. Both bolts must be loosened slightly to enable you to move the component. 7 After the two bolts have been loosened, move the component away from the engine (to tighten the beltl or toward tha engine (to loosen the beltl. Hold the accessory in position and check tha belt tansion. If it is correct, tighten the t wo bolts until snug. then recheck the tension. If it is all right, tighten the two bolts completely. 8 If it is necessary to use a pry bar to move the accessory while tile belt is adjusted, be very careful not to damage the componant being moved or the part being pried against.
12
Underhood hoaas - check end replacement
Caution: Replacement of air-conditioner hoses should be left to a deafer or air-conditioning specialist who can depressurize the system and perform the work safely. The high temptlratures present under tha hood can cause deterioration of tha numerous rubber and plastic hoses. 2 Periodic inspection should be made for cracks, loose clamps and leaks because some of the hoses are pan of the emission control system and can affect the engine's parformance. 3 Remove the air cleaner if necessary and trace the entire length of each hose. Squeeze each hose to check for cracks and look fOf swelling, discoloration and leaks. 4 If the vehicle has considereble mileage or if one or more of the hoses is suspect, it is a good idea to replace all of the hoses at one time. S Measure the length and inside diameter of each hose and obtain and cut the replacement to size. Since original equipment hose clamps ara often good for only one or two uses, it is a good idea to replace them with screw-type clamps.
1·21
Chapter 1 Tune- up and routine maintenance
V8 FOUR·CYLINDER Fig. 1.12 1971 th ro ugh 1986 m odel engine PCVvalve loca tions (Sec 15) 6 Replace each hose one at a time to eliminate the possibility of confus ion. Hoses attached to the heater and radiator contain coolant, so newspapers or rags should be kept handy to catch the spills when they are disconnected. 7 Alter installation, run the engine until it reaches operating temperature. shut it off and check for leaks. After the engine has cool· ed. retighten all of the screw·type clamps.
13
Fuel system check
Caution: There are certain precautions to take when inspecting or ser' vicing the fuel sysrem components. Work in a well·venti/ated area and do not allow opan flames /cigamtte$, appliance pifot fights, etc.) to get near the work urea. Mop up spills immediately and do not store fuel· soaked (ags where they could ignite. 1 The fuel system is under a small amount of pressure, so if any fuel lines are disconnected for servicing. be prepared to catch the fuel as it spurts out. ~ug all disconnected fuel lines immediately after discon· nection to preyent Ihe tank Irom emptying itself. 2 The fuel system is most easily checked with the vehicle raised on a hoist where the components underneath are readily yisible and accessible. 3 If the smell of gasoline is noticed while driying. or after the yehi· cle has been in the sun. the system should be thoroughly inspected immediately. 4 Remoye the gas liller cap and check for damage, co rrosion and a proper sealing imprint on the gasket. Replace Ihe cap with a new one if necessary. 5 With the vehicle raised . inspect the gas tank and filler neck for punctures. cracks and other damage. The connection between the filler neck and the tank is especially critical. Sometimes a rubber filler neck will leak due to loose clamps or deteriorated rubber; problems a home mechanic can usually rectify. Caution: Do not. under any cirrumstances. try to repair a fuel tenk youself (except rubber components) unless you have considerable experience. A welding torrh or any open flama can easily cause the fuel vapors to explode if the proper precautions are not teken. 6 Carefully check all rubber hoses and metal lines leading away from the fuel tank. Check lor loose connections, deteriorated hoses, crimped linas and other damage. Follow the lines up to the Iront of the vehicle, carefully inspecting them 1111 the way. Repair or replace damaged sec· tions as necessary. 7 If a fuel odor is slill evident after the inspection. refer to Sec· tion 36 on the evaporative emissions system.
14
Fuel filter replacement
Caution: G8soline is extremely flemmable so extra safety precautions must be observed when working on eny pert of the fuel system. Do not smoke end do not allow bare light bulbs or open flemes near the vehicle. Also, do not perform this meintenance procedue in a gerage if a natural gas·type water hearer or dryer is locared in the gerage. These models use a variety of fuel·filters. Earlier model F· and L· head four-cylinder engines use e non· replaceable filter screen located in the fuel pump bowl. Tha screen and bowl should be removed and
thoroughly cleaned at the recommended intervals. Later models are equipped with replaceable filters located In the fuel line. The 151 cubic inch four·cylinder and the V6 engine haye screw·in type filters located at the carburetor. 2 This job should be done with the engine cold (efter sitting for at least three hours!. The necessary tools are pliers for the in·line fi lter or open·end wrenches to fit the fuel line nuts of the screw· in type filte" Flare·nut wrenches which wrap around the nut should be used if available. In addition, you will have to obtain a replacement filter (make sure it is correct for your specific vllhlcle and engine) and some clean rags . 3 Remove the air cleaner assembly. If Yacuum hoses must be discon· nected. make sure you note their positions and/or tag them to help during installation. 4 Place some rags under the filter to catch any spilled fuel.
In-line filter 5 Remove the retaining clips or screw·type clamps from the fuel lines and pull the filter f ree (photo!. 6 Install the new fifter in the same position as the old one and push the fuel hoses into place, securing them with the clips or clamps. Later models have a breather fitting and hose which is part of the ECs system; it must be at the top.
Screw-in t ype filter 7 With the proper size wrench. hold the nut ne)[t to the carburetor body. Now loosen the nut fitting and the end of the metal fuel line . A flare· nut wrenc h on this fitting will prevent slipping and possible damage. However, an open·end wrench should do the job. Make sure the larger nut ne)[t to the carbu retor is held firmly while the fuel line is disconnected. 8 With the fuel line disconnected, mOye it to t he side slightly for better access to the inlet filter nut. Do not crimp the fue/line. S Now unscrew the fuel inlet filter nut which was previously held steady . As this fitting is drawn away from the carburetor body. be care ful not to lose the thin washer· type gasket or the spring located behind the fuel l ilter. Also. pay close attention to how the filter was installed. 10 Compare the old filter with the new one 10 make sure they are of the same length and design. 11 Reinstall the spring in the carbu retor body, after inspecting it for damage and defects. 12 Place the new fifter Into position behind the spring. 13 Install a new washer·type gasket on the fuel inlet filter nul {e new gasket is usually supplied with the new fil ter) and tighten the nut in Ihe carburetor. Make sure it is not cross·threaded or oyer-tightened as fuel leaks could result. 14 On all models. reinstall the air cleaner assembly and return all hoses to their original positions. Start the engine and cheCk for fuel leaks.
15
Po. itlve Crankc8la Ventilation (PCVI val va replacement
The PCV valve is located in thll rocker arm cover on in·line and V6 engines and in the intake manifold on va engines. A nose connected to the valve runs to either the ca rbure tor or intake manifold. 2 When purchasing a replacement PCV valve. make sure it is lor your
1
1-22
Chapter 1 Tune-up and routine maintenance
Fig. 1 .14 V6 engine all beth air clea ner co mponents - exploded vie w ISec 16)
Fig . 1.13 F- and l ·h. ad e ngine oR bl th air cl18ner compone nts - exploded vie w (Sec 161 1 Hom 2 Flexible connector 3 Hose clamp
4 Carburetor vent tubfl
7 Clamp 8 Oil cup 9 Clamp 70 Hose
5 Body 6 Screw end lock washer
"
Clamp
6 Breather 7 Clamp 8 Vent tube
9 Ai, pump hose
12 Gasket
particular vehicle. model year and engine si:le. 3 Pull the valve [with the hose attached) from the rubber grommet in the rocker orm covaf or manifold. 4 Lnosen the retaining clamp end pull the PCV valve from the end of the hose, noting ils installed position end direction. 5 Compare the old valve with the new one to make sure they are the same. 6 Push the new valve into the end of the hose until it is fully seated and reinstall the clamp. 7 Inspect the rubber grommet for damage end replece it with 1'1 new one, if faulty. a Push the PCV valve and hose securely into position. 9 More information on the PCV system can be found in Chapter 6 .
16
1 Wing nut 2 Cover 3 Rubber gasket 4 Cork gesket 5 Oil cap
V6 engine 7 Remove the wing nut at the top of the carburetor and lift the air cleaner assembly off. a Remove the oil cup and pour the old oil into a suitsble contain8l. 9 Wash the cup and filter element thoroughly with solvent and dry with compressed air or clean, lint-free cloths. The filter element must be dry after cleaning, with no solvent residue or oil. 10 Check the air cleaner assembly hoses. clamps and connections, replacing defective or damaged parts as necessary. 11 Fill the oil cup with clean oil (S AE 40 or 50 weight in warm weather and SAE 20 in cold weather) and install it in the filter element, making sure the gasket is in position. 12 Attach the air cleaner assembly and gasket to the carburetor, securing it With the wing nut.
Oil bath -type air cleaner servlca 17
Early model F- and L-head and V6 engines are equipped with oil bath-type air cleaners. They must be drained, cleaned and refilled at the specified intervals.
F- and L-head engines 2 Remove the retaining bolt and lift the oil cup from the body of the air cleaner assembly. 3 Pour the oil into a suitable container and wash the cup tl'loroughly with solvent. 4 Detach the breather hose, remove the two wing nut screws and lift the air cleaner assembly from the engine. Wash the assembly thoroughly with solvent, panicular1y in the area of the filtering element. Dry the assembly with clean, lint-free cloths or compressad air. 5 Reinstall the air cleanar assembly. 6 Fill the oil cup with clean engine oil, using SAE 40 or 50 weight in warm weather and SAE 20 in cold weather . Install the oil cup in the air cleaner assembly.
Air filter and PCV filter replac ement
At the specified intervals, the air filter and PCV Iilter should be replaced with new ones. A thorough program of preventative maintenance would call lor the two filters to be Inspected be t ween changes. 2 The air lilter is located inside the air cleaner housing on the top of the engine. The lilter is generally replaced by removing the wing nut at the top 01 the air cleaner assembly and lifting off the top plate. If vacuum hoses are connected to the plate. note their positions and disconnect them. 3 While the top plate is off. be careful not to drop anything down into the carburator. 4 Lift the air filte r alement out 01 the housing (photo). 5 To check the filter, hold it up to strong sunlight. or place 1'1 flashlight or droplight on the inside of the filte r. On filters with a foam cover. first remove the cover. If you can see light coming through the paper ele ment. the filter is 1'111 right. Check all the way around the filter.
Chapter 1 Tune-up and routine maintenance
T7.4 Lifting the air Iilter element from the housing
17.11 Using a screwdriver to remove the PCV filter element Uater model in·line six-cylinder engine shown)
1S
FOUR- and SIX--cYLINDER
OIL FILLER CAP
FlLTeR~
•
1-23
19.3 Typical carburetor choke plate location larrow)
Thermo-controlled A ir Cluner (TAC) check
Leter models are equipped with a thermostatically controlled air cleaner which draws air to the carburetor from different locetions depending upon engine tempereture. 2 This is a simple visuel check; however, il access is tight, a small mirror may have to be used. 3 Open the hood and locate the baffle inside the air cleaner assembly. It will be located inside the long snorkel of the metal air cleaner hous· ing. Make sure that the flexible air hosels) are securely attachad and undamaged. 4 If there is a flexible air duct altached to the and of the snorkal leading to an area behind the grille. disconnect it at the snorkel. This will enable you to lOOk through the end 01 the snorkel and see the baflie inside. 5 The check should be done when the engine and outside ail are cold. Start the engine and look through the snorkel at the baffle. which should move to a closed position. With the ballte closed. ail cannot enter through the end of the snorkel, but instaad enters the air cleaner through the flexible duct altached 10 the exhaust manifold. 6 As the engine warms up to operating temperature, the baffle should open to allow air through the snorkel end. Oepending on ambient temperature. this may take 10 to 15 minutes. To speed up this cheCk you can reconnect the snorkel air duct, drive the vehicle and then check to see il the baffle is completely open. 7 If the thermo-controlled air cleaner is not operating propert y. see Chilpter 6 lor more information.
OIL FILLER CAP FILTER Ivai Fig_ 1_15
Typk:al PCV air filter Installation ISec 171
6 Wipe out the inside of the air cleene r housing with a clean rag. 7 On new filter elements with removable loam covers, remove the cover, soak it in clean engine 011. wring it out and install it on the ele· ment. If the element is being reused. first wash the cover thoroughl y in solvent and squeeze it dry. S Place the old filter lif in good conditionl or the new filter lif the specilied interval has elapsed) back into the air cleaner housing. Make sure it seats properly in the bottom of the housing. 9 Connect eny disconnected vacuum hoses to the top plate and reinstall the plate. 10 On later models, the PCV filter is located inside the air clecmer housing or in the oil filler cap. Remove the top plate as described previously and locate the liltar on the side 01 the housing or remove the filler cap. n Remove the filter element from the reteiner or filler cap Iphotol. 12 Wash the filter element thoroughly with kerosene or solvent and reinstall it. On some filler caps, the element is not removable and Ihe assembly should be cle(lned by blowing compressed air through the filter tube opaning lin the reverse direction of normal air flow) in the cap. If the element is badly clogged or contaminated, replace the complete cep assembly with a new one.
'9
Carburetor choke check lIate models only)
The choke only operates when the engine is cold, so this check should be performed belore the vehicle has been staMed for the day. 2 Open the hood and remove the top plate of the air cleaner assembly. It is usually held in place by a wing nut at the center. If any vacuum hoses must be disconnected, make sure you tag them to ensure reinstallation in their original positions. Place the top plate and wing nut aside. out of the way of moving engine components. 3 LDok et the top of the carburetor at the canter of the air cleaner housing. You will notice e lIat plate at the carburetor opening (photot. 4 Have an assistant press the accelerator pedal to the floor. The plate should close completely. Start the engine while you observe the plate at the carburetor. Caution: Do not position your (ace directly over the carburetor. tiS the engine could backfire, C8uslng s8l'ious bums. When the engine starts, the choke plate should open slightly. 5 Allow the engine to continue running at an idle speed. As the engine warms up to operating temperature, tha plate Should slowly open. allowing more air to enter through the top of the c arburetor. 6 Alter a few minutes, the choke plate should be fully open to the vertical position. 7 You will notice that the engine spead corresponds with the plate opening. With the plate completely closed, the engine should run at a fast idle speed. As the plate opens, the engine speed will decrease.
1
1-24
Chapter 1 Tune-up and routine maintenance
--:",oi\-- LUBRICATE
21,2 The tachometer ~11, screwdriver lind assorted vacuum hose plugs (2) used when adjusting Ihe engine idle speed
21.4
Typical idle speed edjustment
sc re w 10I;8tion8 (arrows)
B If II fault is detected during the ebove checks, refer to Chapter 4 for specific information related to adjusting end servicing the choke components.
20
Carburetor mounting torque check
The carburetor is attached to the top of the intake manifold by two or lour nuts. These fasteners can sometimes work loose from vibration end temperature chengas during normal engine operation and cause II vacuum leak. 2 To properlv tighten the carburetor mounting nuts, a torque wrench is necessary. If you do not own one. they can usually be rented on a daily basis. 3 Remove the air cleaner assembly, tagging each hose to be disconnected with a piece of numbered tape to make reassembly easier. 4 Locate the mounting nuts at the base of the carburetor. Decide what special tools or adapters will be necessary, if any, to tighten the nuts with a properly sized socket and the torque wrench. 5 Tighten the nuts to a torque of about 12 h-Ibs. Do not overtighten the nuts, as the threads may strip. If you suspect that a vecuum leak exists at the bottom of the carburetor, obtain a length of hose about the diameter of fuel hose. Start the engine and place one end of the hose next to your ear as you probe around the base of the carburetor with the other end. You will hear a hissing sound if a leak exists. 7 If, after the nuts ara properly tightened. a vacuum leak still exists, the carburetor must be removed and a new gasket installed. See Chapter 4 for more information. B After tightening the nuts. reinstall the air cleaner and return all hoses to their original positions.
e
21
Engine Idle apeed adjuatment
Engine idle speed is the speed at which the engine operates when no acceleretor pedal pressure is applied. Thia speed is critical to the performance of the engine itself, as well as many engine sub·systems. 2 A hand-held tachometer (photo) must be used when adjusting the idle speed to get an accurate reading. The exact hook·up for these meters varies with the manufacturer, 80 follow the particular directions included. 3 Since these models were equipped with many different carburetors in the time period coverad by this manual, and each has its own peculiarities when setting idle spaed, it would be impractical to cover all types in this Section. Chapter 4 contains information on each individual carburetor used. The carbu retor used on your particular angine can be found in the Specifications Section of Chapter 4. However, all vehicles covered in this manual should hIVe a tune-up decal or Emis· sian Control Information label in the englna compartment, usually placed near the top of the radiator. The printed Instructions for setting idle speed can be found on this decal or label, end should be followed since they are for your particular engine.
Fig. 1.16 Typical heat valve location and lubrication points )Sec 22)
4 Basically, fo r most applications, the idle speed i s set by turning an edjustment screw located at the side of the carburetor (photo). Turning the screw changes the position of the throttle valve in the carburetor. This screw may be on the linkage itself or may be part of the Idle stop solenoid. Refer to the tune-up decal or Chapter 4. 5 Once you have located the idle speed screw, e)(perimenl with diflerent length screwdrivers until the adjustments can easily be made without coming into contact with hot or moving engine components. 6 Follow the instructions on the tune -up decal or Emission Control Information label, which may include disconnecting certain vacuum or electrical connections. To plug a vacuum hose after disconnecting it, insert a properly sized met81 rod into the opening or thoroughly wrap the open lind with tape to prevent any vacuum loss through the hose. 7 If the air cleaner is removed, the vacuum hose to the snorkel should be plugged. 8 Make sure the p8rking brake is firmly set 8na the wheels blocked to prevent the vehicle from rolling . This is especially true if the transmission is to be in Drive. An assistant inside the vehicle pushing on the brake pedal is the l afest method. 9 For all applications, the engine must be completely warmed-up to operating temperature, which will automatiC811y render the choke f8st idle inoperative. 10 Tum the idle speed screw in or out, as required, until the idle speed listed in the Specifications i s obtained.
22
EIIhaust heat valve check
The e)(haust heat valve is located at the junction of the exhaust pipe and manifold. It can be identified by an e)(ternal weight and spring. 2 With the engine and e)(haust pipe cold, cry mOVing the weight by hand. It should move freely. lubricate the valve with graphite at the time of inspection end at the specified intervals. 3 With the engine cold, start it 8nd observe the he8t v8lve. Upon starting, the weight should move to the closed position. As the engine W8rma to normal oper8ting temperature, the weight should move the valve to the open position, allowing a free flow of e)(haust gas through the tailpipe. Since it could take several minutes lor the system to heat up, you could mark the position 01 the weight when cold, drive the vehicle and then recheck the position of the we ight.
23
Exhaust Gas ReCirculation (EGR) valve check
The EGR valve is located on a spacer plate located below the carburetor on four-cylinder engines, on the side of the intake manifold on si)( -cylinder engines and on a machined surface at the rear 01 the intake manifold on VB engines. Most 01 the time when 8 fault develops in this emissions system, it is due to a stuck or corroded EGR v81va.. 2 With the engine cold to prevent burns, reach under the EGR v81ve 8nd m8nU8Uy push on the diaphragm. Using moderate pressure, you should be able to move the diaphragm up and down within the hoosing. 3 If the diaphragm does not move or moves only with much effort.
1-25
Chapter 1 Tune-up and routine maintenance
un REIR
-------•--------
~-.---7"""== '\ = . . _,, , ---- --- ----
~
LEn FROMT
the mechanical linkage actuallv begins to disengage the clutCh disc from the flvwheel and pressure plate. 3 To check the free play. slowly depress the clutch pedal until the resistance offared by the clutCh release mechanism is fell (the pedal will suddenly become much more difficult to move). 4 Meausre the distance the clutch pedal has trevelled and compare it to the Specifications. If adjustment is required. refer to ChaptGl for the step·by· step procedure to follow.
a
J~
RIGHT REIR
25
-
liGHT • ---------....,
FIOMT
FIVE TIRE ROTATION
un REIR ------ ------ un FROM!
RIGHT RElR
---------..., •
----------- RIGHT FROMT FOUR TIRE ROTATION RADIAL TIRE ROTATION BIAS / BIAS BELTED TIRE ROTATION
Fig. 1.17
Tire rotation
The tires should be rotated at the specified intervals and whenever uneven wear is noticed. Since the vehicle will be reised and the tires removed anyway. this ise good time to check the brakes (Sec 31) and/or repack the wheel bearings (Chepter Reed over thesa Sections before beginning. 2 The location for each tire in the rotation saquence dapends on Ihe type of tire used on your vehicle. nre type can be determined by reading the raised printing on the sidewall of the tire. The accompany· ing illustration shows the rotation sequence for each type of tire. 3 See the information in Jading and rowing at the front of this manual for the proper procedures to follow when raising the vehicle end chenging a tire; however. if the brakes are to be checked. do not apply the parking brake as steted. Make sura the tires are blocked to prevent the vehicle from rolling. 4 Preferablv, the entire vehicle should be ra ised at the same time. This can be done on a hoist or by jacking up each corner and lhen lower· ing the vehicle onto jackstands placed under the frame rails. Always use four jackstands and make sure the vehicle is firmlv supported all around. 5 Alter rotation . check and adjust the tire pressures as necessary and be sure to check wheel lug nut tightness.
m.
26
Wheel beering check
Tire rotetlon diagram (Sec 25) In most cases, the front wheel bearings will not need servicing until the brake pads are changed. However, these bearings should be checked whenever the front wheels are raised for any reason. Also, it is very important to adjust and lubricate tha bearings at the specified intervals (Chapter 11). 2 With the vehicle securelv supponed on jackatands and the transfer case in Neutral with the hubs unlocked, spin the wheel and check for noise, rolling resistanCe and free play. Now grasp the top of the tire with one hand and the bottom of the tire with the other. Move the lire in·and·out on the spindle. If it moves more than 0.OO5·inch, the bear· ings should be adjusted as described in Chapter 11. The bearings should be packed with grease at the specified in tervals.
27
Fig. 1.18
Automatic tran.mlnlon oil pan removal (Sec 27)
replace the EGR valve with II new one. If you are in doubt ebout the condition of the valve. go to your locill parts store and compare the free movement of your EGR valve with a new vilive. 4 Further testing of the EGR system and component replacement procedures can be found in Chapter 6 .
24
Clutch pedal frea play check
Proper clutch pedal free plllV is very important for proper clutch operation and to ansure normlll clutch service life. 2 Clutch pedal free plaV is the distance the clutch pedal moves before
Automatic transmls.ion fluid chenge
At the specified time intervals, the transmission fluid should be changed and the filter raplaced with a new one. Since there is no drain plug. the trensmission all pan must be removed from the bottom of the transmission to drain the fluid. 2 Before draining, purchase the specified transmission fluid (see Recommended lubricants (I(Id ((uids) end a new filter. The necessary gaskets should be included with the fitter; if not, purchase an oil pan gasket and an O· ring seal. 3 Other tools necessary for this job include:
JI1C/(stands to support the vehicle in 11 fBised position A wrench to remove the .oil plln bQlts A drain pan capable of holding at least six quarts Newspapef$ and clean fBgS 4 The fluid should be drained immediately after the vehicle has been driven. This will remove any built·up sediment better then if the fluid were cold. Because of this. it may be wise to waar protective gloves (fluid temperature can exceed 350· F in a hot trensmisslon). 5 After the vehicle has been driven to warm up the fluid, feise it and place it on jackstands for access underneath. Make sure the vehicle is firmlv supported by the four stands placed under the frame rails .
1
1-26
Chapter 1 Tune- up and routine maintenance
6 Move the necessary equipment under the vehicle, being careful not to louch any of the hot exhaust components. 7 Pl ace the drain pan under the transmission all pan and remove Ihe oil pan bolts along the rea r and sides 01 the pan. Loosen. but do not remoVfJ. the bolts at the front of the pan. e Carefully pry the oit pan down al the rear, allowing Ihe hot fluid to drain into the pan. If necessary, use II screwdriver to break the gasket seat at the rellr of the pan; however, do not damage the pan or transmission gasket surfaces in the process. 9 S\Jpport the pan and remOIle Ihe remaining b9tts al the front. Lower the pan and drain the remaining fluid into the container. As this Is done. check the fluid for metal particles, which may be an indication of internal transmission failure. 10 Now visible on the bottom of the transmission is thelilterfstrainer held in place by three screws. 11 Remove the three screws, the filter and the a -ring seal from the pick-up pipe. 12 Thoroughly clean the transmission oil pan with solvent. Inspect it for metal particles and foreign matter. Dry It w ith compressed air (if available). 13 Clean the filter mounting surface on the valve body. This surface should be smooth and free of damage and nicks. 14 Place the new a-ring in position on the pick-up pipe and install the strainer and pipe assembly. 15 Place the new gasket in position and retain it w ith petroleum jelly. 16 Uh the pan up to the bottom of the transmission and install the mounting bolts. Tighten the bolts in a diagonal fashion. work ing around the pan. 17 lower the vehicle. 18 Open the hood and remove the transmission fluid dipstick from the guide tube. 19 Since fluk! capacities vary between the various transmission types, it is best to edd e little fluid at a time, continually checking the level with the dipstick. Allow the fluid time to drein Inlo Ihe pan. Add fluid unt il the level just registers on the end of the dipstick. In most ceses, a good sterting point will be four (41 quarts added to the transmission through the filler lube (use a funnel to prevent spills). 20 With the selector lever in Park, apply the parking brake and start the engine without depressing the accelerator pedal !if possible). Allow the engine to run at a slow idle for a few minutes. 2 1 With the brake pedal depressed end Ihe perking brake applied, shih the transmiS$ion t hrough all gear positions end then place it in Park. 22 Check the fluid level on the dipstick, addIng as necessary to bring the level up to the Full mark. 00 not allow the fluid level to go above this point, as the transmission would then be overfull, necessitating the removal of the 011 pan to drain out the excess fluid. 23 Look under the ve hicle for leaks around the oil pan mating surface. 24 Push the dipstick firmly back into the tube and drive the vehicle to reach normal operating temperature 115 miles of highway driving or its equivalent In the city). Park the vehicle on a level surface and check the fluid level on the dipstick with the engine Idling and the transmission in Park. The level should now be at the Full mark on the dipstick. If not, add more fluid as necessary to bring Ihe level up to this point. Again, do not overfill.
28.4 Typicel tra nsmission drain plug location (arrowl
28
Menual !ran.mission lubricant cha nge
The manual transmission lubricent should be dreined and replaced at the specified intervals. Drive the vehicle to bring the transmission lubricant 10 operaling temperature. 2 Raise the vehicle and support it securely. Before beginning this job. you will need: A wrench to remove the transmission plug A drein pen of et feast six·quert cepeciry An adequate suppfy of the specified lubn"cant Jacks tands to support the vehicle in e raised position Newspepars end cfeen regs 3 Place the drain pan under the drain plug and remove the fill plug. 4 Remove the drain plug (photo l and allow Ihe transmission lubricant to drain into the pan . Inspect the lubricant for signs of contamination and metal partides, which could indicate a malfunction in Ihe transmission. 5 Install the fill plug and lill the transmission w ith the specified lubricant Isee Recommanded lubricents end fluids) to the bottom of the fill plug hole. Install the fill plug and tighten it securely. 6 Lower the vehicle, drive it and check for leaks.
29
Tranl fer case lubrice nt cha ng.
The transfer case lubricant should be drained and replaced at the same time as the manual transmission (Sec 281. 2 Follow the procedures in Steps 2 and 3 of Section 28. 3 Remove Ihe drain plug and allow the lubricant 10 run into the pan (photo). On Guadra-Trac models equipped with reduction units. loosen the five retaining bolts and pull the unit forward sufficiently to permit draining. 4 Inspect the lubricant for clues as to the condition of the transfer
Fig. 1.19
29.3 On laler models. the transfer case drain plug lafrow) is accessible through an opening in the skid plate
Removing the automatic t ransmission fl uid filte r (Sac 27)
Fig. 1.20 Removing the differential cove r to drain the lubri ca nt (Sec 30)
Chapter 1 Tune-up and routine maintenance case, such as matel perticles, water and other contamination. S Install the drain plug. Push the Quadra·Trac reduction unit back into position and tighten the retaining bolts. 6 FiJI the transfer case to just below the filler hole with the specified lubricant and install the plug. Tighten it securely. 7 Lower the lIehicle, test driI/Q it and check for leaks.
30
Diffllrllntial lubricant change
Some differentials can be drained by remolling a drain plug, while on others it is necessery to remOlle the cOlier plate on the differential housing. Because of this, be sure to buy a new gasket at the same time the gear lubricant is purchased. 2 MOlle a drain pan lot least lille-pint capacity), rags, newspapers and wrenches under the lIehicie. 3 On drain plug·equipped differentials, remove the lill plug, 101lowed by the drain plug, and allow the lubricant to drain into tho pan. When it is completely drained, replace the drain plug and refill the dillarantial with the specified lubricant to the base of the fill plug hole. Install the fill plug and tighten It securely. 4 On differentials without drain plugs, remOlle the bolts on the lower half 01 the differential COlier plate. Use the upper bolts to keep the cove r loosely attached to the dilferential. Allow the lubricant to drain into
u WEAR INDICATOR _ _«"
tj tj
o o o
H
the drain pan, then completely remove the cover. 5 Using a lint-free rag, clean the Inside of the cover and accessible areas of the differential housing. As this is done, check for chipped gears and metal particles in the lubricant, indicating the differential should be more thoroughly inspected and for repaired (see Chapter 8 lor more information.) 6 Thoroughly clean the gasket mating surface on the cover and the differential housing. Use a gasket scraper or putty knife to remove all traces 01 the old gasket. 7 Apply a thin film 01 RTV·type gasket sealant to the cover flange and then press I new gesket into position on the cover. Make sure the boit holes Ilign properly. 8 Place the cOlier on the differential housing and install the bolts. Ttghten the bolts a little at a time. working across the cover in a diagonal fashion until all bolts are tight. 9 Remove the fill plug on the side of the differential housing or cover and lill the housing with the proper lubriClnt until the level Is at the bottom of the plug hole. 10 Securely instsll the plug.
31
Brske check
The brakes should be inspected every time the wheels are remollad or whenever a problem is suspected. Indicltions of a potential brake system fault are: the lIehicle pulls to one side when the brake pedal is depressed, noises coming Irom the brakes when they are applied, e)(cessille breke pedal travel, pulsating pedal and leakage 01 fluid (which is usually seen on the inside of the tire or wheel).
Disc brakes 2 Disc brakes can be lIisually checked without removing any parts e)(cept the wheels. 3 Raise the vehicle and place it securely on jack.slands. RemOlle the front wheels (See Jacking and towing at the front of this manual, if necessary!. 4 Now visible is the disc brake caliper. which contains Ihe pads. There is an outer brake pad and an inner pad. Both should be inspected. 5 Most later model vehicles come equipped with a wear sensor attached to the inner pad. This is a small, bent piece of metal which is visible from the inboard side 01 the brake caliper. When the pads wear to s danger limit, the meta! sensor rubs against the disc and makes a screeching sound. 6 Inspect the pad thickness by looking at each end 01 the c"liper and through the inspection hole in the caliper body (photo). If the wear
WORN Fig. 1.21
Disc breke waar indicators ISac 31)
31.6 The brake pad lining (arrow) can be seen through the inspection hole in the caliper
1-27
Fig . 1.22 Early model CJ 2A and 3A brake adjultment pointl (Sec 31)
1
1-28
Chapter 1 Tune-up and routine maintenance
FIg.1.23
Early model CJ 3B. CJ 5 end CJ 6 brake adjustment componentl ISec 311
, Bleeder screw 2 Brake btlcking plat.
4 Eccentric adjusting
3 Eccentric locknut
5 Brake line
32.2
screw
sensor clip is very close to the rotor, Of if the lining materiel is l iB-inch Of less in thickness, the pllds should be replaced. Keep in mind Ihat the lining material is riveted or bonded to II metal backing shoe and the metal portion is not included in this measurement. If the lining material is worn to 8 point where It is thinner than the backing plate, new pads are required. 7 It will be difficuh, if not impossible. to measure the exect thickness of the remaining fining material. If you are In doubt 8S to the pad quality. remove the pads for further inspection or replacement. See Chap· ter 9 for disc brake pad replacement. 8 Before installing the wheels, check for leakage and damage to the brake hose Icracking, splining, etc.) around the brake hose connections. Replace the hoses or finings as necessary, referring to Chapter 9. 9 Also check the disc for scoring, gouging or burnt spots. If these conditions exist, the hub/rotor assemblv should be removed for ser· vicing (Chapter 9).
Tools required for spark plug replacement
2
Ratchet/extension Sperk plug socket
3 4
Sperk plug gep toof Torque wrench
Brake adjultment 20 On models without self·adjusting brakes, the brakes must be ad· justed periodicaliV to compenSiilte for wear. With the vehicle raised and supported securelv, locate the adjusting screws. 21 On earlv models, loosen the brake shoe adjusting eccantric locknuts. Rotate the wheel while turning the forward brake shoe ec· centric toward the front of the vehicle until the shoe contacts the drum. Continue rotating the wheel whila backing off the eccentric until the wheel rotates freelv. TIghten the locknut and repeat the procedure for the rear shoe, tuming the eccentric toward the rear of the vehicle. 22 Further adjustment can be made on some earlV models bV turn' ing the eccentric anc:t'lor pins toward each other until the shoe·to·drum clearance is approximatelv 0.005·inch at the lower end and 0.OO8·inch at the uppar end of tha brake shoe lining. This can be checked with a feeler gauge inserted through a slot in the brake drum on eariV models.
Parking brake
Drum brakes Inspection 10 Raise the vehicle and support it securelV on jackstands. 11 Remove the wheels, referring to Jecking end towing at the Iront of this manual, il necessary. 12 Remove the hub and brake drum as described in Chapter 9. 13 With the drum removed, ca refullv brush away any accumulations 01 dirt and dust. Caution: Do not blow thll dust out with compressed air. Make an effort not to inhale the dust beclluse it contein!:! IIsbestos and is harmful to your heelth. 14 Observe the thickness of the lining material on both the front and rear brake shoes. Measura tha amount 01 remaining lining and com· pare this to the Specifications. If the linings look wom, but you are unable to determine their exact thickness, compare them with a new set at an auto parts store. The shoes should also be replaced i f thev are cracked, glazed (shinv surface) or contaminated with brake fluid. 15 Make sure that all the brake assemblV springs ar& connected and in good condition. 16 Inspect the brake components for signs of fluid leakege. With your finger, careful'v pry back the rubber cups on the wheel cv'inder located at the top of the brake shoes. AnV leakege is an indication that the wheel cylinders should be overhauled immediatelv (Chapter 9). Also check the hoses and connections for signs of leakage. 17 Wipe the inside of the drum with a cl'!lan rag and denatured alcohol or braka system cleaner. Again, be careful not to breathe t he dangerous asbestos duat. 18 Check the Inside of the drum for cracks, scoring, deep scratches and hard spots (which will appear as small discolorations). 19 If all parts are found in good condition sfter the inspection pro· cess, reinstall the brake drum (Chapter 9). Adjust the brakes (see below) and lower tha vehicle to the ground.
23 The easiest wav to check the operation of the parking brake is to park the vehicle on a steep hill, with the parking brake set and the transmission in Neutral. If the parking brake cannot prevent the vehi· cle from rolling, it should be adjusted (see Chaptar 9).
32
Spark plug replacement
The spark plugs are located on each side of the engine on a VB or VB and mav or may not be easilv accessible for removal. In-line engines generallv have fewer spark plug accessibilitv problems. If the vehicle is equipped with air conditioning or power steering, some 01 tha plugs mav be difficult to remove (in which case special extension or swivel tools will be necessaryl. Make a survey under the hood to determine if special tools will be needed. 2 In most cases the tools necessary for a spark plug replacement job include a plug wrench or spark plug socket which fits onto a rat· chet wrench (this special socket will be insulated inside to protect the procelain insulator) and a wi re·tvpe feeler gauge to check and adjust the spark plug gap (photo). If the vehicle is equipped with HEI or BID (electronic) ignition, a special spark plug wire removal tool is available for separating tho wire boot from the spark plug. 3 The best procedure to follow whan replacing the spark plugs is to purchase the new spark plugs beforehand, adjust them to the proper gap and then replace each plug one at a time. When buying the new spark plugs it is important to obtain the correct plugs for your specific engine. This information can be found in the Specifications Section but should be cheCked against the information found on the tune·up decal or Emission Control Information labellocatad under the hood or in the factory owner's manual. If differences exist between these sources, purchase the spark plug type specified on the tune·up
Chapter 1 Tune-up and routine maintenan ce
1-29
34.1 Although It Is possible to clean contact points that ere pitted. burned and corroded jes shown herel. they should be replaced Instead Fig. 1.24 Typical contact breeker point compone nts !Sec 3 4 ) , Point mounting screw
2 Condenser lelJd wire 3 Primary lead wire
5 Point ClJm 6 Poim rubbing block 7 Adjustment slot
4 Condenser decal or emIssion label as it was prinled for your specific engine.. 4 With Ihe new spark plugs on hand. aDow the engine to cool thoroughly belore attempting removaL DUring this time. each of the new spark plugs can be inspected lor defects and the gap can be checked/adjusted. 5 The gap is checked by inserting the proper thickness gauge between the electrodes at the tip of tha plug. Tha gap between these electrodes should be the same as that given in the Specifications or on the tune-up decatlemissions lebel. The wire should just touch each of the electrodes. If Ihe gap is Incorrect, use the notched adjuster on the feeler gauge body to IHInd the curved ,ide elaclrode slightly until the proper gap is obtained . Also at this time check for cracks In the spark plug body, indicating the spalk plug should not ba used. If the side electroda is not exactly over the cente r one. use the notched adjuster to align them. e Cover the fenders of the vehitle to prevent damaga to the exterior paint. 7 With the engine cool, remove the spark plug wire from one spark plug. Do this by grabbing the boot at the end of the wire. not the wire itself. Sometimes it is necesury to use a Iwisting motion While the boot and plug wire are pulled free.. Use 01 a plug wire removal tool is recommended. 8 If comp ressed aIr Is available, use it to blow any dirt or foreign material away from the spark plug area. A common bicycle pump will also work. The idea hell is to eliminate the pOlsib~ity of material failing into the engine cylinder as the spark plug is removed. 9 Now place the spark plug wrench or socket over the plug and remove it from the engine by turning in a coufltelClockwise direction. 10 Compare the spark plug with those shown In the accompanying color photos to get an indication of the overall running condition of the engine. 11 Carefully inl8rt one of the new plugs into the sperk plug hole and tighten it es much as possible by hand. The spark plug should screw easily into the engine.. II it doesn't, change the angle 01 the spark plug slightly, as chances are the threeds are not matched !cross-threaded). 12 Finally, tighten the spark plug with the wrench or socket. It is a good idea to use a torque wrench for this to ensure that the plug i. seated correctly. The correct torque figure is given in the Specificetions. 13 Before pushing the spark plug wire onto the end of the plug, inspect it following the procedures outlined in Section 33. 14 Attach the plug wire to the new sperk plug. egain using a twisting motion on the boot until it Is fIrmly seated. Make sure the wire is routed away from the eKhaust mafllfold. 15 Repeet the procedure for the remaining spark plugs, replacing them one at a time to prevent milong up the plug wires.
33 Spark plug w ire., distributor cep and rotor - check and replacement I The spark plug wires .hould be checked at the recommended inteIVals and whenever new spark plugs are installed in the engine.. 2 The wires .hould be inspacted one at a time to prevent milting up the order, which is essentiel fOf proper engine operation. 3 Disconnect the plug wire from the spark plug. A removal tool can be used lor this purpose or you cen grab the rubber boot, twist slightly and pull the wire free. Do not puN 0tI the wire it,lIff, olllyon the rubber boor. 4 ins pact inside the boot for corroskln, which will look like a white crusty powder. Pu.h the wire and boot back onto the end of the spark plug. It should be a tight fit on the plug end. If it is not, llmove the wire and use pliers to carelully crimp tha metal connector Inside the wire boot until it fits securely on the end of the spark plug . 5 Using a clean rag, wipe the entire length of the wire to remove any built -up dirt and grease.. Once the wire i. cieen, check lor burns, cracks and other demage. Do not bend the wire. since the conductor might break . 6 Disconnect the wire from the distributor. Again, pull only on the rubber boot. Check for corrosion and e tight fit in the same manner as the spark plug end. Replace the wire in the distributor. 7 Check the remaining spark plug wires, making sure they are SecUII1'1' fastened al the diSlributOf and apalk plug when the check is complate. 8 If new sperk plug wires Sfe required. purchese a set for your specific engine model. Wire sets are available PIl-cUt, with the rubber boots already instelled. Remove and replace the wires one at a time 10 avoid milt-up. in the firing order. 9 Check the distributor cap and rotor for wear. Look for cracks, carbon tracks and worn. burned or loose contacts. Replace the cap and rotor with new parts If defects ell found . It i. common practice to insta" e new cap and rotor whenever new spark plug wires are installed. When installing a new cap. remove tha wires from the old cap one et a time and attach them to the new cap in the exact same localion do not simultaneously remove all the wires from the old cap or firing order mix-upi may occur.
34 Contact ~tI end condenMr - replacement and adjustment !1953 t hrough 1974 modelsl , Although the contact points can be cleaned and dressed with e fine·cut file, it is recommended that the home mechanic replace them with new onel instead !photo). 2 The contact point sat and condenser should be replaced as a set. Point alignment and spring tension are factory set and should not re quire further adjustment iii they do, bend the stlltio/18ry contact only) . 3 Whenever contact point replacement is done. it is e good idea to
1
1-30
Chapter 1 Tune-up and routine maintenance
use magnetized tools to prevent screws Of nuts from felling down in· to tne distributor {which would require distributor disBssemblV to retrieve them!.
COnt8Ct point remov81 8nd inst8118 tion 4 5 the 6
Remove the distributor cap (Chapter 5). Position the cep (with the spark plug wires still attached) out of way. Use a length of wire or st ri ng to restrain it if necessery. Remove tha rotor, which Is now visible at the top of the distributor
shaft. On some models the rotor is held in position with screws (photol. while on olhers it is 8 push fit on the shaft end can be pulled off. Place the rotor In a safe place where it cannot be damaged. 7 Disconnect the primary and condenser wire leads at the conlact point SElt. The wires may be attached with a small nut Iwhich should be loosened, but not removed), a small screw or a quick-disconnect fining (photos). 8 Remove the screw!s) which secure the contact point set to the
breaker plale Iphotol. Do nor completely 'amove the screws secudng
34.6 Some rotors are attached with screws, which must be removad before the rotor can be separated from the distributor shaft
34 .7A On some models, the primary end condenser wires are attached to the points by e small nut or screw, which must be loosened to detach the wires
34.78 On other models, the wires can simply be pulled off the points (pliers may be required - pull only on the terminals, not the wires I
34.8 Removing the point· mounting screw (on models wIth slotted mounting holes, the screw!s) should be loosened only)
34. 15 Before adjusting the point gap, the rubbing block must be resting on one of the cam lobes (which should open the points)
34 .16A On some models, the point gap is adjusted by inserting a screwdriver into the slot end twisting it to move the stationary point (you should feal a very slight drag on the gauge as it is withdrawn from between the point contactsl
,
34.168 Some modals hava an adjusting screw which must be turned with en Allen wrench to chenge the poin t gep (you should feel a very slight drag on the geuge es it is withdrawn from bet ween the point contacts)
34 .29 On some models, the dwell can be adjusted with the engine running by opening the window in the distributor cap and turning the point-adjusting screw with an Allen wrench
35. 5 The timing light 11 L special curved distributor bolt wrench (2) and vacuum hose plugs (3) used for ignition timing adjustment
Chapter 1 Tune-up and routine maintenance poim sets that hava slots at thase loclltions. Seperate the point set from the breaker plate. 9 The condenser can now ba ramoved from tha distributor. loosen the mounting strap scraw and slide the condenser out of the bracket. or completely remove the condenser and strap. depanding on the particular mounting arrangement. 10 Before Installing the new poiots and condenser. remove a\l old lubri· cant, din. etc . from tha breaker plate and the point cam surface of the distributor shaft. I I lubricata tha point cam with the speciel grease suppliad with the new points or commercially available point cam lube (do not use multipurpose grellsel . Some modal, have a cam lubricator wick mounted on the breakar plate . The wick can ba rotated to provide lubrication if it is still in good condition, but if in doubt, replaca the wick with a naw ana to provide adequate lubrication of tha cam surface. It ia ramoved by squeezing together the base of the retainar with long-nosed pliers and then lifting the unit out of the breaker plate. It i, important that the cam lUbricator wick be adjusted so the end of the wick just touches the cam lobes. Note: On early L- and F-head four~ylindar engines, place one drop of engine oil on the lubricator wick at tha top of the distributor shaft and four or five drops in the oiler locllted on the side of the housing. 12 Place the new condenser in position and tighten the mounting screw . 13 Attach the new contact point set to the breaker plate and tighten the mounting screw(s) until just snug . 14 Connect the primary and condanser wire laads to the new point assembly. Make sure tha condenser laad is positionad tha sama way it was bafore removal. 15 Although the gap batween the contact points will be set whan the dwell angle is adjustad. it is a good idea to adjust the initial gap to stan the engine. With the points in position and the mounting screwls) snug, but not complately tight, make SUI08 that the point rub bing block is resting on one of the lobes of the cam (photo!. To move the cam, turn the crankshaft by placing a wrench over the large bolt at the front of the crankshaft. 18 With the rubbing block on II cam lobe (points fully open), place II blade -typa feeler gauge between the contllCts. The gllp should be as specified. On some models, tha gap can be changad with a screwdriver. Insart the scrawdriver into the adjustmant slot and twist it slightly to move the stationary point (photo I. On other modals, the gap is changad by turning the adjusting screw with an Allen wrench (photo!. Whan the gap is correct, tighten tha mounting screwlsl securely . 17 Befora installing tha rotor , inspact it for cracks and damage. Carefully cheCk the condition of. the metal contact at the top of the rotor . If in doubt as to Its condition, replace it with a new one. 18 Install the rotor . It is keyed to lit on the sheh only one way. Make sure it is completely seated . 19 Belore installing the distributor cap, inspect it for cracks and damage . Closely examine the contacts on the inside of the cap for ex cessiye corrosion . If in doubt as to the Quality of the cap, replace it with a new one. 20 Install the distributor cap. 21 Stan the engine and check the dwell angle and the ignition timing.
27 On non window-type distributors, loosen the breaker point mounting screw slightly, then move the stationary point IStep 181 to change the point gap (dwell). Incraasing the point gap will decmasa the dwell reading, while decreasing the point gap will increase tha dwell raading . TIghten the point mounting screw, Install the rotor end distributor cap and recheCk the dwell. 28 Repeat the procedure until the dwell reading is within the specified range {see Step 341. 29 On window-type distributors, insert a proper size Allen wrench through the window and Into the adjusting screw socket (photo I. 30 Start the engine and turn the adjusting screw as required to obtain tha specif ied dwell reading on the meter. Remove your hand and recheCk the reading. 31 Remove tha Allen wrench and close the window. Shut off the engine and disconnect tha dwell meter. 32 If you cannot obtain a dwell meter, you can get an approximate dwell setting on window-type distributors without one by using the following method. 33 With the engine at normal operating temperature, raise the window and insert the Allen wrench. Start the engine and turn the wrench clockwise until the engine starts to misfire. Then turn the screw onehe" tum counterclockwise. Remove the Alien wranch and close the window. Have the dwell angle Checked and /or adjusted with a meter as soon as possible. 34 Note: On all models, try to obtain a dWflIl setting that is toward the lower end of the specified renge. Then, as the points wear (which increases dWflIJJ, the dwell will remain within the specified range for a longer period of time.
1 35
Ig niti on tim ing - check and adjustment
All later model Yehicles are equipped with a tune-up or Emissions Control Information label Inside the engine compartment. This label contains important Ignition timing specifications and procedures to be followed specific to that vehicle. If information on the label differs from the information given in this Section, the label should be followed. 2 At the specified Intervals, whenever the contact points have been replaced, the distributor removed or a change made In the fvel type. the Ignition timing must be checked and adjusted if necessary. 3 Before attempting to check the timing, make sure the contact point dwell angle is correct (Section 34 ; 1953 through 1974 models only), and the idle speed is as specified (Section 21). Place the transmission in Neutral, apply the par1<::ing brake. warm the engine to operating temperature then switch Ihe ignition Off. 4 Disconnect the vacuum hose from the distributor and plug the now-open end of the hose with a rubber plug, rod or bolt of the proper size. Make sure Ihe idle speed remains correct; adjust as necessary. On 150 cu in four-cylinder models, disconnect the electrical connectors from the vacuum switches located on a bracket attached to the centSf of the firewall . 5 Connect a timing light in accordance with the manufacturer' s instructions (photo). Generally, the light will be connected to the bat-
Dwell angle adjustment 22 Whenever new c ontact points are installed or the original points are cleaned. the dwell angle must be cheCked and adjusted. 23 Setting the dwell angle is actually quite easy; however, e dwell meter must be used for precise adjustment. Combination tach/dwell meters are common tune-up instruments which can be purchased at a reasonable cost. 24 Connect the dwall meter according to the manufacturer's instructions. Usually, one lead is attached to the primary wire at the distributor and the other lead is attached to a good ground on the engine. Make sure the engine selector switch on the meter is in the correct position. 25 Start the engine and allow it to idle until it has reached normal operating temperature. The engine must be warm to achieve an accurate reeding. 26 Note the dwell meter read ing. If it is within the specified range,. shut off the engine and disconnect the meter. If it is not within the specified range. shut off the engine and remove the distributor cap and rotor. Some models have a distributor cap equipped with a metal 'window' which can be reised (and held up with tape, if necessary) for dwell adjustment, instead of having to remove the distributor cap.
1-31
Fig. 1.2 5
Early model L-head engIne timing mark location ISec 35)
1-32
35.11
Chapter 1 Tune-up and routine maintenance
FIg. 1.26
Later model F- and L-heed engine ti ming mark 1000ation ISec 3 5)
Fig. 1.27
va engin e timing mark location ISec 35)
Tvplcal lale model distributor bolt location (arfowl
tery terminals and to the number one III spark plug in some fashion . On V-type engines, the number onll spark plug '- the first one on the right as you are facing th9 engine from tha front. On in-line engines, it is the front spark plug. 6 locate the numbered timing ta" on the front cover of tha engine. It is just behind Ihe lower crankJhah pulley. Clean it off with solvent, If necessary, to reveal the printing lind small grooves. 7 !.Deale the notched groove across the crankshaft pulley. It may be necessary to have an 8 ..1111"1 temporarily tu rn the ignition off and on in short bUr1ts without atartlng the engine to bring this groove into II position where it can aasily ba cleaned aod marked. Stay clear of all moving engine component, if the engine I, tumed over In this manner. S Use white soapstone, chalk or paint to mark the groove 00 the crankshaft pullev. Also put a mark 00 tha timing tag 10 eccordBoce with the number of degrees called for in the Specifications or on t he label in the engine compartment. Each peak or notch on the timing tab represents 2°. The word 8afoffl or the letter A Indicates advance and the letter 0 indicates Top Dead Center (TOe). M an example, If your vehicle specifications call for 8° BToC IBefore Top Dead Center), you w ill mske a mark 00 the timing tag 4 notches bator. the 0. Some models have a T or TOe mark.
FIg . 1.28
9 Make sure that the wiring for the tim ing light is clear of all mov' ing engine components, then start the engine. 10 Point tha flashing timing light at the timing marks, again being cafeful not to come in contect with moving parts. The marks you made
VB Inglne timing ml rk
~llon (Sec:
351 FIg . 1.29 151 cu in fout-cyllnder timing sCIHl I nd mar1l Iocltlon ISec 35)
Fig. 1.30 Typical 150 cu in four -cylinder and in-line six-cylinder engine ti m ing marks (Sec 35)
Common spark plug conditions NORMAL Symptoms: Brown to grayish-tan color and slight electrode wear. Correct heat range for engine and operating conditions. Recommendation: When new spark plugs are installed, replace with plugs of the same heat range.
TOO HOT
WORN Symptoms:
Rounded electrodes with a small amout1t 01 deposits on the tiring end. Normal color. Causes hard starling In damp or cold weather and poor fuel economy.
RecommwKl.tlon:
Plugs have beerI left in the ~ 100 long. Replace WIth new plugs 01 the same heat Jange. Follow the nIC'
ommended maintenance schedule. CARBON DEPOSITS Dry sooty deposiIs Indicate a nch!Tllxb.n or weak Igoilion. Causes ,misfiling, hard Su.1tng and hesltalloil. RKOmf1lfHKhtlon: Make sure the plug has the correct Ileal raoge. Check lor • clogged air lIIIer or problem In the fuel system or 80gIne ~ system. Also check tor Ignition system problems, Symptoms:
ASH DEPOSITS Symptoms: Ugh! broWl'1 deposiIs
encrusted on the side or center electrodes Of both. 0eriIIed from 011 andlor fuel .oditives. ExC$$SIYa amounts mil)' mask the sparl!, causing mISfiring and hesitation dutlng 8CC8lerltion. Recommfffidallon: If excessive deposits acc::umulate over II IIhort tll'Tl8
or low mileage. W1stall new
guide seals to prevent seepage 01 011 into the combuSlIOIl cl'lambln. Also try cl'langmg ~ ~ne brands. v~
Oil DEPOSITS Symptoms: 0iIv coatIng caused by poor oil control. Oil is IeeImg past worn velva guides or piston rings into the combustion chamber. Causes hard starting, misliong 8I"Id hesitation.
R&eommend.t/on:
Correct the
S)rmploms: BIiI!Itered, white Insu· lator, eroded electrode and abseflce of c\epoI!IIIs. Aesvltl if1
shortened plug life. R~tIon: ChecIc for the conect plug heat tange, OVet· advenced IgrvtIOn tlnwlg, te.l fuel mlxt\Q, Intake manifold vacuum Ieak!;, stICking vatves and insufficient engine cooling .
PREIGNITION Symptoms: Melted eIec1rodes. Insulators ere white, buI may be dirty due 10 misfiring Of ftying debris In the oornbt.II!IIlon chamber. Con lead to engine damage Recommendation: CI">eck lOf the ComICt plug heat range, OVet· adv~ Ignition tinliog, te.l fuel mIlrtl.nI, InI!IufIicient BI1gIIlB cooling and lack of lubrication .
HIGH SPEED GLAZING S)rmptoms: Insulalor /las yellow. Ish, gWed appear1II'ICB. 1ncIicat_ thaI combustion cI"Iarnt:.- temper· ,tInS haYI risen -..:IdenIy dln1g h8rd aoceI«etion. Normal depos/tI!I melt 10 farm , conductMl coating. Causes miI!I1irlng al high speeds. R&eommflfld,tfon: Inslall new plUQI!I. ConsIder using , colder plug if drMng I"Iabits warrant.
DETONATION Symptoms: Insulalors may be cracked or chipped. Improper gap !letting techniques can also result In a fractI.nd insuIalOf bp. Con lead 10 piston damage R_~tIon: Make __ the
fuel ri-l!nock values meet engIOB requlflm8ntl. Use care wtlII"I set· ling lhe gaps on new plugs. Avoid lugging lhe engine.
mechanical condition with neces· sary ~ and install new plugs.
MECHANICAl DAMAGE GAP BRIDGING Symptom.., CombustlO(1 deposits lodge between the electrode,. Heavy deposi" accumulate and bridge the electrode gap. The plug ceaI!IeS to fire, resultlflQ In , deed
"If'--
Reeomm,nd.tlon:
Locale the faulty plug end remove too deposits from b e ' - the electrodes.
SympIoms: May be c.JIed by a foreign objecl In the combusllon charnbef Of the piston sttiklng an l!"lCOfl'eCt reach (100 long) plug. Causes a dead cylinder and could result In plslon~. Rec:otnmMcNltlon: Aepair the mechanIceI damage. Remove the foreign obte<;1 from the engine and/or lostall the ComICl reach
."'-
1
1-34
Chapter 1 Tune-up and routine maintenance
should appeat ltalion81)'. " the marks are in alignment. the liming Is correct. If the markl .fe not aligoed, turn off the engine. 11 Loosen the bolt at the base of the disuibutor (phOto). On some vehicles th i, task is made moeh easier with 8 special curved distributor wrench. lQosen the bolt only 'lighdy, just enough to tum the distributor. (See Chlpter 5 for furtner details, if necessary.) 12 Now restart the engine and turn the distributor until the timing martl coincide. 13 Shut off tha angina and tighten tha distributor bolt, being careful not to move the dillributor. 14 Start the angine and recheck the timing to make sura the marka ara still in alignmenl. 15 Disconnect Ihe timing tlghl, unplug Ihe distributor vacuum hose and connect Ihe hose to Ihe dlslrlbutor. 16 Drive the vehicle .nd listen for pinging noiles. They will be most nOliceeble when the engine is hoi end under a load (climbing a hill, acceleratIng Irom • IIOP!. " you hear engine pinging, the ignition tim· ing Is too lat .dvanced (Balore Top Deed Centerl. Reconnect the liming IIghl and lurn the diltributor to move the mark 1° or 2° in the retard direction. Road test the vahicle egain to check for proper operation. 17 To keep pinging .t • minimum yet 81i11 allow you to operate the vehicle at the specified timing setting, it is a good idea to use gasoline 01 the same oct.ne at .11 time ... Switching fuel brands and octane levels can decrelse performance and economy and possibly damage the engine.
36 Evaporatlva Control System IECS) filt,r raplacment The function of the ECS emilSions Iystem is to draw luel vapors from the tank and carburetor. store them in e charcoal canister, and then burn them during normal engine operation. 2 Tha liltar at the bottom of the ch81coal canister should be reo placed at the specified intervals. If, however, a fuel odor is detected, the canister. filter and system hose ••hould immediately be inspected. 3 To replace tha lilter, locale the canister at tha front of the angine compaflment. It will have s8ller.1 hosel running out the top of it. 4 Remove the two bolte which lecure the bottom of the canister to the body. 5 Turn the canister upslde·down end pull out the old filter. II you
FUEL VAPOR STO RAGE HOSE ·TO·
A"
AIR CLEANER SNORKEL
carloot turn the canister enough, due to Ihe short length of the hOS8S, the hoses must be marked wIth pieces of tape end then disconnected from the top. e Push the new filter InlO the boltom of the canister, making sure it is seated all the way around.
7 Place the canister btlck into position and tighten the two mounting bolts. Connect the verious hOSBS if they were disconnected. 8
37
The ECS system is explained in more detail In Chapler 6.
Cylinder compraliion check
A compression check will tell you what mechanical condition the engine Is in. Specifically, it can tell you if the compressIon is down due to leakage caused by worn piston rings, defective valves and seats or a blown head galket. 2 Begin by cleaning Ihe erea around the spark plugs before you remove then. This will keep dirt from falling into the cylinders while you are parforming the compression test. 3 Remove the call high·tension leed from the distributor and ground it on the IInglne block. Block the throttle and choke valves wide open. 4 With the comprelsion gauge in the number one cylinder ' s spark plug hole, crank Ihe engine over at least four compression strokes and observe Ihe gauge. Tha compression Ihould build up quickly in a healthy engine. Low comprelsion on the fir\llttoke. followed by gradually in· cllasing prellura on IUccllllive strokes. indicates worn piston rings. A low comprllllion rllding on the first stroke, which does nOt build up during lucceilive strokes, indicates leaking valves or a defective lwIad galket. Record the higneS! gauge reading obtained . 5 Repeal thll procedure for the remaining cylinders and compare the resonllO the Specificatiorl5- Compression readings 10" above or below the specified amount can be considered normal. 6 Pour a couple ofl8aspoonl of engine oil (a squit! can works graat for thll) into each cylinder, through the spark plug hole, and repeat the telt. 7 If the compression increasel aher the oil is edded, the piston rIngs are definitely worn. II the compression does not increase significently, tha leekage is occuVing at the valves or head gasket. Leakege palt the valves m.y be cauled by burned valve seatslfaces. warped, bent or cracked valvel, valves that are out of adjustment, incorrect valve tim· ing and broken valve springs. 8 If IWO adjacent cylinders have equally low compression, there is a strong possibility that the head gasket between them is blown. The eppearance of coolant in the combustion chambers or the crankcase would verify thll condition. 9 If tha compreulon Is higher than normel. the combustion chambers are probably coated with cerbon deposits. II that is the case. the cylinder head!s) should be removed and decarbonized. 10 II compression Is way down. or varies greatly between cylinders, it would be • good Idea to heve a leak·down lest performed by a reputable automotive repair shop. This test will pinpoint exactly where tha leakaga il occurring and how severe it is.
38
Battery -
check and maintenance
Caution: CertlJin prtlClJurions musr be followed when checkmg or sarvicing rhe bartery. Hydrogen glJs. which is highly flammable, is a/wtlYs present in rhe bartary cells so keep lighted robllcco lind IJny orher open flemes or sperts away from rhe barrery. The electrolyttl inside tha blltrery is ectulllly dilute sulfuric IJcid. which ClJn be hlJzard· QUS to your skin and caus. injury if spllJshed in the eyI!Is. It wiN also ruin clothlJs and painted surfaces. 1 Tools and materials reqUired for battery maIntenance include aye and hand protection, baking soda. Petroleum jelly, a battery cable puller, cable/terminal post cleaning tools and a hydrometer Iphoto).
CheCking 2
Check the battery for creckl end evidence of leekage. To chack tha electrolyte level in the battery. remove all vent caps. If Iha battery level Is low. add diltilled water until the level is above the cell plates. There Is an indicator in each cell to help you judge when enough water has been added. Do not overfill. Note: Some models may be aquipped wirh maintenence·free blJtteries which heve no provision
3
Fig . 1 .31
Evaporative Control Syltem IECS) canilter inltallatlon (Sac 36)
Ch apter 1 Tune-up and routine maintenance lor need} for tldding wtlter. Also, some models mlfY btl tlquipped with 'Illnslucent tntrtlries so thB tllectrolyttl MYel Clln btl obstllVfld without IlImoving tiny vent caps. On thtlse btltteries, the IflveI should bfl blltWtlen the upper end lower lines. 4 Periodically check the specific gravity of the electrolyte with an hydrometer. This is especially important during cold weather. If the reading is balow the specified range. the battery should be recharged . Malntenance-Iree batteries have a built-in hydrometer whiCh indicates the battery state-ol·charge. 5 Check the tighlness 01 Ihe battery cable clamps 10 ensure good alecuical connections. If corrosion is evident, remove the cables Irom the battery terminals fa puller may be reQuiredl, clean them with a battery terminal brush, then reinstatl them {photosl. Corrosion can be kept to a minimum by applying a laver of petroleum j-eIiV or grease to the terminal and cable clamps aftar they ara assembled. 6 Inspect the entire length of eeeh battary cable for corrosion, crecks and frayad conductors. Replace the cables with new onas if they are damaged {Chaptar 51. 7 Make sure that the rubber protector over the positive terminel is not torn or missing. It should completely cover tha tarmlnal. 8 Make sure that the battary is securely mountad, but do not ovar· tighten the clamp bolts. 9 Tha battery case and caps should be kept clean and dry. If corro sion is evident, clean the battery as 8IO:plained in Step 12. 10 If the vahicle is not being used for an extended period, disconnact the banery cables and have the battary chargad approximataly every six weeks.
Cleaning 11 Corrosion on the battery hold-down components and inner fender panels can ba removed by washing with a solution of watar and bakIng soda. Once the area has been thoroughlv cleanelj, rinse It with clean wlter. 12 Corrosion on tha battary case and tarmlnals can a'so be removed with a solution of water and baking soda and a stiff brush. Be careful thaI none ollhe solution is splashed inlO your eyea or onto your akin
38 .1 Eye and hand protection, baking loda, petroleum jelly and tools reQuired lor battery maIntenance
lwear protactive glowal. 00 not allow any of the baking soda and water solution to get into the battery cells. Rinle tile battery thorou-ghly once it is clean. 13 Metal parts of the vehicle which have been damaged by apilled battery acid should be painted with a zlnc·based primer and paint. Do thia only after the ar88 has bHn thorou-ghly cleaned and dried.
Charging 14 As mentioned before. if the batterV'a specific gravity Is below the spacified amount, the battery must be recharged . 15 If the battery Is to remain In the vehicle dOting charging, discon· nect the cables from the battery to prevent damage to the electrical system. 16 When batteries are being cherged, hydrogen gas (which is vary explosive and flammablel is produced . Do not smoke or IIl10w en open fleme nell, a charping or e ff1Cflntly chargsd battery.. Also, do nor plug in the bettllry charperuntH the cOfIflflCrions haw bII8fI tmlcJ.II' rhe ber· tery oosrs. 17 The average tima necessary to charge a battary at the normal rate is from 12 to 16 hours (sometime, longer). Always charge the battery slowly. A Quick charge or boost charge is hard on a battery and will shorten its lile. Use a battery charger that is rated at no more than 1nO the amplhouf reting of the battery. 18 Remove all of the vent caps and cover tha hole. with a clean cloth to prevent the spattering of electrolyte. Hook the betlery charger leads to the battery posta (positive to po.ltive. negative to negative), then plug in the charger. Make sure It is set at 12 volts (6 volts on early models) if it hes a .etector switch. 19 Watch the battery closely during charging to make sura that it does not overheat. 20 The battery can be considared fully charged when it Is g8ulng freely and there is no Increase in specific gravity during three sl.lCcessiV'8 readings taken at houny intervals. Overheating 01 the battery during charging at normal charglog ratas, excessive oassing Ind continual low specific gravity readings are an Indication that the battery shO\.lId be replaced with a new one.
38 .5A Battery terminal corrosion usually appears as a white fluffy powder
38 .5C Cleaning the battery terminal post with a special tool
1-35
38.50
38.5B Removing the cabie from the battery terminal post {always remove the ground cable first and hook it up 181tl
Cleaning the battery cabla clamp
1
1-36
Ag. 1 .32
Chapter 1 Tune-up and routine maintenance
Chedr;lng the valve IIh ...·to·v!llv ••tl m cI •• nlnea
Fig. 1.3 3
ISec 401 39
Cooling Iyatl m u rv lclng tdralnlng, flu . hlng and refilling )
Periodically. the cooling system should be drained. flushed and refilled to replenish tha antifreeze mho:tur. and prevent the formation of rust and corrosion which can impair the performance of the cooling .Vltem and ultimllte'y cause engine damage. 2 At the lame time tha cooling system I. ,.rviced, all 00581 and the rediator cap should be Inspected and replaced if faulty. 3 Since .ntifreezela 8 poisonous solution, be careful not to spill any 01 the coolant mixture on the vehicle', peint or your own skin. If this happens, rin •• Immediately with plenty of clear water. Also, consult your Iccalautnarlt'.' about the dumping of antifreeze before draining the cooling syalem. In many areas. reclamation cenlers hIVe been leI up 10 collecl automobile oW and drained antifreeze/water mixtures rathel' than allowing these liquids to be added to the aewaga system. 4 With the engine cold, remove tha radiator cap. 5 Move a IIrge container under the radiator to catch the coolant mill' ture al it II drained. 6 [Xain the radiator. Most models sre equipped with a drain plug It the bottom of the redistor, which can be opened using a wrench to hold the fitting while the pet cock II turnad to the open poaition. If the drain has ellcessive corrosion and cannot be turned aasily. or if the radiator is not equipped with a drain, dilConnect the lower radiator note to drain the coolenL Be careful that none of the solution is splsshed onto your Ikln or into your eyes. 7 II so equipped, remove the engine block drain plugs. e On Iystems with I coollnt retervoir, dlaconnect the overflow hose and remove the reservoir. Flush It out with cleen wate r. 9 Place a water hose la common garden hose is flnef in the radiator filler nICk at the top of the radietor and flush the Iystam until tha wa ter runs clear at all drain points. 10 In levera cales of contamination or clogging of the radialor, remove it {lee Chapter 31 and reverse flush It. This involves simply in· sertlng the hose in the bottom radiator oUllel to allow the clear water to run againlt the normal flow, draining through the top. A radietOf repair shop should be consuhed if further cleaning or repair is necessary. 11 If the coolant is regularly dralnad and the Iystem refilled with tha correct antifreeze mixture, thare Ihould be no nMd to employ chemical cleanerl or delcallHI. 12 To rlfill the system, reconnect the radiator hose(sland install the drain plug. securely in the engine. Speciel thread'Maling tape (available alauto parts storesl should be used on the drein pluga installed In I he engine block. Install the coolant reservoir and the overflow hose where applicable. 13 On vehicles without a coolant latervoil', refill the system through the radiator filler cap until the coolant level ilabout one 111 inch below the Iiller neck. 14 On vehicla. with a reservoir, fill the radiator to the base of the filler neck and then add more coolant to the reservoir. 15 Run the engine until nannal operating temperature is reached. then with the engine idling, add coolant up 10 the correct level. 16 Always refill the system with a mixtura of high·quality antifreeze and water In the proportion called for on the antifree~e containe r or in your owner's manual. Chapter 3 alao contains information on anti·
Wlpar blade repleCtlment (Sec 4 11
freaze mixtures. 17 Keep a close wetch on the coolant level and the various cooling hoaes during the l irst lew miles of driving. Tighten tha hose clempI and/o r edd more coolant mixtura as necessary.
40
V.lvs cleara nce adjustment IF· .nd l ·head anglnel onlyl
Note: The F· and L·head engines ere tha only engines that reqwre periodic valve adjustments. AH ofhefengines used in the Jeep CJ series are equipped with hydraulic lifters, which are se/f-sdjusting. The valves on F· and l -head engines must be edjusted at the apecified intervels with the engine cold lat room temperalUrel. 2 Prior to adjustment. remove the valve cover on the side 01 the engine IF- and l-headl and the rocker arm cover IF·head). 3 Velve cleerence is measured by inserting II leeler gauge between the valve stem and,Jiher (F· and l ·heed) and rocker aIm and pUlhrod IF·head) with the liher on the heel or low portion of the camlheh. 4 Rotate the engine with a wrench on the crankshaft pulley unltl the valve il closed, then continue to rotele it approximately 90" further to make sure the lifter lion ths heel of the cam lobe. 5 Insert a feeler gauge betwaen the lifter and valve stem 01 pushrod and rocker arm to determine Ihe clearance . Compare the measured Clearance to the Specilicetions. 6 To edjust, loosen t he lilter or rocker arm locknut and turn the ad· lusting nut in or out to obtain tha specified clearance. Tighten the locknut While holding the adjusting screw so It won't turn . 7 Begin the checkIng and adjustment procedure at the number one cylinder and work beck to the number lour cylinder. After all the valves are adjusted. it is a good idea to go back end double,check the cleareoces to make sure that they have not changed during the lighten· ing of the adjustment screw. 8 Inspect the valve and rocker arm cover gasket surfaces to make lure they are in good condition. 11 there is any doubt. inslall a new gasket aher cleaning the surface. 10 prllclude the possibility of leak •.
41
Wlndl hield wip ers - Inspection and replac ement
The windshield wiper and blade assembly should be inspacted periodicelly for demage. loose components and cracked or worn blade elements. 2 Roed film can build up on the, wiper blades and affect their effi· ciency so Ihey should be washed regularly with a mild detergent solution. 3 The action of the wiping mechen ism can loosen the boIlS. nuts and lallsners so they should be checked and tightened. as necessary. at the same time the wiper blades are checked. 4 If the wiper blade elements ara cracked. worn or warped. they should be replaced With new ones. Raise the wiper erm away from Ihe windshield, push the arm end into the wiper blade end rotete the blade around the tip of the arm. Attach the new blade to the arm tip and rotate it into posit ion.
2A-1
Chapter 2 Part A General engine overhaul procedures Conlin.. Crankshaft - inspection. Crankshaft - removel •• Cylinder head - cleaning and inspection. Cylinder head - disassembly Cylinder head - reassembly Engine block - cleaning . . Engine block - inspection . . ...•... Engine disassembly - general information .••.•. • Engine overhaul - general information. .. . ... Engine rebuilding alternatives .••..... Engine removal - methods and precautions •• • •.•.
16
12 8 7 10 13 14
6
3 4
5
Genere' Information Included in this portion of Chepter 2 are general overhaul procedures common to all engines used in Ihe vehicles covered by this manuel. The materiel ranges from advice concerning how to prepare lor and approach en engine overhaul to detailed, step-by-step procedures cove,ing removeland installation of internal engine componan lS and the in.pectlOn of parts. Kaep in mind thet the information here should be used in conjunclion wllh one of the othar ParIS of Chapter 2 (depending on the particular engina involved), To accomplish a typical engine overhaul, rafer to the procedures in tha appropriate Part of Chapter 2 to remove the engine Irom the vehicle and begin engine disassembly. Once the ax ternal componenls have been removed, proceed to Chapter 2, Part A. lor the the remainder of the engine teardown. certain cleaniog and in· IpIICtion procedures and the installation of ,nternal parts. Return to the Ippropriate Part of Chapter 2 10 complete engine reassembly and inItall it In the vehicle. In order to aVOid confusion and reduce the possibility of errors, alt • pecifications and clearances for each particular engine are included In the appropriate Part of Chapter 2 - not Part A.
2 Repait ope-ratkml pOllible with the engine in th. vehicle Many major repall opelations can be accomplished without removing the engine from the vehicle. h is a very good idfla to clean the engine compartment and the exterior of the engine with soma type of pressure washer before any work I, begun. A clean engine will meka the job easiar and will prevent the
General information •.• • ..... Initial start-up and break-in after overhaul Main and connecting rod bearings - inspactlon Piston/connecting lod assembly - inspection Piston /connecting rod assembly - inSllltalion and bearing oil clearance check ... .... _ .•... Piston/connecting rOd assembly - removal Piston rings - Installation •.•. Rapsir operations possible with the engme in the vehicle Valves - servicing ........ _ .
1
20 17 15
,. 11 18
2
•
possibility of getting dirt into internal areas of the engine. Remove the hood (Chapter 12) and cover the fenders to provide es much working room as possible and to prevent damage to the painted surface. If oil or coolant leaks develop, indicating a need for gasket or seal replacement, the repairs can geoerally be made With the engine ,n the vehicle. The oil pan Qasket, the cylioder head gaskel(sJ. '"take and exhaust manifold gaskets, liming chain cover gaskets and the front and rear crankshaft oil seals are acceSSible With the engme in place. In the case of the rear crankshaft oil seal on the 150- and ISI-cubic-inch four·cylinder engines, the transmission, the Clutch components and the flywheel! drive plate must be removed first. Exterior engine components, such as tha water pump, tha startar motor, the alternator, the distributor, the fuel pump and the carburator. as well as tha intake and 8lIhaust manifolds, are Qutte eaSily ramoved 101 repair with the engine in plal;:e. Since the cylinder headls) can be removed without puning the 8Ogm8, valve component servicing can also be accomplished With the engine in the vehicle . Replacement, repairs to or inspection of the timing gears or sprockets and chain and the oil pump are all possible with the engine In placa. In extreme case. cauaed by a lack of necessary equipment, repall or replacement 01 piaton rings, pistons. connectIng rods and rod bear· ings and reconditioning of the cylinder bores is possible with the eng1ne in the vehicle. However. this practice is not recommended becaul8 of the cleaning and preparation work that muat be done to the components involved. Detailed removal, inspection. repair and installation procedures for the above mentioned components can be found In the appropriate Part of Chapter 2 or tha other Chapters In this manual.
2A
2A-2
Chapter 2 Part A General engine overhaul procedures
3 Engine overhaul - geMral Information II is nOI always easy to delermine when, or if, an engine should be completely overhauled, since a number of factors must be considered. High mileage is not necessarily an Indicetlon thet an overhaul is need· ed while low mileage. on the other hand, 'does not preclude Ihe need lor an overhaul. Frequency 01 servicing is probebly the single most im· portent consideration. An engine that nel reguler (and frequent) aU end Illter changel, as well as otner required maintenance, will moSI likely glVfl many thousands of miles of reliable service. Conversely, e neglected engine mey require an overheul very eerly In its lile. El(CeISIVe oil consumption is an indica tion tnat piston rings and/or valve guides ere in need 01 atlention (make sure thet oil leaks ere not responsible belore deciding tnat Ine rings end guides are bad). Heve a cylinder compression or leek-down test perfonned by an el(perienc· ed tune'up mechanic to determine lor certeln the el(tenl 01 the work reqUired. If the engme Is making obviOUS knocking or rumbling noises, the connecting rod end/or mein bearings are probebly et leu It. Check the oil pressure with e geuge (insteUed in place of the oil pressure sending uni t) and compare it to the Specifications. If it is el(tremely low, the bearings and/or oil pump are probebly worn out. Loss 01 power, rough runmng, el(celSive valve train noise end high luel consumption rates mey also point to the need for an overheul (especially if they ere all present et the leme timel. If e complete tune· up does not remedy the sltuetion, mejor mechenical worll. is the only 10lutlOn. An engine overheul generelly involves restoring the inlernel parts to the spedlicetions of a new engine. During en overheul, the piston rings are replaced end the cylinder wells ere reconditioned (rebored and/or honed). 11 a rebore is done, then new pistons ere elso required. The mem end connecting rod bearings ere repleced with new ones and, if necessary. the cl anksheft mey be reground to restore the journals. Generelly, the valves ere serviced es well. since they ere usuelly in le$lthan·perfeet condi tion al tnis polnl. While the engine is being over· heuled, other componenlS sucn el tne carburetor, the dislributor, the Itartel and the alternator can be rebuilt allo. The end result should be allke-new eflQlne that will gMt as many trouble-Iree miles es the originel. Belore beginning the engine overhaul, reed through the entire pro· cedure to lemilierize yourself With the scope end requirements 01 the job. Overheullng en engine is not that difficull, but it is time consum· ing. Plan on the vehicle being tied up for e minimum of two weeki, especially if perts must be taken to en eutomotive machine shop for repelr or recondItioning. Check on avellability 01 parts end make sure thet eny necessary special tools end equipment ere obteined in advance. Most work can be done with typicel snop hand 100110, elthough e number 01 precision meesuring tools ere required for Inspecting perts to deler· mine if they must be replaced. Olten e reputable eutomo tive machine shop will handle Ihe inspection of perts end offer advice concerning reeondltioning end replecement. Nota: Alwfl'l$ wait until the engine hilS beM comp/erely disassembled end 1111 compOflf!nts, especially rhe englnft block, httVe been inspected before deciding whllt service and repair opera tions must be perfofffled by lin IIlJtOmotive machine shop. SII'lCe the block's condition will be the mejor lector to consider when determ,ning whether to OVflrheul the origineJ engme or buy e rebuilt one. never purchase parts or have machine work done on other com· ponents unlil the block nes been tnoroughly inlpected. As e gene rei rule, time is Ihe primary cost of an overhaul, so it does not pay to In· stell worn or sub·standard petls. As a Iinel note. to ensure mel(imum life end minimum trouble from a rebuilt engine. everything mUBt be allembled with cere in a spollessly cleen environment.
4
Englna rebuilding ahem.tllres
The home mechanic ;10 faced wilh a number of op tions when per. forming an engine overhaul. The deciSion to replece the engine block, piston/rod essemblies and crenkshaft depends on a number of fectors, with the number one consideretion being Ihe condition 01 the block. Other consideretions are cost, access to mechine shop facililies, perts eveileblllty, lime required to complete the project end el(perience.
Some 01 the rebuilding allemallves include: Individual parts - If the insp«tion procedures ffIVfIal that fhe engine bfock and most engme components are in reusable condition, purchasing individuIII parts may be the most economical alterna tive. The block, crankshaft and piston/rod assemblies should all be inspected carefuNy. Even If the block shows/ittfe wear. the cylindar bores should recaiVfla finish hone; a job fOl an automotive mechine shop. M . .ter kit (cranksheft kitl - This rabuild package usually consists of a reground crankshaft and a matched set of pistons lind connect· mg rod$. The pistons will already be installed on the connectmg rods. Piston rings and thll nllCaSSllry bearings mayor may not be includlld In the k;" These kits lire commonly available for standard cylinder bores, as WflN liS for engine blocks which haW been bored to a regular oversize. Short block - A shon block conSis ts of lin engine block w ith a crankshaft and pistonhod assemblies already installed. A ll new beal(ngs are incorp0f'll,ed lind all ClllalllnClls will be corrllCt. Depltnding on where t he short block is purchesed, II guaf'llntee mey bllmcluded. Thfl IIxisting camshaft, valve train components. cylinder head/s) lind ax· temlll parts Clln be boltlJd t o the short block with little 01 no machme shop work necessary. Long block - A long block consists of a short block plus oil pump, oil pan, cylinder head(s), rocker aIm cover/sl, cemshaft and villva train components, timing gBlJfS or sprockets end chain lind timing gearA:hain ~r. All components 11M ins talled with new bearings. seills and gaskets ~ted throughout. The inSlllNlltion of fTIIJnifolds and ex teffllll parts is aU that is neceSSllry. Sofflll form of guaranree is USUII/Iy included With the purchase. Give carelulIhoughl10 which allematlve IS best lor you and discuss Ihe Silualion with localaUIOmOlive machme shops. auto parts dealers or dealership pansmen before ordering or purchasijng replacameO! pans.
5
EngIne ramoval -
methods end preceutionl
If It has been decided Ihet an engine must be removed for overhaul or mejor repeir work, certein prelimmery steps should be teken. loceting a suitat1le work eree is elltremely Important. A shop is, of course, the most desireble place to work. Adequate work spece along with Slorege spece for the Vflhicle is very important. lIa shop or garaQi! is not eveilable, at tne very least e flat level, clean work surlace made of concrete or asphalt Is reqUired. Cleaning the engine compertment and engine prior to remove! Will help keep tools cleen end organized. An engine hoist or A-Ireme will elsa be necessary. Meke sure thet the equipment is reted in ellcess of the combined weight of the engine and its eccessories. Salety Is of primary importance. considering Ihe po tential nezaros Involved in lifting the engine out of the vehicle. If the engine is being Mmoved by e novice, a helper should be eveilable. Advice and eid from someone more 8lCperienced would elso be helpful. There ere many instances when one person cennot simulteneously per· form ell 01 the operationl required when lilting the engine out 01 tne vehicle. Plan the operetion ahead 01 time. Arrange for or obtein eM of the tools and equipment you will need pflor to beginning the job. Some of the equipment necllssery to perlorm engine removal and instellallon seleIy end with relative eese ere (in eddition to en engine hoist) e heavy· duty tloor jack. compillte sets 01 wrenches end sockets al described In the fronl of th is manuel, wooden blocks end plenty of rags end cleaning solvent l or mopping up the ineviteble spills. If the hoist Is to be rented, make sure thet you errenge for it in edvence and perform beforehand all of the operetions possible without It. This will seve you money and lime. Plan for tna vehicle to be ou t of use lor e considereble emount of time. A machine snap will be leq';nre(l to perform some of the work which the home mechenic cannot eccomplisn due 10 e leck 01 speciel equipment. These shops often nave e busy SChedule so it would be wile to consult them prior to removing tne engine in order 10 accurately eSlimete the amount of time required to rebuild or repeir componentl thet mey need work. Alweys use elltreme clutlon when removing and installing the engine; serious injury can result from cere less ections. Plan ehead. Teke your lime end e job of I his nature. although mejor, cen be accomplished luccessfully.
Chapter 2 Part A General engine overhaul procedures
,
' c..
Fig. 2.1
Measuring the In.telled velve .prlng height with e .teel rule ISec 7)
6 Engine dlse...mbly - gener.1 Information It i. much eesler to dismantle end repair the engine if it is mounted II portable· type eng ina stand. For a reasonable fee, these stands tan ohen be rented from an equipment rental yard. Bafore the engine it mounted on II stand, the Ilywheelklriveplata should be removed from the engine (reler to the appropriata Section). II a stand is not evailable, it is possible to dism8fltle the engine with it blocked up on a sturdy workbenCh or on the floo r. Be extra cereful not to tip or drop the engine when working without a stand. I! you are obtaining a factory replacement or reconditioned engine. all external components must coma off first - Just as they will if you .,. doing II complete engine overhaul yourself. These include: on
Altemator and brackats Distributor and spark plug wires Thermostat and cover Oil filter Cerburetor Inteke and exhaust menifolds Water pump Engine mount brackets Clutch and flywheel or driveplate
NOli: When removing the external components from tha engine, pey close ertention to details that trnIy be helpful Of important during in· 'teHation. look for the corfllct positioning of gaskets. seals. $plIcers. pins, washafS, bolts and othllr small items. If you are obtaining what is termed a short block, which consists of the block, crankshaft, pistons and connecting rods all assem· bled, then the cylinder headls), oU pan and oil pump will have to be removed also. Remove all of the components accordIng to the procedures describ· ed in the appropriall Chapllrs 01 this manual.
7
2A-3
Cylinder head -
dl.a.sembly
Nota: New and rebuilt cylinder heads are commonly available for most engines at dealerships and auto /HrtS stOff1S. Due to the fact tmt SOm6 !J{}eCieHzed tools are necessary for tha disassembly and inspection pro· cedures. end replacement perts may not be readily avaiJeble, it mey be more practical and economical for the home mechanic to purchase e replacement head (or haads) rather than taking the tlma to disassem· ble, inspect and recondition the original head(s).
1 Cylinder head disassembly involves removal and disassembly 01 tha intake and exhaust valves and their related components. If so equipped, remove the rocker arm nuts/bohs, beHs lor pivots) end rocker arm •. Lebel the parts or 1I0re them separately so they can be reinstalled In their original locations.
7.3 Use a valve spring compresso r to compress the springs, then remove the keepers from the valve lIem
2 Bafore the valvas are removed, arrange 10 label and .tore them, along with their related components, so they can be kept separete and reinstalled In the same valve guides they are removed from. Also, measure the valve spring In.talled height !for each valve) and compare it to the Specilications. If It i. greatar than apecified, the valve .eats and val\le faces need attention. 3 Compre" the valve .pring on the lirll valve with a .pring compressor and remove the kaapars Iphoto). Carefully release the valve spring compressor and ramove the retainer (or rotator), the .hlald III so equipped), the springe, the seal lor 011 deflector), the sprIng lIIat end the vat\le from the head. II the valve bindeln the guide {won't pull through), puah it back into the head and deburr the area around the keeper groove with a fine lile or whetstone. 4 Repeat the procedure for the remaining valve$. Remember to keep all the part. for each \lalve tooether so they can be reinstalled In the same locations. 5 Onca the \lalves have been removed and .afely stored, the head should be thoroughly cleaned and inspected. If e complete engine ova/haul is baing done, finish the angine diNnembly procedure. before ooginning the cylinder head cleaning end inspection proce".
8
Cylinder head - cleaning and Inspection
Thorough cleaning of the cyWnder head and related valve train components, followed by a detailed In.pection, will enable you to decide how much valve service won.. must be dona during the engine ovartlaul.
Cleaning 2 Scrape eway all traces of old gasket m.uerlal and sealing com· pound from the head gaskllt, intake manifold and exhaust manllold teet· ing surfacas. 3 Remove any built·up ICale from around tha COOlant passages. 4 Run a stiff wire brush through the oH hole. to remove any deposits that may have formed in them. 5 It is a good Idea to run en appropriate Ilze tap Into each of the threaded holes to rem ova eny corro.ion or thread sealant that mey be present. If compressed air i. available, Ute it to clear the holes of debris produced by this operation. 6 Clean the exhaust and intake manifold .tud threads in a .imHar manner with an appropriate size die. Clean the rocker arm pivot bott or stud threads with a wire brush. 7 Next, cleao the cylinder head with solvent and dry it thoroughly. Compressed air will speed the drying proce.. and ensure that all holes and recessed areas are clean. Nota: D«arbonizing cfHImicals are available and may prove I'8ry useful when cleaning cylindar hfled8IJnd vlllvft tlllin components. Tn.y a",1<'ery caustic and should be u3«/wirh caution. Be sure to 'oHow the instructions on the con tainer. 8 Cleen the rocker arma, pivot. and pu.hrod. with so""eot and dry them thoroughly. Compressed air will apeed the drying procell end can be used to clean out the oil passage'.
2A
2A-4
8.20 II
Chapter 2 Part A General engine overhaul procedures
Measurll the valve Item dh!JIT'ItIUtr
tnr.e
points
Fig. 2 .2 Us • • Imlll no_ g.oga to determine the In.lda dlillnetet at the vl lv. guide. (the g~ II thIn mNlWrMl whh II micrometer) (Sec 8 )
B.21A Measure the tree length 01 each valve spring with. diel or Vernier caliper
Ag. 2 .3
A dlal ln dlCelor un llao be
used to determine the vllv. Item·toguld. cIo.. ranee (Sec 81
9 Clean ell the velve springs, keepera. retlliners, rotators, shields and spring .eaU with solvent end dry tnem thoroughly. 00 the perts from one valve at • time so no mlJ(ing 01 pert. between vetves occurs. 10 Scrape off any heavy deposits thai may h8Vtl formed on the valves, Ihen UIB I motorized wire brush to remove deposits from the valve heed. and atem •. Agein, make lure the valv8' do not get mixed up.
Inspection Cylinder head 11 Inspect the head very clllefully for creck!;, evidence of coolant leeklgl and other dlmlge. II creck. are found, a new cylinder heed should be obtlined. 12 U.ing I streightedge Ind feeler gauges. check the head gSlket mlting .urflce for warpage. II the head i. warped beyond the limIts given in the Specifica tions, it cln be re.uffacad It an automotive machine shop. 13 EXlmine the valve aeats in "ch of the combustion chambers. II thay are pitted, cracked or burned, the heed will requi re vllve servici thlt Is beyond the scope of the home mechanic. 14 M"sure tha inside diametars of the valve guides (at both ands and the center of aach guide) with I .mall hole gauge and a O-to-l-Inch micrometer. Record the measurements for future reference. These measurements, along with the valve .tem diameter measurements, will enable you to compute the valve stem-to-guide clearances. These clearences, when compared to the Specifications, will be one flctor that will detennine the extent of valve lefVice work. required. The guides are measured at the ends and . t the center to determine il they are worn in a bell-mouth pattetn (mora weer at the endsl. II they are. guide reconditioning or replacement Is necessary. AI.n alternative, use I dial Indicator to measure the Iiteril movement of each valve stem with the valve In the guide and approximately 1116-lnch off the seat (see the accompanying illustrat ion).
8 .2 1B Check each valve spring for squareness
Fig . 2 .4 The margin w idth on each v. tve mUll be •• • peclfled (If no m argin exl'lI, the v.lv. mull b. replaced) (Sec: 81
Rocklr arm component. 15 Check the rocker Irm Ilces (thll contact the pushrod ends and valve stems) for pits. wear and rough spots. Check the pivOI conlact areas as well. 16 Inspecl the pushrod ends for sculling and excessive wear. RoH the pushrod on a flal surface. such as a piece of glass, to datarmine II it Is bant. 17 Any damaged or excessively worn parts must be repllced with new ones. V.tv.s 18 Carefully inspect each valve lace for cracks, pits and bumed spots. Chack Ihe valve slem Ind neck for cracks. Rotate the valve and chack for any obvious indication Ihat it is benl. Check the end 01 the lIem lor pits and e)lcessive wear. The pre.ence of any 01 these condilion. indicates the need for valve service by a properly eqUIPped profeSSIOnal 19 M easure the width of the valva margin (on each valvellnd com· pete it to the Specifications. Any valve with a margin narrower than specif ied will have to be replaced with a new one. 20 Measure Ihe valve stem diameter (photo). Note: The tlxhaust lIlJIV'Is ustld in the GM lSI cu fn four-cylinder engine have tapered stems and are approximattlly O.OOl';nch larger et the tip end than at thtl head tlnd. By subtracting the stem diameter1rom the corresponding vBlve guide dilmeter, the vBlve stem·to-guide cle8fance is ohtBined. Compare the fesuits to the SpecificBtions. If the ttem·to·guide clearance is gr88ttf than specified, the guides will hIVe 10 be lecondltloned Bnd new valva may hIVe to be installed, depending on the condition of the old OI'l81. Valve component. 21 Check each valve spring for we8f Ion the ends) and piU. Me8Surt the I reelength (photo) Bnd compare it to the SpecifICations. Any sprif'l9l that are short er than speclfied have sagged and should not be reused_ Stand the spring on B lIat lurlace and check it for squBfeness Iphotol.
2A-5
Chapter 2 Part A General engine overhaul procedures
10.6 Checking the valve stem seals IGM 151 cu in four-cylinder engine only) for leekage
11 .2 A special tool is required to remove the ridge hom the top of each cylinder
22 Check the spring retainers (or rotators) and keepers for obvious weer and crecks. Any Questionable parts should be replaced with new ones, as extensive damage will occur in the event of failure during engine operetion. 23 If the inspection process indicetes that the valve components are in generally poor condillOn and worn beyond the limits specified, which is usually tha case in an engine that is being overhauled, reassemble the valves in the cylinder head and refer to Section 9 for valve servicing recommendations. 24 If the inspection turns up no excessively worn pens, and if the valve faces and seats are In good condition, the valve train componentS can be reinstalled in the cylinder haad without major sarvicing. Refer to the appropriate Section for cylinder head reassembly procedures.
9
Valv.s -
servicing
Because of the complex nature of the job and the special tools and equipment needed, servicing of the valves, the valve seats and the valve guides (commonly known as a 'valve Job'lls best leh to a professional. 2 The home mechanic can ramove and disassemble the head, do the initial cleaning and Inspection, then reassemble and deliver the head to a dealer service department or a reputable automotiva machine shop for the actual valve servicing. In the case 01 an F- or L-head engine, the block will also have to be taken to the mechine shop for valve ser· vice worll:. Refer to Chapter 2F lor'\he procedure to follow when removing the valvas from the block. 3 The dealer service department, or automotive machine shop, will remove the valves and springs, recondition or replace the valves and valve seats, recondition the valve guides, check and replace the valve springs, spring retainers or rotBlors and keepers (as necessary), replace the valve seals with new ones, reassemble the valve components and make sure the installed spring height IS correct. The cylinder head gasket surface will also be resurfaced if it Ie warped. 4 After the valve job has been performed by a professional, the head will be In like-new condition. When the head is returned, be sure to clean it again, very thoroughly {before installation on the engine) , to remove any metal particles and abrasive grit that may still be present from the valve service or head resurfacing operations. Use compress· eel air, if available, to blowout all the oil holes and passages.
10 Cylinder head - rea..embly Regardlss, of whether or not the head was sent to an automotive machine shop for valve servicing, make sure it Is clesn before beginning reassambly. 2 If the head was sent out for valve servicing, the valves and related components will alreadv be in place. 3 Lay all the spring sealS In position, then lubricate and install new leals lor deflectors) on each 01 the valve guides ($iM-cylindef 8nd VB angines only) . On 811 fOUf' cylinder engines the lIIals are installed in the lower grooves in the valvas altar the aprlngs are com· pressed (lubricate the saals before installationl. V6 engines are not
11.6 Checking connecting rod end play with a feeler gauge
eqUipped with seals. 4 Nellt, install the velves(taking care not to damage the new lealsl, the springs, the shields iii so equipped I, the retainars lor rotators ) and the keepers. Note: On V6 angines, the spring must be in· ISttlNed with the clolSefy ISpaced coils neMt to the hud. Coat the valve stems with clean moly·based grease 101 engine assembly lubel before sUpping them into the guides. When compre..ing the springs with the valve spring compressor, do not let the retalnel"l contect the valve guide seals or deflecton! WM-qlinder and VB enginelS only). Make certain that the keepe rs are securely locked in their retaining grooves. 5 Double check the Installed valve spring height. If it was correct before disassembly, It should still be within the specified limits. 6 On fouf-cylinder engines only, check the valve lIem seal, with a vacuum pump and adapter (photol. A properly installed seal should not leak. 7 Install the rocker arms and tighten the Dohs/nuts to the specified torque. Be sure to lubricate the pivots with moly-based grease or engine assembly lube.
11
Pillon/conOKting rod a ..embl,. -
removal
Prior to removing the piston/connecting rod assemblies, remove the cylinder l:iaed(sl end the oil pan by raferring to the appropriete Sections. 2 Using a ridga reamer, completely remove the ridge at the top of each cylinder (follow the manufacturer's instructions provided with the ridge reaming tool1lphoto). Failura to remove the ridge before at· tempting to remove the piston/connecting rod assemblies w1ll result In piston breakage. 3 With the engine in the upside-down position, remove the 011 pick· up tube and oil pump from the bottom of the engine block. 4 Before the connecting rods are removed, check me end playas follows. Mount e dial indicator with its lIem in line with the crankshaft and touching the .ida of the number ona cylinder connecting rod cap. S Push tha connecting rod forward, as far as possible, and zaro the dial indicator. Nellt, pUlh the connecting rod all the way to the rear and check the reading on the dial indicator. The distance that it moves is the end play. If the end play ellceeds the service limit, a new con necting rod will be required. RepeBl the procedure for the remaining connecting rod •. 6 An altemative method is to slip feeler geuges between the con· necting rod and the cranbhait throw until the play is removed (photo). The and play is then equal to the thickness 01 the feeler gauge!s). 7 Check the connecting rods and connecting rod caps for identification marks. If they are not plainly marked , Identify each rod and cep using a small punch to make the appropriete number of indentations to indicate the cylinders they are associated with. S loosen aBCh 01 the connecting rod cap nulS approximately 1/2 tum each. Note: On F- end ( -head engines, first remove the stamped locking nuts 8nd discard t~m. Remove the number one connecting rod cap and bIIaring Insert. Do not drop the bearing insert out 01 the cap. Slip a short length of plastic 01 rubber hose over each connecting rod cap bolt [to protect the crankShaft tournai and cylinder wall when the piston is removedl (photo) and push the connecting rodfplSlon
2A
2A-6
Chapter 2 Part A General engine overhaul procedures
11 .8 To prevent damage to the crank'hlft journels and cylinder walll, slip ,8(:tlo"1 of hose over the rod bolu before femovlng Ihe pistons
Ag. 2.6
CheciUng
cr~bh.ft
and pllIY
12 . 5
Checking cranuhalt lind pley
with 8 feeler gauge fGM 151 cu in fourcylinder engine shownl
13.1 Using pller. to remove II lOft plug from the block
with. d/IIIlndlcllt(N" Is..: '21
14.4A A telescoping gauge cen be used to determine the cylinder bore diamater
fl1---- • ----\I
11--'--Y1 , --1:-1
14.8 The gauge i, then measured with II micrometer to determine the bore size in Inche.
fig. 2 .6 Measur. the diameter of each cylinder ;,..t under the . . .t ridge fAI. It the ceflter (8) end It the bottom Ie) (Sec '4)
ISlembly out through the top of tne engine. Use. wooden tool to push on Ihe upper beering Insert In the connecting rod. If resistance is felt , double-check to make sure Ihat 811 of the ridge was removed from the cylinder. 9 Repeat the procedure for the remainIng cylinders. After removel. ra88semble the connecting rod caps and bearing Inserts in their respec tive connecting rods and install the cap nutt linger tight. Leaving the old bearing Inserts In place until raassembly win help porevant the con oectlng rod belN'ing surfacas Irom being accidentally nicked or gouged.
Before begInning this procedure, the preliminary steps outlined in Chapter. 2B. 2e, 20, 2E or 2F las approprlateJ must be completed. 2 II not already done. remove the piston assemblies from the engine
Ag. 2 . 7 The cyllnd ... hone should leave e cross-hatch panem with the lines intersecting It Ipporoxlmately I 60· Ingle ISec 141
block. es described in Section '1 . Be sure to mark each connecting rod and bearing cap so they will be properly mated during reassembly. 3 Before the c rankshalt is ramoved. c heck the end playas follows. Mount a dial indiCator with the stem in line with the crankshaft and just touching one of the crank throws (see accompanying illustrationl. 4 Push the crankshaft all the way to the rear and lero the diel Indicator. Next. pry the crankshaft to the front 8S far as possible and check the reading on the dial indicator. The distance that it moves is the end play. If it is greater Ihan specified. c heck the crankshaft thrust surfaces lor wear. If no wear is apparent. new main bearings should correct the end play. 5 II e dial indicator is not available. feeler gauges can be used. Gently pryor push the crankshaft all the way to the Iront of the engine. Slip feeler gauges between the crankshaft and the Iront lace 01 the thrust main beering Iphoto] to determine the clearance (which is equlvslent to crankshaft end play).
Chapter 2 Part A General engine overhaul procedures
14.7
Honing a cylinder with a surfacing
hon.
15.4 Cleaning the piston ring grooves with a piston ring groove cleaning tool
6 Loosen each of the main bearing cap bolts lf4 of a turn at a time, until they can be removed by hand. Chack tha main baarlng cap. to laa if they are marked as to their locations. They are usually numbered consecutively (beginning wilh 1) from the front of the engine to the raar. If they are nOt, mark them with number stamping dies or a center punch Iphotol. Most main bearing caps have a cast-in arrow, which points to the front of the engine.. 7 Gently tap the caps with a soft-fsced hammar, then separate them from the engine block. If necesaary, use the main bearing cap bolta .. levers to remove the caps. Try nOI 10 drop the bearing insert If It comes out WIth the cap. a Carefully hft the crankshaft out of the engine.. It is a good idea to have an assistant available. sinca the crankshaft is quite heavy. With the bearing inserts in place in the engine block ancMn the main bearing caps, return the caps to Iheir respective locations on the engine block and tighten the bolts finger tight.
13
Engine block - cleaning
Remove the soft plugs from the engine block. To do thia, knock the plugs into the block lusing a hammer and punch), then grasp them with large pliers and pull them back through the holes Iphotol. 2 Using a gasket scraper, remove all traces of gasket material from !he engine block. Be very callful not to nick Of gouge the gasket saal Ing surfaces. 3 Remove the main bearing ca~s and separata tha bearing Inserts from the caps and the engine block. Tag the bearings according to which cylinder they removed from (iwd whether they were in the cap or the block) and set them aside. 4 Using a hell wrench of the appropriate size. remove the Ihreaded 011 gallery plugs from the front and back of the block. S If the engine is edremely dirty, it should be taken to an automotive machine shop to be steam cleaned or hot tanked. Any bearings left In the block Isuch as the camshaft bearings) will be damaged by the cleaning process. so plan on having new ones installed whila the block " al the machine shop. e After the block is returnad, clean all oil holes and oil galleries one more time (brushes for cleaning oil holes and galleries are available at most auto parts stores). Flush the passages with warm water until the water runs clear, dry the block thoroughly and wlpa all machined surfaces with a light, rust -preventative oil. If you have access to compressed air, use it to speed the drying process and to blowout all the 011 holes and galleries. 7 If the block i, not edremely dirty or sludged up. you can do an edequate cleaning job with warm soapy water and a stiff brush. Take plenty of time and do a thorough job. RegBfdless of the cleaning method used, be very sure to thoroughly clean all oil holes and galleries, dry !he block completely and coat all machined surfaces with light oil. S The threaded holes in the block must be clean to ensure accurate torque readings during reassembly. Aun the proper size tap into each of the holes to remove any rust, cOfrosion, thraad .ealant or sludga and 10 restOle any damaged threads. If possible. u.e compressed ai, 10 clear the hole. of debris produced by this operetion. Now is a good time 10 thoroughly clean the threeds on the head bolts and the main bearing cap bolts as wei!.
2A-7
15.10 Checking the pi.ton ring side cle.rance with. feeler g.uge
9 Reinstall the mein bearing cap. and tightan the bolts finger tight. 10 After coating the sealing surfaces of tha new soft plugs with a good quality galket sealel, Install them in the angine block. Make lure they are driven in straight and saated properly Of leakaga could result. Special tools are available for this purpose. but equally good results can ba obtained using a large socket (with an outside diameter slightly larger than the outside diameter of the soft plug) and a larga hammer. 11 If the engine is not going to be reassembl ed right away, cover it with a large plastic tresh bag to keep it clean .
14
Engine block - In",.etlan
Thoroughly clean tha angine block as described in Section 13 and double-check to make lure that the ridge at the top of each cylinder has been completely removed. 2 Visually check tha block for cracks, rull and COrTosion. Look fOI stripped thread, in the threadeCt holes. It Is also a good idaa to hava the block checked for hidden cracks by an automotive machine shop that has the special equipment to do thl. typa of work. If defects are found. have the block repaired , if possible. or replaced . 3 Check the cylinder bores for scuffing and scoring. 4 Using the appropriate precision measuring tools. maasure each cylinder's diameter at tha top lJust undar the rldoel. centel and bottom of the cylinder bore. panlfefto the crankshaft allil (photosl. Nallt, measure each cylinder's diameter at the sarna locations across the crankshaft allis. Compare the results to the Specifications. If the cylinder walls are bedly scuffed or .cored, or if they ara out-of-round or tapered beyond the limIts given In tha Specifications, have the engine block febored and honed at an automotive machina shop. If a rebore is done. oversize pistons and ring' will be required al well. 5 If the cylinders are in reasonably good condition and not worn to the outside of the limits, and If the piston-to-cylinder clearancas can be maintained properly, then they do not have to be reborad; honing is all that is necessary. 6 Before honing the cylinders, Instatl the main bearing caps {without the bearings! and tighten the bolt. to the specified torque. 7 To perform the honing operation, you will need the proper size flellible hone (with fine stonasl, plenty 01 light oil or honing 011, some rags and an electric drill motor. Mount the hone In the drill motor, compress the stones and Ilip tha hone into the first cylinder (photo!. lLrbricate the cylinder thoroughly, turn on the drill and move tha hone up and down in the cylinder at a pace which wilt produce a fine crOll· hatch pattem on the cylindef" walla (with the crOll-hatch lines intersecting 81 approximately a 60" anglel. Be sure to use planty of lubricant and do not taka off eny more meterial than is absolutely necessary to produce the desired fin ish. Do not withdraw the hone from tha cylinder while it i, running. Instead, Ihut off the drill and continue moving the hone up and down in the cylinder until it comas to a completa stop, then compress tha stone, and withdraw the hone. Wipe tha o~ oot of Ihe cy linder and repeat the procedura on the remaining cylinders. Remember, do not remo .... toO much material from the cylindar Willi. If you do not have the tools or do not desire to perform the honing operation, mosl eutomotlve mechine shops will do It for a reasonable
f,.
2A
2A-8
Chapter 2 Part A General engine overhaul procedures
8 After tha honing job Is complate. chemfer the top edges of the cylinder bores with e smell file so the rings will not catch when the pistons ere instelled. 9 Next, the entire engine block must be thoroughly washed again with werm, soepy water to remove all traces of tha abrasive grit produced during tha honing operation. Be sure to run e brush through ell oil holes and galleries end flush them with running watllr. After rinsing, dry the block and apply a coet of Ught rust preventative oil to all machined surfaces. Wrap the block in a plastic trash bag to keep it clean and set it aside until reassembly.
15
Piston/connecting rod a... mbly - In'pection
Before tha inspactlon proceas can be carried out, the piston /connecting rod assemblies must be cleaned and the original piston rings removed from the pistons. Note: Always usa naw piston (ings when the engine is rellssambl&d. 2 Using a piston ring installation tool, carefully remove the rings from the pistons. Do not nick or gouge the pistons in the process. 3 Scrape all traces 01 carbon from the top (or crown) 01 the piston. A hand-hald wire brush or a piece of fine emery cloth can be used once the majority of the deposits have been scraped away. Do not, under any circumstances, use a wira brush mounted in a drill motor to remove deposits from the pistons. The piston material Is soft and will be eroded awey by the wire brUSh. 4 Use a piston ring groove cleaning tool to remove any carbon deposita from the ring grooves. If e tool is not available, a piece broken off the old ring will do the job. 8e very careful to remove only tha carbon deposits. Do not remove any metal and do not nick or scretch the aides 01 the ring grooves (photo). 5 Once the deposits have been removed, clean the piston/rod assemblies with solvent and dry them thoroughly. Make sure that the oil hole in the big end of the connecting rod and the oil return holes in the back sides of the ring grooves are clear. 6 II the pistons are not damaged or worn excessively, and if the engine block is not rebored, new pistons will not be necessary. Normal piston wear appears as even vertical wear on the piston thrust surfaces and slight looseness of the top ring in its groove. New piston rings, on the other hand, should always be used when an engine is rebuilt. 7 Carelully inspect each piston for cracks around the skin, at the pin bosses and at the ring lands. 8 Look lor scoring and scuffing on the thrust faces 01 the skirt, holes in the piston crown and burned areas at the edge of the crown. If the skin is scored or scuffed, the engine may have baen suffering from overheating and/or abnormal combustion, which caused e)(cesslvely high operating temperaturas. Tha cooling and lubrication systems should be checked thoroughly. A hole in the piston crown, an extreme to be sure, is an indication that abnormal combustion (preignition) was occurring. Burned areas at the edga of the piston crown are usually evidence of spark knock (detonation). If any of the above problems axlst, the causes must be corrected or the damage will occur again. 9 Corrosion of the piston (evidenced by pitting! indicates that coolant is leaking into the combustion chambar and/or the crankcase. Again, the cause must be corrected or the problem may persist in the rebuilt engine. 10 Measure the piston ring side clearence by laying a new piston ring in each ring groove and slipping a feeler gauge in besida it (photo). Cheek the claarance at three or four locations around each groove. Be sura to use the correct ring for each groova; they are different. If the side claarance is greater than specified, naw pistons andlor rings will hava to be used. 11 Check the piston-to-bore clearanca by maasuring the bore (see Section 14) and tha piston diametar (photo). Make sure that tha pistons and bores are correctly matChed. Mea!ura the piston across the skirt, on the thrust faces lat a 900 angle to the piston pin!. directly in line with the centar of the pin hole. Note: On V6 engines, make the meesurement Tl4-inch below the oil ring groove. Subtract the piston diameter from the bore diameter to obtain tha claarance. In the case of an F- or L-head engine, the manufacturer also recommends th e following alternative method of determining piston·to-bore clearance. Obtain a piece of O.OO3-inch thick feeler gauge stock which is 3f4-inch
Wide. Feeler gauge stock comes in 12 ·inch lengthS and is ganerally available at automotive parts stores. Insert the piston into the cylindar bora upside-down with the fealar gauge elCtanding the full length of the piston on the thrust side (opposite the slod. Anach a suitable scala to tha feeler gauga and measure the amount of force necessary to remove it from between the piston and bore. The scale should register between five and ten pounds. If the pull is excess iva, a slightly smaller piston or additional honing of the cylinder bore is necassary. Too linle pull indicates the need for a larger piston. If it is greater than specified, tha block will have to be reborad and new pistons and rings installed. Check th e piston-to-rod clearanca by twisting tha piston and rod in opposite directions. Any noticeable play indicates that there is e)(cessive wear, which must be corrected. The piston/connecting rod assemblies should be taken to an automotive machine shop to have new piston pins installed and tha pistons and connecting rods rebored. 12 If the pistons must be removed from the connecting rods , such as when new platons mUlt be installed, or If the piston pins have too much play in them, they should be taken to an automotive machine shop, While they are there, it would be convenient to have the connecting rods checked for bend and twist, as automotiva machine shops have special equipment for this purpose. Unless new pistons or connecting (ods must be instelfed, do not disassembla the pistons (rom the connecting rods. 13 Check the connecting rods lor cracks and other damage. Tamporarily remove the rod caps, lift oUl the old bearing insarts, wipe tha rod and cap bearing surfaces clean and inspect them for nicks, gouges and scratches. After checking the rods, replace the old bearings, slip the caps into place and tighten the nuts finger tight.
16
Crankshaft - Inspection
Clean the crankshaft with solvant and dry it thoroughly. 8e sure to clean the oil holas with a still brush and flush them with solvent. Check the main and connecting rod bearing journals for uneven wear, scoring, pitting and cracks. Check the remainder of tha crankshaft for cracks and damage. 2 Using an appropriata siza micrometer. measure the diamater of the main end connecting rod journals (photo) end compare the results to the Specifications. 8y measuring the diameter at a number of points around the journal's circumference, you will be able to determine whether or not the journal is worn out-ol-round. Take the measurement at each end 01 the journal, near the crank throw, to determine whether the journal is tapered. 3 If the crankshaft journals ara damaged, tapered, out-of-round or worn beyond the limits given in the Specificatioins, have the crankshaft reground by a reputable automotive machine shop. Be sure to use the correct undersize bearing inserts if the crankshaft is reconditioned. 4 Refer to Section 17 and examine the main and rod baa ring inserts. If the bearing inserts and journals are all in good condition, do not decide to reuse tha bearings until the oil clearancas have been checked.
17
Main end connecting rod beerlngs - Inspection
Evan though the main and connecting rod bearings should be replacad with new ones during the engine overhaul, the old baarlngs should ba ratained for close e)(amination, as they may reveal valuable information about the condition of the engine. 2 Bearing failure occurs mainly because of lack of lubrication, the presence of din or other foreign panic las, overloading the engine and corrosion. Regardless 01 the cause of bearing failure, It must be corrected before the engine is reassembled to prevent it from happening again. 3 When e)(amining the bearings, iemove them from the engine block, the main bearing caps, the connecting rods and the rod caps and lay them out on a clean surfaca in the same general position as their loca· tion in the engine. This will enable you to match any noted bearing problems with tha corresponding crankshaft journal. 4 Din and other foreign particles get into the engine in a variety of ways. If may be left in the engine during assembly, or it may pass through filters or breathers. It may get into the oil, and from there into the bearings. Metal chips from machining operations end normal anglne wear are often present. Abrasives are sometimes left in angina com-
Chapter 2 Part A General engine overhaul procedures
15. 11 Maasura tha piston dlamatar diractly in lina with tha piston pin hola f.ICc.pt on V6 engines}
16.2 Measura the diametar 01 aach crankshalt journal at aaveral pointJ to datact taper and out-ol-round conditions
2A-9
, 8 .3A Usa tha pilton to SQuare up tha ring in the cylinder prior to checking the ring end gap
2A 18.3B Measure the ring end gap with a laaler gauga
1B.9A Installing tha spacar/expander in tha oil control ring groove
ponenls ahar reconditioning, especially when pans ara not thoroughly cleaned using the proper cleaning methods. Whatever tha lOurce. thesa foreign objects oltan and up embadded in the soft bearing material and ara easilv recognizad. Large panicles will not embad in the bearing and will score or gouge the baaring and shaft. The best pravention for this Qusa 01 bearing failura is to clean all parts thoroughly and kaap everything spotlessly clean during engina assembly. Frequent and regular engine oil and lilter changes ara also recommended. 5 Leek 01 lubrication (or lubrication breakdown) has a number of intarralated causes. Excessiva heat (which thins tha oil I, overloading (which squeeles the all from the bearing lacal and 011 leakage or throwoff IIrom axcessive bearing clearances, worn oil pump or high angine .peeds) all contribute to lubrication breakdown. Blocked oil passages. which usually are tha result of misaligned oil holes in a bearing shall, wi. also oil-starva a bearing and destroy it. When leck of lubricetlon it tha cause of beaflng failure, the bearing material is wiped or extrud ed from the stael backing of tha bearing. Temperatures may increasa to the point where the steel backing turns blue from overhaating. 8 Driving habit. can hava a definita affect on bearing lifa. Full-thronle. Iow-spead operation (or 'lugging' the angine) puts very high loads on bearings. which tands to squeeza ou t the oil film . Thase loads causa the bearings to flax. which produces fine cracks in the bearing face (fatigua failura) . Eventually the bearing material will loosen in placas Ind taar away Irom the steel becklng. Short-trip driving laads to corrosion 01 bearings becausa insufficient engine heat Ia produced to drive off tha condensed water and corrosiva gasas. Thesa products collact In tha engina oW, form ing acid and sludga. As tha oil is carried to tha Wlglna bearings. tha acid attacks and corrodes the bearing matarial. 7 Incorrect bearing installation during angina assembly will lead to bearing failura as wall. Tight-filtlng bearings leave in.ufficient bearing 011 claarance and will rasult in all starvation. Din or fOfalgn paniclas trapped behind a bearing Insan result in high spots on tha bearing which lead to failure.
Bafore installing the new piston rings. tha ring and gaps must be
18.9B Do not usa a piston ring tool whan installing the oil ring sida rells
checked. It is assumed that tha piston ring side clearance has been checkad and v&fified correct (Section 15) . 2 Layout the piston/connecting rod assambllas and tha naw ring sets so tha ring sets will be matched with tha same piston and cylinder during tha and gap measurement and angina assambly. 3 Inlert tha top (number onal ring into tha first cylinder and squara it up with the cylinder walla by pushing it In with tha top of the platon {photol. The ring should be near tha bottom of tna cyHndar at the lower limit of ring travel. To measura tha end gap, alip a feeler gauga betwaen the ends of tha ring {photol. Compara the maasurament to the Specifications . 4 II the gap Is larger Of smallar than specifiad, d-ooble-check to make sure that you hava tha correct rings befora proceeding. 5 If the gap ia too amal. It must be anlarged or the ring ands may coma in contect with aach other during angine operation, which can cause serious damaga to tha angina. Tha end gap can be incraased by liling tha ring ands vary carefully with a fine file . Mount the lild In a vise aqulpped with soft JawI, slip tha ring over tha fila with the ands contacting tha fila fece and slowly mova tha ring to remove matarial from tha ends. ~n performing this operation, fiIfI only from the ourside in. 6 Excass and gap is not critical unless It II greatar than O.04O-inch (, mm). Again, double-check to make sura you hava the corract rings for your angina. 7 Repeat tha procedure for aach ring that will ba installad In tha first cylinder and fOf each ring in the remaining cyWndars. Remember to kaap rings, piston. and cylindera matched up. B Once tha ring end gaps hava baan checked/corrected, tha rings can be installed on tha plltons. 9 The oil control ring Howast ona on the piston) Is Instelled first. It Is composad of thraa separata componentl.. Slip the spacer expander Into tha groova (photo), than Inatall tha upper aida rail. Do not usa a piston ring insta/ldtion tool on the oil ring side mils, IS they may be dflr7llJged. lnstaad, place ona and of tha ald. rail into the groova betweaen tha spaca axpandar end tha ring land, hold it firmly in piece and slida a fif198l" around tha piston while polhing the rail into the groova jphotol. Naxt, Instalt thalowar side rait In the lima mannar. 10 After tha thraa oil ring components hava been installed. check to
2A- 10
Chapter 2 Part A General engine overhaul proc edures
,id,
make lur. thlt both the upper and lower rail. can be turned smoothly In Ihe ring groove. 11 The number two (middle) ring 'alnSlalied nllKl. II is s!emped with • m.rk 80 it ceo be readily distinguished from the top ring (the top ring I, merked Top or T). Not.: Do not mix up the top and middhl rings since they htlve different cross sections. On F· and L-head fouf-cylfndllf engin8s, the lOP ring can be distinguished by the bevel on the inside edge, while the middle ring M •• &Iightly tepfmtd ftJce only. On these engines, the T or Top stamped on the rings {odiclt., only how the ring Is to IH instef/ed, not th, groove it is iflSttlfled In. 12 USB III piston ring instaUation tool and make sure that lha Iden· tifiClItion mtlrk I, feeing up, then ,lip the ring Into the middle groove on the piston {photol. 00 not expand the ring env more than Is necessary to slide It over the piston. 13 Finallv, Install the number 008 (topl ring in the same malVl8f. Make sure the identifying mark is facing up. '4 Rapeat the procedure lor the ramaining pistons and ring •. Be carelul not to confuse the number one end number two rings.
19 PI.ton/conneetlng rod . ...mbIV - In.tlilition .nd belrlng 011 clel rl nc. check Balore installing the piston/connecting rod assemblies, the cv~nder walls must be perfectlv cleln, tha top edge 01 aach cvlinder must be chamfered. and the crankshah must be In pleca. 2 Ramove tha connecting rod CIP from the and of me number ona connecting rod. Remova the old bearing InHrts and wipe the bearing lurfaces 01 the connecting rod and cap with a clean. lint-free cloth Ithev must be kept .potles.IV clean). 3 Clean the b8Ck side of tha new upper bearing half, then laV it in
Fig. 2.8
Tv plcal piston ring marX. {alw.V' In.tall the rings w ith t ha marks facing up) (Sec 181
place in the connecting rod. Make .ure that the tab on tha beaflng hts into the recess in the rod . Also. the oil holes in each rod and upper bearing insert must lina up. 00 not hammer the beanng In58ft IOta place and be very careful nOI to nick or gouge the bearing face . Do not lubricata the bearing at thiS rime. 4 Clean the back side of tha othar bearing insert and install it in the rod cap. Again. make surelha lab on Ihe bearing fits into the recess in the cap, and do not applv any lubricant. It IS critically important that the mating surfaces of the bearing and connecting rod are perfectly clean and oil-free when they are assembled. 5 Position the piston ring gaps as shown in the accompanying illustrations. then slip a seclion of plastic or rubber hose over the con necting rod cap botts. Nota: On F- end L-head fouf-cylinder englnas only, position the rings so that none o( the gaps are aligned with each otMf Of the r·slot in the piston SK'lt. S Lubricate the piston and flngs with clean eng!ne 011 and attach a piaton ring comprassor to the piston. Leave the skirt protruding about 1/4-inch to guide the piston into the cylinder. The rings must be compressed as far as possible. 7 Rotate the crankshah until the number one connecting rod journal is as lar from the number one cylinder as possible Ibottom dead
NU... UJ Ca-IU'ON ~'NO
1B. 12 Installing the compre..lon ring. Inota tha spacial tool)
19 .10 If resi.t ance is encountered when tapping tM piston/connecting rod .ssembly inlO the block. stop immedilltafy and make sure the rings are fuUy compressed
Fig. 2.9 Piston ring gap poa/tlon. /V8 and V8 englnesl/Sec 19)
19.12 Position the Plastigege strip on tha beering journal, parallel to tha journal a,ds
19.14 The cru.hed P!astigage is compsr ed to the scale printed on the container to obtain the bearing oil clearance
Chapter 2 Part A General engine overhaul procedures
2A-11
center), and apply a uniform coat of enQIf18 011 to the cylinder walls. With the notch or arrow on top 01 the PIston (or the F on the skirt) lacing to the front of the engine, gently place the piston/connecting rod assembly Into the number one cylinder bore and rest the bottom edge of the ring compreSSOf on the engine block. Tap the top edge of the ring compressor to make sure it is contacting the block around its entire Circumference. Note: On 150 cu in four-cylinder and in-line six-cylinder engines, the oil holes in the connectJng rods must face the camshaft. On GM foor-cylinderengines, the projections on the rods must face the front of the engine. On the numbers on the rods and caps must face out and the oil holes must face in. On F- and L-head four-cyfinder engines, the connecting rod identification number must face the camshaft side of the block. On VB engines, the right bank piston/connecting rod assemblies must be installed with the bosses on the rods and caps facing forward. On the /eft bank, the bosses must face fO the rear. In both esses, the connecting rod oil holes win face the camshaft (up). 9 Cleen the number one connecting rod journal on the crankshaft and the Dearing faces in the rod. 10 Care fully tap on the top of the piston wilh the end of a wooden hammer handle (photo! while guiding the end of the connecting rod into place on the c rankshaft journel. Th e piston rings may try to pop out of the ri ng compressor just before entering the cylinder bore, so keep some downward pressure on the flng compressor. Work slowly. and if any reliltance il felt I I the pilton antarl the cylinder. stop immediately . Find out whet il hanging up and 'ill it before proceeding. Do not, for any reason, fotell the piston into the cylinder, as you will break II ring and/or the piston. 1 1 Once the piston/connecting rod assembly ia installed, the connect· ing rod bearing oit clearence mUlt be checked before the rod cap II permanently bolted in place. 12 Cut a piece of tha tha appropriate type Plastigage s~ghtly shorter than the width of the connecting rod bearing and lay it in place on the number one connecting rod Journal, parallel with the journal axis (it must not cross the oil ho le In the journal! (photoL 13 Clean the connecting fod cap bearing 'aca, remove tha protective hosas from the connecting rod bolu and gently Install the rod cap in place. Make sure the meting mark on the cap Is on the same side as the mark on the connecting rod. Inllall the nuts and tighten them to the specified torque, working up to It In three steps. Do nor rotat. the crankshaft at any ri~ during this oparation. 14 Remove the rod cap, being vary careful not to disturb the Plastigage. Compare tha width of the crulhed Plastlgage to the scale printed on tha Plast igaga container to obtain the oil clearancelphotol. Compare It to the Specifications to make lure the clearance is correc t . If the eiearanca is not correct, double-check to make sure that you have the correct size bearing Inserts. AIIO, fecheck the crankshaft connecting rod Journal diameter and make sure that no dirt or 011 was bet· ween the bearing inserts and the connecting rod or cap when the clearance was measured. 1 5 Carefully scrape all traces of the Plastigage material off the rod journal and/or bearing face (be very careful not to scratch the bearing - uae your fingernail or a piece of hardwood I. Make sure the bearin9 faces are perfectly clean, then apply a uniform layer of tlean, hlQhQuality moly-based grease or engine euembty tube to both of them. You will hava to push t ha piston Into the tylinder to eKpose the face of the bearing in58n in the connecting rod; ba sure to slip the protec· tlve hoses ovar the rod bolts first. 16 Slide the connecting rod back into place on the journal, remove the protective hoses from tha rod tap bolts, install the rod cap and tighten the nuts to the specified tO fQue. Again, work up to the torque in three steps. 17 Repeet th e entire procedure lor the remaining piston/c onnecting rod assemblies. Keep the ba ck sldel of the bearing inserts and the inside of the connecting rod and cap per'et tly clean when assembling tham. Make sure you have the tOffect piston lor the cylinder and that the notch, arrow Of F on the piston faces to the front 01 the engine when the piston is installed. Remember, use plenty 01 oil to lubricate the piston belore instatting the fing compressor aod tap. Also, when installing the rod caps tor the final time, be lure to lubricate the bear ing taces adequately. Not.: Dn F· lind L-helld four-cyllnder engmes, the connecting rod Clip nuts are locked With stamped nuts. Used stamped nu ts should be discarded and leplaced with new ones. These locking stllmped nuts should be installBd wi th the flet face agamsr the connecting rod nut. Turn ellch locking nut finger tight, then 113 ·turn more with a wrench.
8 TOP COMPRESSION RING
/
BOTTOM COMPRESSION RING
~
~OIL cC-~/ ~g~~AOL
~~LAAIL ___ / , )
vas.
AAIL
SPAC ER
;~
C---'-~ ~
-=-~- -----~
80TTOM OI L CON TR O L RAIL
I MAGINA RY LINE THROUGH CENTER
~OFPIST ON -'~ J SKIR T
(:5
~
------
IMAGINARY LINE PARALLEL TO PIS TON PIOoi RING GAP POSITION MAY V ARY ! 20 0 FROM POSITION I LL UST R ATED
Fig_ 2.10 Piston ring gap positions (150 cu in four-cylinder and in-line six-cylinder engines) (Sec 19)
ENGINE FRONT
" 11."
Flg. 2 . 11
Pilton ring .nd gap posltionl (G M 151 cu in four-cylinder engine.) Is.<: 19) A Oil ring spacer gap 8 Oil ring sida rail gaps C Second compression ring gllp D Top compression ring gap
2A
2A-12
Chapter 2 Part A General engine overhaul procedures
Once the engine toes been prop61'ly inlltalled in the vehicle. doublectoeck the engine oil and coolant levels. 2 With the spark plugll out of the engine end the coil high-tension lead grounded to the engine block, crank the engine over until oM pressure regillers on the gauge (if so equippedl Of until the oil light goes off. 3 Install the spark plugs. hook up the plug wlfes and the coil tolgh tension lead. 4 Make sure the carburetor choke plate Is closed, then start the engine. It may take a few momenta for the gasoline to reach the carburetor. but the engine should start without a great deal of effort. S As soon 81 the engine starts, it should be set at a fasl idle (to ensure proper oil circulatlonl and allowed t o warm up to normal operating tempenlture. While the engine is warming up, make a thorough check for oil and coolent leeks.
6 Shut Ihe engine 011 and recheck the engme oil and coolan t levels. Also, check Ihe ignilioo liming end the engine idle speed Irefer to Chapter 1) and make any necessary adjustments. 7 Dnve the vehicle 10 en area with minimum traffic, accelerate 81 full throttle from 30 to 50 mph, then allow the vehicle to slow to 30
mph with the throttle closed. Repeat the pfOcedure 10 or 12 limes. This w,U load the pislon rings and cause them to seat properly a9ain51 Ihe cylinder walls. Check again for oil and coolant leaks. 8 Drive the vehicle gently fOI Ihe flfst 500 miles Ina sustained hIgh 5peedsl end keep 8 conslant check on the oil level. It is not unusual for an engme to use oil during the break-in period. 9 At approllirnately 500 to 600 miles, change the oil and filte r, re torque Ihe cylinder head boilS and recheck the valve clearances lif applicablel. 10 FQr Ihe n8)11 few hundred miles. drive the vehicle normelly. 00 not pamper it or abuse it. 11 Alter 2000 miles. chenge the oil and filter again and consider the engine fully broken In.
26-1
Chapter 2 Part B 151 cu in four-cylinder engine Content. CarnshClft lind bearings - removal and installation .. Crankshaft pulley hub and front oil seal - remollal and installation ....... . Crankshaft - inspection. Chapter Crankshaft - installation lind main bearing oil clearance check ........... . Crankshaft - removal Cylinder head - reassembly Chapter Cylinder head - disassembly Chapter Cylinder head - cleaning and inspection Chapter Cylinder head - installation Cylinder head - removal . . . . . . . . .. Engine block - cleaning. . . . . . . . . . . . . . . . . . . .. Chapter Engine block - inspection .................. Chapter Engine disassembly - general information Chapter Engine - ins tallation .................. _ _ _ _ _ _ _ _ _ Engine overhaul - general information Chapter Engine rebuilding alternatives Chapter Engine - removal_ Engine removal - methods and precautions Chapter E.haust manifold - removal and installation _ __ _ ___ _ Flywheel and rear main oil seal - removal and installation _ . General information _. . .. _ . . . . . . . . . . . . . . .. .
38 31 2A
40 39 2A 2A 2A
30 29 2A 2A 2A 41 2A 2A 22 2A 28 37 21
Hydraulic lifters - removal, inspection and ..... _ . installation Initial start-up and break-in aher ovemaul .... Chapter Intake manifold - removal and installation Main and connecting rod bearings - inspection Chapter Oil pan - removal and installation ....... _ . Oil pump - disassembly, inspection and reassembly Oil pump driveshaft - removal and installation Oil pump - removal and installation _ .. _ . . . . . . Piston/connecting rod assembly - inl;pection .. _ . Chaptar Piston/connaction rod assembly - installation and bearing oil clearance check Chapter Pistonfconnectlng rod assembly - removal . Chapter Piston rings - installation •...... _ . _ ...... _ . Chapter Pushrod cover - removal and installation ..... _ . _. Repair operations possible with the engine in the vehicle ... _ . _ . . _ . Chapter Rocker arm cover - removal and installation ...... . Rocker arms. push rods and valve springs - removal and installation lengine in vehicle) Timing gear cover - removal and installation Valves - servicing. _ .. . ..... _ . _ .... _ . Chapter
Specifications
General
•
Displacement Bore and stroke CompressIOn ratiO Oil pressure
151cuin 4.0 x 3.0 in 8.24: 1 36 to 41 psi at 2000 rpm
Cvlinder bores Taper limit 1980 1981 through 1 983 Out-of-round limit 1980 1981 through 1 983
0.0005 in max . 0.002 in max. 0.0005 in max. 0.0015 in max.
Pistons and rings Piston diameter Piston -to-cylinder bore clearance Top Bottom. Piston ring side clearance ........ . Piston ring end gap Top ring 2nd ring Oil ring side rails . Piston pin diameter .. Piston pin-to-piston clearance Standard Service limit Piston pin-to·connecting rod clearance
3 .9968 to 3.992 in 0.0025 to 0.0033 in 0.0017 to 0.0041 0.0030 in Cylinder location and distributor rotation 0.010 to 0.010 to 0.015 to 0.92705
0.022 In 0 .028 In 0 .055 in to 0.92745 in
0.0003 in 0.0005 in Press fit
26 2A
27 2A 34 36 33 35 2A 2A 2A 2A 25 2A
23
24 32 2A
28
26-2
Chapter 2 Part B 151 cu in four-cylinder engine
Crankshaft and connecting rods Main journal
Diameter . . Teper limit Out-ol-found limit . Main bearing oil clearance Standard Service limit ... Connecting rod journal Diameter Taper limit . . Oul-ol·round limit Connecting rod bearing oil clearance
2 .2988,"
0.0005 in mall, 0.0005 in mill!. 0.0005 in 0.0022 In
2.000 in 0.0005 in mex. 0.0005 in max.
0.0005 in
Stand.rd Service limit Connecting rod end play . Crankshaft end play .
0.0026 In 0,017 in 0.0035 to 0.0085 in
Camshaft Bearing Journal diameter . ......•....•....•.••.•... Bearing oil clearance Standard Service limit lobe lift end play
1.869 in 0.0007 in 0.0027 In 0.230 in 0 .0015 to 0.0050 in
Cylinder head and valve train 0 .008 in msx.
Cvlinder head warpage limit
4"
Velve Illal angle . Valve seat width Intake ElChaust Valve 'ece angle . . . . .. . Velve margin minimum width ... Valve stem·to·guide clearance Standard 1982 and 1983 Itxhaus t only All others .. . . . .. . Service limit Valve spring pressure (lbs et specified lengthl Closed Open Velve lash adjustment Ufter leakdown rate .. Lifter diemater Lifter bore diameter . Lifter-to·bora clearance . Pushrod length . . ........ .
0,0353 to 0.0747 in 0.058 to 0.097 in
45' 1/32 in
0.020 in 0.010 in 0.0027 in 78 to 86 at 1.66 in 172 to 180 at 1.254 in Zero 12 to 90 seconds w ith a 50·lb load 0.8 120 to 0.84 27 in 0.8435 to 0.8 445 in 0.0025 in 8.927 in
Torque specifications
Ft·lb
Nm
Adapter· lo·intake menifold Camshaft thrust plate·to·block lcrews Carburetor· to·manlfold nuts Connecting rod nuts Crankshaft pulley hub bolt Cylinder head bolts Dislflbutor clamp bolt . Distributor clamp pivot bolt Driveplate-to·crankshaft bolts Drivepleta·to·converter bolts. EGR velve· to·manlfold Exhaust manifold bolts . ... . . Exhaust pipe·to·manifold nuts . . Fen end pulley·lo·we ter pump ..... Flywheel·to·crankshaft bohs . Fuel pump·to·block Intake manifold . . .. . .. . Main bearing cap bolts .. . Oil filter adapter·to-block Oil pan drain plug Oil pan bolts . Oil pump cover bolts Oil pump·to· block boits. Oil pump·to·dr;veshaft plate Oil screen support nut
10 to 16 4 .4 to 9 10 to 16
14 to 20 6 to 12 14 to 20
30
40
157 to 163
217 to 223
..... .. . .......
92
125
.. ...... ..
6 to 12 9 to 15 42 to 48
9 to 15 14 to 21 57 to 63
..... -. ,
.............
...... ..
...... . .. .
........... .. ...
........ ... ....
.. ..... ........ ....
40 6.6 to 11 36 to 42 34 to 40 15 to 21 65t071 12to18 34 to 40
"
9 to 15 47 to 53 49 to 55 21 to 27 90 to 96 17 to 23 47 to 53
65
ee
32 to 38 23 to 28 4 to 7 d to 12 15 to 21 710 13 25 to 31
44 to 50 31 to 37 61011 14 to 20 22 to 28 11 to 17 35 to 41
28· 3
Chapter 2 Part B 151 cu in four-cylinder engine Air injection bracket Pressure plene -la-flywheel boils Cnmkshaft pulley bolt
34 to 40
... . . ..
Pushrod cover boils . Rocker Rocker Rocker Starter
arm cover bolts arm stud arm-la -stud nuts . bolts
. ..... ..
15 to 22 22 to 28 4.4 to 9 4 to 10 57 to 63 17 10 23 141020 19 to 25
Thermostat houSing bolts .
5 9
Timing cover Timing cover-to -block Water oullel housing
... ...
Weier pump
141020 14 to 20
47 to 54 20 to 30 31 to 37 6 to 12 7 to 13 73 to 79 24 to 30 21 to 27 27 to 33 2 to 8 6 to 12 20 to 26
20
10
26
26
Fig. 2.12
CyWnder heed components
exoloded vie w
1 PCV velve 2 Oil fifler cap 3 Intake manifold aN8ching bofts 4 Intake fflenifoJd
5 6 7 8
9 10 " 12
,3
Rocker arm capscrew Rocker arm pivot betl1 ttnd nut Valve spring rereiner 855embly Rocker arm cover Coolant hose flttmg Inteke manifold gasket Cylinder head Cylmderheadboll Velve spring
14 Pvshrod guide 15 Cylinder head plug , 6 Cylinder helJd core plug , 7 Exhaust manifold , 8 Exhaust mlJnifold bolt , 9 Dipstick tube attaching screw 20 Exhaust manifold hea r shield
21 Exhaust manifold-tO<-(Jxhaust pipe stud
22 VlJ/ves 23 Pvshrod 24 VlJ/ve lifter 25 ExhlJust mlJnifo/d gask.lJt 26 Cylinder head gasht
28-4 21
Chapter 2 Part B 151 cu in
four~ cylinder
engine
Genenli infonnatkm
The 151 cubic-inch four-cylinder engine was manufactured by General Motors Corporation for AMC/Jeep. It was the standard Jeep
CJ engine for 1980 through 1983 model years. The engine features a crossllow cylinder head, hydraulic val .... e lifters and non-adjustable rocker arms. The camshaft is mounted in the engine block and is gear driven by the crankshaft. The oil pump is mounted in the crankcase alld driven by the camshaft. The crankshaft is supported by five main bearings. 22
Engine removal
Note: The fol/owing sequence of opefBtions does not necessarily need to be performed in the order given. It is. rBther; B checklist of B'IIf!rything that must be disconnected Of removed before the engine cen be lifted out 01 the vehicl6. If your vehicle is equipped with 8n automatic transmission, the engine removel procedure will be slightly different from the procedure for IIfJhicles equipped with e manual transmission. It is IIfJry important that aI/linkages, electricel wiring, hoses and cables be removed or disconnected before attempting to lift the engine cleer of the vehicle, so double-check eWJrything thoroughly. 1 Open the hood and tilt it all the way beck to provide clearance. 2 Disconnect the negative cable f rom the battery and the body ground wire Irom the dash panel. 3 Remove the air cleaner assembly. 4 Raise the vehicle and support it securely on jackstands. 5 UnbOlt the exhaust pipe from the manifold end disconnect the oxygen sensor !if so equipped). 6 Remove the startar motor. 7 Disconnect the distributor end oil pressure sending unit wires. 8 On manual transmission-equipped models, disconnect the clutch hydraulic slave cylinder and remove the f lywheel inspection plate. Remove the ballhousing-to-angina bolts. 9 On automatic transmission-equipped models, mark the torque converter-to-driveplata felatilie position, then remove the attaching bolts. Remove the torque conliertar housing-to-engina bolts. 10 Lower the vehicle and support the transmission with a jack. 11 Tag or mark all of the liacuum hoses and disconnect them. 12 Disconnect the bowl vent hose and mixture control solenoid wire from the carburetor Inot all vehicles!. 13 Disconnect the wires from the alternator. 14 Disconnect the throttle cable and the choke and solenoid wires from the carburetor. 15 Disconnect the coolant temperature sending unit wire from the engine. 16 Drain the coolant into a suitable container and remove the lower radiator hose. Remove the heater hoses. 17 Remove the fan shroud, upper radiator hose. radi ator and shrOUd. 18 Disconnect and plug Ihe power sleering hoses. 19 Remove the engine mount nuts. 20 Attach e suitable lifting d9\lice to the engine. Reise the engine and mOlie it carefully forward to disengage it from the trena mission. It mey be necessary to reise end lower the transmission with the jack to separate the engine from the transmission. lift the engine from the engine compartment. 23
BEA D OF RTV A S SHO WN PUS H ROO COV ER
Rocke r arm cove r -
remo val and installation
Note: If tha engine has been removed from the VfJhicle, disregard tha following steps which do not apply. 1 Remove the eir cleener. 2 Remove the PCV valve end hose. 3 If so equipped, remove the PUlSAIR air hose from t he air vallie. 4 Remove the sperk plug wires from the plugs and mounting clips, lebeling each wire as to its proper position. 5 Remove the rocker erm COVflr bolts. 6 Remove the rocker arm cover. To break the gesket seal. it mey be necessery to tap the COlier with your hand or a rubbe r mallet. Do not pry on the cover. 7 Prior to installel lon, clean all dirt. oil and old gesket material from
FIg. 2. 13 Recommended sealant applicatio n for intta llation of the rocker arm and pushrod cOlie rs (Sec 23 and 25) the seating surfaces of the cOlier and cvlinder heed with a degreaser. 8 Place a continuous 3116-inch (5 mm) diameter bead of RTV-type sealent or equilialent around the sealing lip of the cover. Be sure to epply the sealant to the inside of the mounting bolt holes. 9 Place the rocker arm cover on the cylinder head while the sealent is still wet, install the mounting bolt~ and tighten them to the specified torque. 10 Complete the installation bV reversing the remOlial procedure.
24 Rocker arms, pu sh rods and val ve springs - removal and inttallation (engine in vehicle) Note: Valve mechanism components must be reinstalled in their original positions. Place elf removed components in a compartmented box to aid in identification. 1 Remove the rocker erm COlier as described in Section 23. 2 If only the push; od is to be replaced, loosen the rocker nut enough so the rocker arm can be rotated away !rom the pushrod. If the rocker arm or valve spring is to be replaced, remove the rocker arm nut and ball and lift off the rocker arm. 3 Pull the push rod out 01 the hole. 4 " the valve spring is to be removed, remove the sperk plug from the cylinder being serviced. 5 There are two methods of keeping the valve in place while the lielve spring is remOlied. If you have access to compressed air. attach an eir hose edepter to your air hose and insert it into the spark plug ho le. When air pressure is applied, the vallies will be held in place by the pressure. 6 If you do not halie access to compressed air, bring the piston to top dead center (TDC) on Ihe compression stroke. Feed a long piece of 114-inch nylon cord in through the spark plug hole until it fills the combustion chember. Be sure to leave the end 01 the cord henging out of the spark plug hole so il can be remOlied easilv. 7 Thread the rocker arm nut onto the rocker arm stUd. Position a valve spring compressor tool over the spring and hook it under the rocker arm nut . Using the nut to secure the tool, apply downward pressure to the lialve spring. If ca re is taken. a screwdriver can also be used in th is manner to compress the spring. Compress the spring just enough to allow the remOliel of the keepef5. then let up on the spring. S Remove the vallie spring retainer. cup shield, liallie spring and valve stem oil seal. The valve stem oil seel must be repleced with a new one whenever the keepers have been disturbed. 9 Inspection procedures for the various valve components are detailed in Chapter 2A. 10 Installalion is the r9\lerse of the remolial procedure. Prior to installing the rocker arms, coat the bearing surfaces of the arms and rocker arm balls wilh engine assemblV lube or moly-based grease. The valve mechanisms require no speciel lash edjustment.
25
Pu shrod cove r -
removal and inllallation
Remolie the intake manifold as described in Section 27.
26-5
Chapter 2 Part B 151 cu in four-cylinder engine
TAPPET BODY
~
BALLCHECKVALV£ RETjAIN.ER BAll CHECK
~
/ PLUNGER RETURN SPRING
VALVE
~~ o~ /
'WNGE R
/
BAll CHECK VALVE SPRING (HIGHBAll LIFTER ONLY)
PLUNGER '"" /
I te' .~ '"J
ROCKER FEED METERING DOse
FRONT
I
INTAKE MANIFOLD
lOCK RING
Fig. 2 .14
Exploded lIiew of the hyd reullc 1IIIIIIe lifter (Sec 261
2 Remove the pushrod COlIer bolts and hft off the COlIer. If the ga$l{el seal is difficult to break. tep lightly on the COlier with a rubber mellet. Do oot pry on tile COlier, 3 Using a degreaser. thoroughly clean the saaling surfaces on the cover end enginll block 10 remove all oir and old ga5ket material. 4 Prior to installation of the COlier. place a continuous 31'6·inch 15 mm) bead of RTV·type sealant or equillalentto the sealing lipol the pushrod cOlier. 5 With the sealant still wet. place the COlier in po!litlon on the block, install the caller bolts and tighten them to the specified torque. 6 Install the intake manifold and related components.
26
Hydreullc lifters - remollel. inspKllon end In.telletion
A noisy lIelve lifter is easiest to detKt when the engrne is idling. Piece a length 01 hose or tubing near the position of each Intake and axheust lIelve while listening at the other end 01 the tube. Another method i. to remOlle the rocker arm COlIer and. with the engine idling. pIece e finger on each of the lIel... e spring reteiners. one et a time. If e ... ellie lifter is defecti... e. it will be ellident from Ihe shock felt et the r.tainer lIS the ... allie seats. • 2 Proliided Ihal adjustment is correct. the most likely cause ot a noisy ...al ... e lifter is e piece of dirt trapped between the plunger and lifter body. 3 Remo ... e Ihe rocker arm co ... er as deSCribed In Section 23. 4 Remo ... e the Intake manifold as described in Section 27. 5 Remo ... e the pushrod co ... er as described in Section 25. 6 loosen the rocker arm nul and rOlate Ihe rocker arm away from the push rod . 7 Remo ... e the pushrod. 8 To remove the hfters. a special hydraulic hfter remOllal tool can be used. or a sharp scribe can be positioned at the top of Ihe lifter end used to force the lifter up.. Do not use pliers 01 other tools on the outside of the lifter body. es they will demage th. machined surfece and render the Iliter useless. 9 The lifters should be kept seperate for reinstallation in their original positions. 10 To dismantle a ... allie lifter. hold the plunger down with a push rOd and then elltract the pushrod seat retainer uaing a small screwdriver. 11 Remo ... e the pUSh rod seat and the metering ... alve. 12 Remo .... the plunger. ball check ... el ... e and plunger spring . Remove the ball check lIal .... and spring by prying with a small screwdriver. 13 Examine all components for w.er. Check the bell for flat spots. If any are noted. r.plac. the complete lifter assembly. 14 Examine each lifter lor scoring. wear and erosion of the camsheft lobe mating surface. Any imperfections on the liher body surfec. is cause for r.placement. Wear in the lift., bar. in the block is rare. 15 Rea8lembly should b. performed in the following manner: a) Plac. the check ball on the small hole in the bottom of the plunger.
Fig. 2 . 15
Recomm.nded tlght.ning lequencI for the Intlk. menlfold mountiog boltl IS.c 27)
bl Insert the ch.ck ball spring in the s.at in the ball r.taln.r al"ld place the retainer over the ball so that the spring rests on the ball. Using a small screwdri....r. care fullv press the retainer rn · to position in the plunger. el Plec. the plunger spring over the ball r.tainer. in...ert Ih. lifter body and slida it ov.r Ihe spring and plunger. Make sure the oil holes in tha body end plunger line up. d) Fill the assembly with SAE lOW oil. Place the m.tering ... al ... a and push rod seat into po.ition. press down on the seat and install the pushrod seat r.tain.r. 16 When Installing Ihe lifters. make sur. they are replac.d In their original bor•• and coat th.m with engine assembly lube or clean engine oil. 17 Complete the installation by reversing the steps in the remo ... al procedure.
27
Intaka manifold -
r.mo ....l and In.talletlon
R.move the eir cleaner. baing sur. to leb.1 the lines and hos•• as to their proper locations, 2 Remo ... e the PCV hose. 3 OisconneCI the negati.... batt.ry cable. 4 Drain the cooling Syst.m as described In Chapter 1. 5 Remo ... e the carburetor as described In Chapter 4. 6 Remove the carburetor bas. gasket. 7 Dlsconn.ct the ... acuum lines from the carburetor spac.r. 8 Remo ... e the EGR lIalve. 9 Remo ... e the carburetor spac.r. 10 Remove the carburetor spac.r gasket. 11 Remove the throttle linkag. al"ld aet it to one SIde for clearance. 12 Remove the heater hose from the inteke manifold. 13 Remo ... e the upper alternator brack.t. 14 If .quipped. remove tile PULSAIR eir lIalli. brack.t. 15 Remo .... the bolts thet secure the Intak. manifold to the cy linder head and lift off tha intake manifold. 16 Remo ... e the menifold gask.t. 17 If the intake manifold Is to be r.placed with eooth.r. transl.r any remaining components stiU ettached 10 the old manifold to the n.w 01"18. 18 Before in.tahiog the manifold. clean the cy~nder head aod manIfold gesk.t surfaces. All old gasket material end s.aling compound mUSt be remo ...ed prior to installetion. 19 Apply a thin b.ad of RTV·type sealant to the Intaka manifold and cyijnOer head mating stKfacea. Be certain that the sealant wil not spraad into the air or coolant passage. when the manifold is insllned. 20 Plac. a n.w intake manifold gasket on the manifold. place the menifold in position againat the cylind.r heed and install the mountIng bolts finger tight. 21 Tighten the manifOld mounting bolts to the specified torque in the seqlHlOC. shown in the accompanying Illustration. Work up to the torque
28
28-6
Chapter 2 Part B 151 cu in four-cylinder engine
in three or four stepl. 22 Install the remaining components in the reverse order of removal. 23 Fill the radiator with coolant, steft the engine end check for leaks. Check the carburetor idle speed and adjust if necessary. 8S deacribed in Chapter 1.
28
btl.ust manHold - removal and In l1alladon
If the vehk:1e I, equipped with air conditIOning. carefully 8)lamine the routing of the hose. end the mounting of the compressor. 'lUu may be able to remove the exhaust msnilold without disconnecting the air conditioning system. If you are in doubt. take the vehicle to 8 deal.r or other qualified automotive repair shop to have the system depressurized. Caution: Do not, und~ any circumstances., disconnect any lines white the system is under pressure. 2 Remove Ihe air cleaner. 3 Remove the carburetor pre· heat tube. 4 Remove the englna all dipstick tube. 5 Remove the exhaul! senIOr loceted on the exhaust manifOld. S Remove Ihe compressor mounting bracket. 7 Label the four spark plug wires as to their positions. Disconnect them and move them to the side for clearence. 8 Disconnect the exhaust pipe from the exhaust manifold. The eK' haust pipe can be hung from a piece at wire attached to the frame. 9 Remove the exhausl manifold end bolts lirst, then remove the center bolts and the exhaust manifold. 10 Remove tha 8Khaust manifold gasket. 11 Before installing tha manifold, clean tha mating surfaces on the cylinder head and manifold. All old gasket material should ba removed. 12 Place a new exhau.t manifold gasket Into position on the cylinder head, then place the manifold into position and install the mount· Ing bolts lin~r tight. 13 Ttghten the manifold mounting bolts to the specified torque in the sequence Ihown in the accompanying illustration. Work up to the final torque in three 0' four steps. 14 Install the remaining components In the reverse order of removal, using new gaskets wherever one has been removed. 15 Start the engine and check for exhaust leak. between the manifold and cylinder head and between the manifold and exhaust pipe.
29
CyHnde. head -
removal
Note: If the engine has been removed lrom the vt1hic/e. disrBf/lJrd the lol/owing steps which do not epply. 1 Remove the intake manllold lIS described In Section 27. 2 Remove the exhaust manifold as described in Section 2B. 3 Remove the bolts that 88Cure the alternator bracket to the cylinder head. 4 Oisconnect the air conditioning compreaaor and swing II out 01 the way lor clearance. Do not discolIIIKt any of the lines unleU th. system n.s been dlJpreuurized.
29. 10 Removing the rocker arms from the pivots
29. 12
EX HAUST
MANIFOLD GA SKET
RIVET
Fig. 2 .1 6
bh.....t mani fold in.tallation and boll l ightening sequence (Sec 281
5 Disconnect all electrical ana vacuum lines from the cvlinder head. 6 Remove Ihe upper radiator hose. 7 Disconnect the spark plug wires and remove the spark plugs. Be sure 10 label the plug wires as to their correct locations. 8 Remove tha rocker arm cover. To break the gasket seal, ,t may be necessary to strike the cover with your hand or a rubber mallet. 00 not pry on the sealing surfaces. 9 In disassembling the valve train components. It is important that once removed, all of the components be kept separate 10 they cen be installed in thei r orip lnal positions. A cardboard box or rack numbered according to engine cylinders, can be used for this. 10 Remova each of the rocker arm nuts or bolts {photol. 11 Lift the rOCker arms 011. 12 Remove Ihe pushrods {photol. 13 Remove the thermostat hOUSing from the cylinder head. 14 Remove all Vlcuum valves and SWitches from the cylinder head. 15 Ramove the engine lihing brackets. 16 Remove Ihe air conditioning complassol mounting bracket. 17 LDosen each of the cylinder head mounting bolts one turn It a time unt il they cln be removed. Note the length and position of each batt to aid in reinstallation. 18 lift tha head frae of the engine. If the head is stuck to the engine block, do not attampl to pry it free, as Ihis may damage the sealing surfaces. Instead, use I hammel and a block of wood to dislodge the head. 19 Remove the cylindar head gasket
Removing the pushrods
30.5 The cylinder head mounting bolts should be coated with seallnt (Irrowsl prior to Installation
Chapter 2 Part B 151 cu in four-cylinder engine
10
6
2
3
7
31
2B-7
Cranklhaft puler hub and front 011 Mal - removal and Installation
Note: If the engine hes been removed from the vehicle. disregard th e fo/fowing steps which do not tlPply.
Fig. 2.17
30
Recommended tightening sequence for tha cylinder haad bolts (Sec 30)
Cylinder haad - Installation
If not already done, thoroughly clean the gasket surfaces on both the cylinder head and the angina block. 00 not scratch or otharwisa damaga the sei:lling i:lraas. 2 To get tha proper torque readings, tha threads of tha haad bolts must be eiean. This also holds trua for the thrai:ldad holes in the engine block. Run a tap through these holes to ensura that they are clean. 3 Place tha gi:lsket in pli:lce over the engine block dowel pins. 4 Carefully lowar Ihe cylinder head onto the engine. over tha dowel pins i:lnd tha gaskets. Be careful not to move tha gi:lsket while doing this. S Coat both the threads ot the cylinder head aUi:lching bolts and the point at which the head and stem meal with a sealing compound and install each tinger tight. 00 not tighten any at the bolts at this time (photol. ~ 6 TIghten each of the bolts i:I little at i:I time in the sequence shown in Ihe i:lccompanying illustration. Continue tightening in this sequence until tha proper torque feading is obtained. As a tinal check. work around the head in a logical front-to·rear sequence to make sura none of the bolts have been overlooked. 7 Install the exhaust manifold as described in Section 28. 8 Install each 01 the valve lifters lif removed) in its proper bore. 9 Pli:lcll i:I smi:lll amount of engine assembly lube on each end of tha push rods and install each in its original position. Make sure the push rods are seated properly in the lifter cavities. 10 Place each of the rocker arms and corrllsponding rocker balls on' to its original stud or bolt. The rocker balls and valve stem ends of the rockllr i:lrms should rllceive i:I small amount of engine assembly lube. 11 Tighten Iha rocker arm nutsl~olts to the spacified torque. 12 Install the rocker arm cover. 13 Install the intake manifold as described in Section 27. 14 Install the remaining engine components in the revarsa order of removal . 15 Fill the radiator with coolant, start the Ilngine and check for leaks. Adjust the ignition timing as required. Be sure to recheck the coolant lavlli once the engine has warmed up to opera ting temperature and cooled back down again.
31.4 Marking the position 01 the crankshaft pulley in relation to the hub
1 Remove the engine drive bOlts. Refer to the appropriate Chapters for each accessory. 2 Remove the radiator to provide working clearance. 3 With the parking brake applied and the shifter in Park (automatic) or in gear (m anuall to prevent the engine from turning over, remove the cri:lnk pulley bolt. There is considerable torque on this bolt and a breaker bar will probably be necessary. 4 Mark the position of the pulley in relation to the hub (photo). Remove the bolts thet secure the crank pulley to the hub and lift off the pulley. S Using a hub puller, remove the hub from the crank~haft (photo). 6 Carefully pry out the oil seal from the front cove r with a large screwdriver. Be sure not to distort the cover. 7 Install the new seal with the helical lip toward the rear of the engine. Drive the seal into place using a special front oil seal instelling tool or an appropriate-size socket. S Apply a light coat of oil to the inside lip of the seal. 9 Position the pulley hub on the cra nksheft and. using a slight twisting motion. slide it through the seal un til It bottoms against the crankshaft gear. The crank pulley hub bolt can also be used to press the hub into position (pho to ). 10 Install the crank pulley onto the hub, aligning the merks made duro ing remova l. 11 Install the crenk pulley hub bolt and tighten it to the specified torque. 12 Comple te the installation by reversing the removal steps. TIghten the drive belts to their proper tension.
2B 32
Timing gear cover -
removal and Installation
Note: If the engine has been removed from the vehicle, disregard the following steps which do nor apply, 1 Remove the crank pulley hub as described in Section 31. 2 Remove the lower alternator bracket. 3 Remove the nuts that secure the front engine moUn! to the cradli3. 4 Remove the fan shroud end, if equipped, the eir conditioner compressor bracket. S Loosen the drivebelts. 6 Remove the bolts that secure the timing gear cover to the engine block and oil pan. 7 Pull the cover forward slightly and. using a sharp knife or other suitable cutting tool, cut the front oil pan seal flush with the cylinder block at both sides of the cove r. 8 Remove the timing gear cover. 9 Remove the timing gear cover gasket. 10 Using a degreeser, clean al( dirt and old gasket material from the sealing surfaces of the timing gear cove r, engine block and oil pan. 11 Replace the front oil seal by carefully prying it out of the timing
31.5 Using a hub puller to remove the hub from the cranks haft
31.9 Pushing the hub onto the crankshaft with the hub bolt
26· 8
Chapter 2 Part B 151 cu in four-cylinder engine
geer cover with 8 large scr8wdrivar. 8e lure nOI to distort the COVII 12 1011111 the new seal with the helical ~p toward the inside of the COVI'. OriVI! Ihe s8al into place using I special front oil Ilal insta lling toOl or an eppropriate-sill socket, Po flIt block of wood wHialso work Iphoto). 13 Prior 10 instelling Ihe cover. in81all a new front oil pan gasket. Cut the ends off of the gasket as shown In the accompanying figure Bnd install It on the cover by pressing the rubber tips Into the holes provided. 14 Apply II thin coat of ATV-IYPII geske! sealant to the timing gear cover gaskel and place It in position on the cover. 15 Apply I bead 01 RTV-Iype sealant to Ihe joint between the oit pan and engine block. 16 Using the crank pulley hub a5 a centering tool, Insert the hub into
FIg.2. 18
Driveplate and ring gaa( automatic transmission/ 2 Oil filter 3 Pvshrod cover and bolts Piston 5 Piston rings Piston pin 7 Connecting rod 8 Connecting rod bolt 9 Dowel pin 10 Dipstick Ilnd tube
•
•
"
33
011 pump drlve. haft - ramoval and in.,all l ' ion
Not.: If the engine hes been removed Irom the vehicle. disregard tha
Engine lower e nd compone nts - exploded view
Camshlllt button
12 Flywheel end ring geer (manual mmsmissionl
13 Dowel pin I. Engine block 15 Pilot and/or converter bushing Rellr mllin oil selll 17 Cr.nkshaft 18 Block core soft ((rHze} plug
"
the front cover seal and place the cover in position on the block with the hub on the crankshaft. 17 In5tall the oil pan-to-cover bolts Ind plrtlally tighten them. 18 Install the bolts Ihal SacUII Ihe cover 10 the block and lighten III of the mounting bolts to the specified torqulI. 19 Remove the hub from the flont cover seal. 20 Complete the installation by reversing the removal procedure.
/9 Timing gear oiler
20 Mllln bearings
21 Mllln bearing caps 22 Connecting rod bearing "P 23 Connecting rod ballring 2. Crankshllft gellr 25 Timing gear cover 2' Timing gear cover oil selll 27 Crankshaft pullev hub
28 Cfankshaft puffey 29 Cranksheft puffer hub bolt
30 Crankshaft puffey bolt
31 Cllmshaft timing g88r 32 C.mshaft thrust plllte 33 3' 35 3.
scrllw Cllmshlllt thrust plate Cllmshaft Cemshaft bearing Oil pump driveshaft (etlliner plll,e, gllsket and bolt
2B-9
Chapter 2 Part B 151 cu in four-cylinder engine
d) Trim the ends off of the front gasket as indicated in the ac· companying illustration to form a good joint with the side gaskets. e) Apply a bead of RTV·t,:,pe sealant at the split lines between the front gasket and the side gaskets. The pan cen now be installed.
fallowing steps which do no/ apply.
1
Remove the air eleanor. 2 Removo the carburetor bowl vent line at the rocker arm cover. 3 Remove the upper alternator bracket. 4 Remove the alternator. 5 Remove the oil pump driveshaft retainer plate bolts. 6 Remove the bushing. . 7 Remove the shaft and gear assemblv. 8 Thoroughlv clean the sealing surfaces on the cvlinder block and retainer platt\. 9 Inspect the gear teeth to see if they lire chipped or broken. Replace the gear if necessary. 10 Inslall the oil pump driveshaft into the block and turn it until it engages with the camshaft drive gear in the oil pump body. 11 Applva 11l6·inch 11.5 mml diameter bead of RTV·!Vpe sealant to the retainer plate so that it completelv seals around the oil pump driveshaft hole in the block Iphoto). Install the retainer plate mount· ing bolts and tighten them secure IV. 12 Complete the installation by reversing the removal procedure.
34
Oil pan - removal and Installation
Due to clearance problems with the chasis crossmember, the ojl pan can onlv be removed with the engine out of the vehicle. 2 Remove the oil pan retaining bolts and lift off the oil pan. It may be necessary to use a rubber mallet to break the seal. 3 Prior to installing the oil pan. clean any dirt or old gasket material from the sealing surfaces of the oil pan and engine block. 4 The oil pan gasket consists of four sepafllte gasket pieces. Each must be carefullv installed in its proper place to form a good junction with tho other pieces it joins with. al Install a rear oil pan gasket in the reaf ma1n bearing cap and applva small quantity of RTV·type sealant in the depressions where the pan gasket engages in the block. bl Install the front oil pan gasket on the timing gear cover, press· ing the lips Into the holes provided in the cover (photo l. cl Install the side gaskets on the oil pan. using grease 10 hold them in place.
5 Place the oil pan into position egainst the block {photol and in· sert the rear and side mounting bolts. Tighten these bolts snugly before installing the front bolts in the timing cover. Tighten all of the bohs to the specified torque.
35
Oil pump - removal and in.tallatlon
1 Remove the oil pan as described in Section 34. 2 Remove the two oil pump flange mounting bolts and the nut from the main bearing cap bolt. 3 Lift off tha oil pump and screen as an assemblV. 4 II the oil pump is to be overhauled. refer to Section 36. 5 To install the pump, align the shaft so it mates with the oil pump drives haft tang.
r "
~
~D
OIL PUMP
~!~ ~c(~COV'R~~ _ '\f ::...~
WIRE HARNESS PROTECTOR
Fig. 2.19 The Iront oil pan gasket must be cut as shown to form a proper seal with the side gasket. (Sec 34)
32. 12 Using a block of wood to install the front oil seal in the timing gear cover
-
PAN ~\ S __
CUT THIS PORTION FROM NEW SEAL
2B
PRESSURE REUEF AND SPRING
OIL PUMP GEARS
OIL
•
OIL PUMP PICKUP TUBE AND STRAINER
0ILA1~~ c:::l
PUMP BODY
GASKET
.~
OILPUMP DRIVESHAFT
Ag. 2.20
33.11 ApplV sealant to the retainer plate prior to installation
• e ,.
- -ro
OIL PAN lTS
OI:PAN - " DRAIN - C OIL PAN REINFORCEMENTS
Oil pump and pan components - exploded view
34.4 During installation the rubber tips on the front oil pan gasket should be pressed into tha holes in the timing gear cover
28-10
34.5
Chapter 2 Part B 151 cu in four-cylinder engine
Lower the oil pan carefully Into
po.ition and do not disturb the gaskets
36.3 Removing Ihe drive gear and shaft and the Idler gear from the oil pump bo
36.46 Withdr8wing the pressure regulator valve Iisembly
36.6 If the gears show signs of weilr or dlmege they should be replaced with new ones
6 Place the oil pump housing Ilange in position and josteD the mounting boh(.1. No ;aaket is needed between the pump flange and the block. 7 Install the oil pump screen bracket over the main be8ring cap bolt
and Inllal1 Ihe nut. a
rtghten the pump mounting boltla, and screen support nut to Ihe
specified torque. 9
36
Inllall the oil pan.
011 pump -
dl .....mbly. Inlpectlon and reassembl y
In moSI cases it will be more praclical and economical 10 replace a laully oil pump wilh a new or ",buill unh. II h Is decided 10 overhaul Ihe oil pump. check on availability 01 inlernal parts before beginning. 2 Remove the pump COV1!f relaining screws and the pump cover. In · du mark the geer teeth to permit reassembly in the same position. 3 Remove the idler gear, drive gear end sheft Irom the body (photol. 4 Remove the pressure regulator valve retaining pin (photol, the regulator valve and Ihe related parts (phoIO), 5 The screen assembly is factory-fiuad 10 Ihe pump body and can· not be separated. 6 Wash all the parts in solvent and dry them thoroughly. Inspect the body for cracQ, wear and damage. InspeCI Ihe gears (photo). 7 Cheek the drive gear for Ioosenell In the pump body and the inside of the pump cover for wear that would permit oil leakage past the ands of the gears Iphoto). If either the gears or body are WQm or damaged, the enti", oil pump assembly must be replaced . 8 In'Peet the pickup screen and pipe nsembly for damage to the scr"", pipe and relief grommet. 9 Inslall the p",ssure regulator valve and related parts. 10 Inslali the drive gear and shah in the pump body, followed by the Idler gaar with the smooth side toward the pump cover opening. lubricate the parts with engine oM. 11 Install Ihe cover and tighten the screws to Ihe 5pecified torque. 12 Turn Ihe driveshaft to ensure thet the pump operata5 fraely.
37
Flywha~
36.4A Removing the pressure regulator valve retaining pin with needle -nose phers
36.7
Inspect the pump cover for wear
and fear main 011 se.1 -
removal and installation
To gain access to the flywheel, either the engine or the transmisSion must be removed from the vehicle. If other engine work is needed, remove Ihe engine as descflbed in Section 22. If no other work necessiteting the removal of the engine needs 10 be done, It would be easier 10 remove the trensm sission as described in Chapter 7. 2 If equipped with e manual transmi ssion, remove the clutch from Ihe flywheel as described in Chapter 8 . 3 The flywheel can be unbolted from the rear flange of Ihe crankshafl. To prevent the flywheel from IOrning, e long screwdriver or similar tool can be run through the flywheel and positioned against the engine block (pho to ). 4 Once the bolts are removed, the flywheel can be lilled off. 5 Remove the flywhee l spacer if so equipped. 6 If the rear main bearing seal mull be replaced, pry it out of tts bore. 7 hamine the flywheel ring gear for any broken or chipped teeth . If Ihls condition exists, the flywheel muSI be replaced with a new one. a On manual transmission ffywhBfJ/s, inspact the clutch friction face for 1C0ring. Light scoring may be corrected using emery cloth, but where Ihere is deep scoring the lIywheel must be repleced with e new one or clutch damage will soon OCCur. 9 On automatic transmission fI'Iwhaafs , examine the converter securing bolt holes for distortion. This condition, too, necessitates the replacement of the flywheel . 10 Before installing the flywheel. clean the mating surfaces of the flywheel and the crankshaft. 11 "the oil seal was removed . apply a light coat of engine oil to Ihe inside lip of the new sea' and instaM i t in ita bore. 12 To install the flywheel , use a new spacer lif equipped I and posi lion it in place against the crenkshaft and insert the mounling bolts, securing them only finger light, It is a good idee to use a Ihread locking agent such as LDctite, or equivalent, on the bolt threads. 13 Again, while preventing the flywheel from lurning. tighten the bolts
Chapter 2 Part B 151 cu in four-cylinder engine
37.3 A long screwdriver can be used to prevent tha flywheel from turning during bolt removal
38.21 Lubrlcata the camshaft lobes and journals prior to Installation of the shaft In the block Ithe dial indicator is usad here to verify that the piston is at TQP Oaad Centar)
38.13 Support the camshaft Insida the block (arrQw) during removal (withdraw the camshaft straight out, teking cere not to gouge the bearing surfaces with the cam lobesl
Camshaft and bearlngl -
38.17 M. .suring the cam bearing jourllli diameter with a micromater
2B 38.22 Tha camshaft and crankshaft gears muSl be positioned with the timing marks (arrQwsl aligned
a little at a time until they ara all at the specified torque. 14 Complete the remainder of the instellation procedure by revers· ing the famoval Slaps. 38
2B-11
removal and Installation
•
Remove the engine as described in Section 22 and mount it on a suitable stend. 2 Remove the rocker arm cover. 3 Loosen the rocker arm nuts/bolts and pivot the rocker arms clear of Ihe pushrods. 4 Remove tha pUlhrods. 5 Remove the pushrod cover 6 Remove the valve lifters as descflbed in Section 26. 7 Remove the distributor. 6 Remove the fuel pump. 9 Remove the oil pump drlveshaft and gear assembly. 10 Remove the front pulley hub as described in Section 31. 11 Remove the timing gear cover as described in Section 32. 12 Remove the two camshaft thrust plate screws by working through the holes in the camshaft gear. 13 While supporting the camshaft with your fingera Inserted through theluel pump hole to PllM!f1t damaging the camshaft bearings. carefully and slowly pull the camshaft straight out Irom the block (photol. 14 If the gear must be removed Irom tha tams haft. it must be pressed off. II you do not heve access to a preas. taka it to your daalar Of an automotlva machine shop. The thrust plata muat be positioned so that the Woodruff key in the shaft does not damage It when the shalt is pressed out. IS E~amine the beaflng surfaces and the surfaces of the cam lobel. The oil pan may have to be removed to thoroughly inspect the bear· ings. Surface scratches. if they are very shallow. can be re' mQved by rubbing with a fine emery ClOth or oilaton e. Any deep scar· Ing will necessitate a new camshaft.
40.5 Installing the main bearings in the block
16 Mount the camshaft on V-blocks and usa a dial gauge tQ measure lobe lift. Reject a camshaft Which does not meet the specified limits. 17 USing a micrometer, measure the journal diameters (photQ). Again, reject a camshaft which does not meet the specified limits. 18 If the camshaft bearings are worn, they must be replaced using the following procedure: 8) Remove the Qil pan 11 it is stili in place. b) Remove the flywheel. CI Driving irQm the inside ou t. remove tha expansion plug from the rear cam bearing. d) Using a camshaft bearing remover set, available from a dealar or auto parts stQre, drive out the frOflt bearing toward the rear. al Drive Qut the fear bearing toward the front. fl USing an axtension on the bearing remover. drive out the centef bearing toward the raar. g) Install the new bearings by reversing the removal procedure. Be lura all of the oil holes are aligned. Note: The (ront bMtring must be driwn in until it is .pproximattlly 118-inch from the front of the cylinder block In ordar to unCOVflr the oil hole to tha timing gear oil nozzltl. hI Aher installing the new bearings. Instell a new camshaft fear ellpenaion plug flush with the rear surlace of the block. il Reinstall the flywheel and Qil pan.
19 If the camshaft gear has been removed from the camshaft. it must be prassed on prior to installation of the camshaft. a) SUPPOft the camshaft in an arbor pre .. by using press plate adaptors behind tha front journal. b) Place the gear spacer ring and the thtVst plate over the end of the shaft. c) Install tha Woodruff key in the shaft keyway. dl Install the camshaft gear and prell It onto the shaft until it bottoms against tha geaf spacer ring. el USe a feeler gauge to check the end clearance of the thrust plate. It should be 0.0015 to 0.0050·lnch. II the Clearance Is
2B-12
Chapter 2 Part B 151 cu in four-cylinder engine
40.10 Place the Plastigage strip (arrow) on the journal, parallel to the journal Ixis
40.14 The oil clea'llnce is obtained by comparing the crushed Plastigage to the scale printed on the container
• less than a.OOl5-inch, the spacer ring should be replaced . If the clearance is more than O.OO50-inch, the thrust plate should be replaced. 20 Prior to Installing the cemshaft, verify that the numbs. one pislon is 8t TOC. Coat 8ach of the lobes and journals liberally with a molybased grease or engine assembly lube. 21 Slide the camshaft into the engine block, again taking extra care nOI to damage the bearings (photo). 22 Position the camshaft and crankshaft gears so that the valve tim ing marks line up (photo). With the shafts in this position, the engine is in the number four (4t cylinder firing position. 23 tnstallthe camshaft thrust plate mounting screws and tighten them to the specified torque.
39 Crankaheft - ramoval 1 Remove the engine from the vahicle liS dascribed in Saction 22. 2 Remove the crankshaft pulley and hub assembly as described in Section 31. 3 Remove the oil plln. 4 Remove the oil pump assembly. 5 Remove the timing gear cove r. 6 Remove the pistons and connecting rods from tha crankshaft as described in Chapter 2A. 7 Remove the flywheal as described in Section 37. 8 Refar to Chap tar 2A for tha remainder of the crankshaft removal procadure.
40
Cranka heft - Install ation and main baaring 011 claa ranca chac k
Nota: H a naw or fflground crankshafr Is being ins raIled, or if rhe original crtJnkshaft hB$ been fflground, maka sure rha correct bearings are used. 1 Crllnkshilit instalilltion is ganerally one of the lirst steps In engine reassembly; it is assumed at this point that the engine block and crankshaft hllV8 been cleaned, inspected and repaired or reconditioned . 2 Position the engine with the bottom fac ing up. 3 Remove the main bearing cap bolts and lift out the ClipS. LilY them out in the proper order to help ensura correct InSl8l1l1lion. 4 I! they are still in placo, ramove the old bearing insert s from the block lind the mllin bearing caps. Wipe the main bearing surfacas of tha block lind CliPS with II clean, lint-free cloth (they must be kept spotlessly clean). 5 Clean the back side o f the new main bearing inserts and lay one
bearing hal! in each main bearing saddle (in the block) (photo) _ Place the o ther bearing half from each bearing set in the corresponding main bearing cap. Make sure the tab on the bearing insert fits into the recass in the block or cap. Also, the oil holes in the block and cap must line up with the oil holes in the bearing insert. Do not hammer the bearing into pface and do not nick or gouge the bearing faces_ No lubrication should be used at this rime. 6 The thrust bearings must be installed in the number five (rea.) cap and saddle. 7 Clean the face ~ of the bearings in the block and the crankshaft main bearing journals with a clean, lint-free cloth _ Check or clean the oit holes in the crankshaft, as any dirt here can only go one way straight through the new bearings. 8 Once you are certain that the crankshaft is clean, carefully lay it in position (lin assistant would be very helpful here) in the main bearings with the counterweights lying sideways. 9 Before the crankshaft can be permanently installed. the main bearing oil clearllnce must be chllcked. 10 Trim seven pieces of the appropriate type of Plastigage slightly shorter than the width of the main bearings lind place one piece on each crankshaft main bell ring journal, pllrallel with the journal IIxis !photol. Do not lay them across any oil holes. 11 Clean the faces of the bllarings in the CliPS lind install the caps in their respective positions (do not mix them up) with the arrows pointing toward the front of the engine. 00 not disturb the Plastigage. 12 Stllrting with the center mllin and working out toward the ends, tighten the main bellring CliP bolts, in three steps, to the spacified torque. Do not rotata the crankshaft at any time during this operation. 13 Ramove the bolts and carfefully lift off the main bearing caps.. Keep them in order. Do not disturb the Plastigage or rotate the crankshaft. I! IIny of the main bearing caps are difficult to remove. tap gantly from side-to-side with a soft-Illced hllmmer to loosen them. 14 Compare the width of the c rushed Plastigllge on each journal to the scale printed on the Plastigllge container to obtllin the main bearing oil clearance (photo). Check the Specifications to make sure it Is correct. 15 If the clearance is not correct, double-check to make sure that you have the right size bearing inserts. Also. reCheck the crllnkshllft main bearing journal diameters and makll sure that no dirt or oil WIIS between the bearing inserts and the main bearing caps or the block when the clearance was measured. 16 Using II piece of hardwood or your fingernail, carefully scrape 1111 traces 01 the Plastigage mllterial off the mllin bearing journilis lind lor the bearing Illces. Do not nick or scrlltch the bearing faces, 17 Carefully lift the crankshaft out of the engine. Clelln the bell ring faces in the block. then apply a thin laver of clean, high-Quality moly-
Ch apter 2 Part B 151 cu in four-cylinder engine based gruse or engine assembly lube to each 01 the bearing laces. Be sure to coat the thrust Dearing laces as well. Make sure the cranklhalt journals are clean, then carefully lay it back in place in the block. Clean the Iscas 01 the Dearings in the caps, then spply a thin leyer 01 clean, high·quality moly·based greese or engine assembly lube to each of the bearing laces and install the caps In their respective posi· tions with the arrows pointing toward the front 01 the engine. Install the bolts Ind tighten the bolts in caps one through four to the specified torque. "erting with the center mlin and working out toward the ends. Work up to the linal torque in three steps. Tighten the bolts in the number five (reer) cap to 10 It-Ib, then use a lead or brass hammer to tap the crenkshaft to the rear, then the IrOn1, to center the thrust bearIng. Tighten the rur cap bolts to the specified torque. 18 Rotate the crankshaft a number of times by hand and check for any obvioul binding. 19 Nelft, check the crankshaft end play. Thil can be done with a feeler gaUge or a dial Indicator set (see Section 12 In Chapter 2A). 20 wbricate the seal lip with moly-based grelse or engine assembly IUDe, then center the seal over the reer end of the crank.shsft with the sesl lip feclng the from of the engine. Using s soit-fsced hammer, cSf8fully drive the 5esllnto the groove in the meln beering cap and block until it i••eated. Mske sure it is driven in aquarely. 21 InSlall the Woodruff key in the front of the crenkshaft, then slip the liming gelr into place. 22 Refer to the Ippropriata Sections Ind inlllil the pistonfconnectII\g rod Issemblies, the camshaft, the oil pump, the oil pan, the flywheel, the timing gear cover and the pulley hub.
41
Engine -
InstaHatian
Lower the engine carefully into the engina co~partment and mate
26 -13
it to the transmission. On rMnUM tr8flsmisslon$, make sure the tranarrns· sion input shah is COmtC1/y installed in the pilot bushing and clutch disc. 2 Connect the hoses to the power IIeering pump. 3 Connect the heater hoses to the heater core. 4 Connect the coolsnt temperature sending unit, oil pressure send Ing unit, choke, solenoid and milo:ture conlrol solanoid wires. 5 Connect the carburetor end evaporative system vacuum hOles. 6 Connect the csrburelor bowl vent hose. 7 Connect Ihe ailemllor wiring harness. 8 Attach the Ihrottle cable to Ihe carburetor and secure it with the bracket. 9 Place the fan shroud In position over Ihe fan and install the radiator and ho.as. Attach the shroud 10 Ihe ,.Idiator and fill the radiator with the .pecified coolant. '0 Reise the vehicle and .• uppon it securely. 11 On automlltic transmissions. align the convener-Io-driveplate marX. made during l"Ii'TIO'II'al, then Install the attaching bolt. end lighten them to the specified forque. Apply thread-locking compound to the bolt threads before inslllllng them. '2 Install the transmission-to-torque converter housing attaching bolt. and tighten them to t he specified torque. '3 On mlInuaJ transmissions, in.leilihe flywheel inspection plate and clutch hydrauliC slave cylinder. '4 Install the angine mount nuts and tighten them securely. 15 Install the staner motor aod bracket. '6 Connect the cable and solenoid wire to the st8ner. '7 Connect the distributor wires. 18 Connecl the elfhaust pipe to the manifold and inst8111he olfygen sensor wire (il so &quipped). 19 Connect the nagative battery cable and body ground wire. 20 Inltall the air cleaner assembly. 21 FiU the engine to the correct level with the recommended oil. 22 Refer to Chapter 2A for lhe Initial stan-up and break-in procedure •.
28
28-14
Chapter 2 Part B 151 cu in four-cylinder engine
Notes
•
2C-l
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines Contents Camshaft and bearings · Inspection and replacement. . . . . . . . . 59 camshaft and timing chain/sprockets - installation ...... 67 Camshaft - removal . . . . • . . . • • . . • . . . . . . . • . • • . • • . . • . • . . . . 51 Crankshaft - removal . . . . .. . ............... ~ . . . .. Chapt8f 2A CranKshaft - inspection . ......................... Chapt8f 2A
Crankshaft - installation and main bearing 011 clearance check .•
64
Cylinder head and rocker gear - Inslallation . . . . . . . . . . . . . . . . . 69 Cylinder head - cleaning and Inspection ............. Chapter 2A Cylinder head - disassembly . . . . . . . . . . . . . . . . . . . . . .. Chapter 2A Cylinder nead - reassembly ..•..•.. Chapter 2A Cylinder head - removal ...•.•.. ..•... .. . 48
Engine - installation . .. .. .. ...
. .. .. . .. ... ...
71
Engine · removal .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Engine block - c1eanli'lQ ' . . . . . . . . . . . . . . . . . . . . . . . . .. Chapter 2A Engirl6 block - inspection ... . . . . . . . . . . . . . . . . . . . . . Chapter 2A Engine disassembly - general Infotmation ........... Chapter 2A Engine mount flexible cushions· replacement. . . . . . . . . . . . . . 44 Engine overtlaul • general Information .............. Chapter 2A engine reblJllding alternatives. . . . . . . . . . . . . . . . . . . . Chapter 2A engine removal - methods and precautions . . . . . . . . . .. Chapter 2A External components - installation ........................ 70 External components - removal ..................... . .... 46 FlywtIeeI and starter nng gear - Inspection and servicing ...... 6t FlywheeVdnvepiate • installation ................ 65 FlywheeVdriveplate - removal ......................... 55
General Information . . . . . . . . . . . . . . . . . . . . . . .......... 42 Initial start-up and break·ln after ovemaul ............ Chapter 2A lubrication system· general in formation ................... 54 Main and connecting rod bearings - inspection ....... Chapter 2A Main and connecting rod bearings - seIec1iofl .............. 63 Oil pan • removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Oil seals - replacement ..... .. ......... . . . . . . . . . . . . . . . . . 62 011 pump and 011 pan - Installation ........................ 66 Oil pump - disassembly, Inspection and reassembly . . . . . . . . . . 60 Oil pump - removal ........ .......................... 53 Oversize and undnze component designation .... .. ....... 43 Piston/connecting rod assembly - installation and bearing oil clearance check ........................... Chapter 2A Piston/connecting rod assembly - inspection ......... Chapter 2A Piston/connecting rod assembly - removal ... Chapter 2A Piston rings - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2A Repair operations possible with the engine In the vehicle Chapter 2A Rocker gear - Inspection and ovemaul .. . . . . . . . . . . . . . . . . . . . 56 Rocker gear - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 TIming chain and sprockets· inspection ........... 58 TIming cover. chain and sprockets· removal. . . . . . . . . . . . . . . . 50 Valve liftet'S· installation . . . . . . . . . . . . . . . . . . . . . . . .. .. 68 Valve lifters - descripllon and removal ..................... 49 Valve lifters· Inspection and ovemaul ..................... 57 Valves - serviCing ....... . Chapter 2A
Specifications
General Displacement Six-cylinder .................. . Four-cylinder ............. . Bore and stroke 150 co In engine ....................................... . 232 co in engine 258 co in engine ............. . ............. . Oil pressure
600 rpm . . . . . ....... _..... ................ . Above 1600 rpm .......• . ..... . ............ , .... .
232
Of
258 cu In
150 cu In 3.876 x 3.188 in 3.750 x 3.50 in 3.750 x 3.895 In 13 psi 37 to 75 psi
2C
2C·2
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
General (continued) Firing order Four-cylinder . ..... . . . Si)(-cyllnder . . .. . .. . . .
' -3-4-2 1-5-3-6-2- 4
FRONT
Four-cylinder engine
(0
Engine block Cylinder bore
Diameter
... . .. . ... .
Taper limit ................ . Out -af-round limit •.•..•..•.....•..........•. . ...•..•.... Deck warpage limit . . .
3.8751 to 3.8775 in a 001 in 0.001 in 0.002 in over 6 in
Pistons and rings Piston-la-bore clearance Starxlard ............................................. . Preferred .... . ..... . ............. . ..... . .......•..• .. .. Piston ring side clearance Compression Standard .....•.••.••.•..•..•• • •. • •• • • . •..•.. • . • • . . . Preferred ........................... . .. . .. . .. . .. . .. . Oil control Standard Preferred Piston ring end gap Compression ............................... . Oil control
q (2)
CD 0)
~
four-cylinder 0.0009 to 0.00 17 in 0.0012 to 0.0013 in
• 0.0017 to 0.0032 in 0.0017 In 0.001 to 00008 In 0.003 in
®®0®®@
0.010 to 0.020 in 0.010 to 0.025 in
Crankshaft Mainjoumal Diameter .................. . ....... .. .... . .. . . Taper limit .•. Out 01 roond limit Main bearing oil clearance Standard . .• . Preferred ...... . ............ . ..... . ...... . . .. . Connecting rod joumal Diameter ..... . .. . Taper limit . . . . Out-ol-round limit . . . . . .. . . . . . Connecting rod bearing oil clearance Standard ........................ . Preferred ..•.....•..•..•.••.. Connecling rod end play Crankshaft end play
2.4996 to 2.5001 In 0.0005 in 0.0005 in 0.00 1 to 0.0025 in 0.002 in 2.0934 to 2.0955 in 0.0005 in 0.0005 in
®®0®®@
Inline six-cyflnder engine (1975·1986)
2.029 to 2.030 2.019 to 2.020 2.009 102.010 1.999 to 2.000 0.001 100.003 0.265 in
In
in in in in
Zero (engine operating)
Cylinder head and valve train Head warpage limit ... . . . •..•.••..•.••.•.... Inlake valve seat angle .. . . .. •.....•.••. • ..•..•.•..• . Exhaust valve seat angle .......• . .... . . ... . Intake valve seat width . . . . . . ... ••.. Valve seal n.moutllmit •..•....•.••..•.•• . • . Valve guide inside diameter . .•.•.. • .••..•.•..•.. . .•..•. . • . .• . Intake valve face angle . . . . Exhaust valve lace angle . . Valve margin width •.•..•. . •.•..• . .. . Valve stem d iameter .•.••.•..•..•. . ...•.. Valve stem-to- guide clearance. Valve spring lree length Utter/tappet type . . .. . . .. . .... . Valve lash adjustment ... . ... .
•
0.001 to 0.003 in 0.0015 to 0.002 in 0.010 to 0.00 19 In 0.0015 to 0.0065 in
Camshaft Bearing joomal diameter Number' ... . .. . Number 2. Number 3 ..... . Number 4 ............... . Beari ng oil clearance •....•..•..•..•.••.•..• . .•....•.•• . •. . Lobe lift . .. . .•.......•...• •. . • .. • ..•.. End play
fnline siK-cylinder engine (1972-1974)
0.002 in over 6 in 44 .5" 44 S 0.040 to 0.060 in 00025 in 0.313 10 0.3 14 in
44' 44' 1/ 32 in minimum 0.311 to 0.312 in 0.001 to 0.003 in 1.82 in Hydraulic Z~O
Cyfinder location and distributor rotation
Chapter 2 Part C 150 cu in four~cylinder and all utter bore diameter ..... . . . . . . . . . . . . . . . . . .. . Ufter diameter . . . . . . . . ........ . Utter-to·bore clearance .... . .......................... . Pushrod diameter .............................. . Pushrod length .. . . . . .......... .
in~line
six-cylinder engines
2C-3
0.9055 to 0.9065 In 0.904 to 0.9045 in 0.001 to 0.0025 in 0.312 to 0.315 In 9.640 to 9.660 in
Oversize and undersize component code letter definition Code letter B All cylinder bores ..................... . ...... . M All crankshaft main beanng Journals P All connecting rod bearing tournals ...... . C All camshaft bearing bores ... . ....... .
0.010 In 0.010 In 0.010 In 0.010 in
oversize undersize undersize oversize
Six-cylinder engine Engine block Cylinder bore Diameter ..... Taper limit 1972 through 1981 1982 and later Out-ol-round limit 19721hrough 1981 ....... . 1982 and later ... Deck warpage limit ....
3.7501 to 3.7533 In 0 .005 In 0 .001 in
0.003 In 0 .001 In 0.006 in max.
Pistons and ring s Piston-to·cylinder bore clearance Standard .. Preferred . . .. . ..... . '; ' Piston ring side clearance 1972throu9h 1980 Compression (standard) ........... .. . . ........... . Compression (preferred) ............. . .....•.....• . 011 control (standard) . . . . ....• . ..•.. . ...... Oil control (prelerred) .........• . . . . ..•..•..•..•..• . 1981 and later Compression (slandard) Compression (preferred) Oil control (standard) Oil control (prelerred) .............................. . Piston nng end gap • Compression (all) ..... Oil control 1972 and 1973 only All others ...... .... . Piston pin diameter Piston pin'lo-piston clearance Standard ............. . .................. . .. . Preferred ....... .................. ............ ....... . .
.... .........
0.0009 to 0.0017 in 0.0012 to 0.0013 In
0.001510 0.003 in 0.0015 in 0.001 100.008 in 0.003 In 0.0017 to 0.0032 in 0.0017 In O.OCl1 10 0.008 in 0.003 in 0.010 to 0.020 In 0.01510 0.055 in 0.010 10 0.025 In 0.9304 100.9309 In 0.0003 10 0.0005 In 0.000510
Crankshaft Main journal Diameter 1972 through 1981 .... 1982 and later Taper limit . .. . ... Out·ol·round limit . . Main bearing 011 clearance 1972 and 1973 . . .. 1974 through 1980 Standard Preferred 1981 and later Standard Preferred Connecllng rod journal Diameter ....... . ........................... . Taper limil . . .. .... .......................• . .•..... . Out-ol·round limit . .. ..........................•..
2.4986 2.4996 0.0005 0.0005
to 2.5001 in to 2.5001 in in In
0.001 to 0.002 In 0.001 to 0.003 in 0.0025 in 0.001 10 0.0025 In 0.002 In 2.0934 to 2.0955 In 0.005 In 0.0005 In
2C
2C-4
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
Crankshaft (continued) Connecting rod bearing oil clearar'ICe 1972 and 1973 ...............••.••..•.••.••. 1974 and 1975 Standard ....•.•..•.••.••... . Preferred .................. . 1976 through 1980 Standard Preferred 1981 and later Standard .................... . Preferred .... .... .. Connecting rod end play 1972 1973 through 1980 .•..•.. 1981 and later •.•..•.••.•..•... .. .••..•.•• . •• . Crankshaft end play •..•.••.•..•..•.••••. .
0.001 to 0.002 in 0.001 to 0.003 in 0.0025 In 0.001 100.0025 in 0.0015 to 0.002 in 0.001 to 0.003 In 0.0015 to 0.002 in 0.008 to 0.010 in 0.005 10 0.014 in 0.010 to 0.019 in 0.0015 to 0.0065 in
Camshaft Bearing journal diameter Number 1 ... . Number 2 .. . Number 3 .. . Number 4 .. . Bearing oil clearance .•• . Lobe lift 1972 through 1974 ............ . ........ . 1975 and 1976 . .... •..•..•.••• • •. • . .•.. • . 1977 through 1979 2321258 with 1 bbl. carn 258 with 2 bbL carb 1980 ..•..•..•..•... 1981 and later .•..•....... End play .. ...•....••.•..• .
2.029 to 2.030 in 2.019 to 2.020 in 2.009 to 2.010 In 1.999 to 2.000 in 0.001 100.003 in 0.254 In 0.232 in 0.232 in 0.248 in 0.248 in 0.253 in Zero (engine operating)
Cylinder head and valve train Head warpage limit .••.• •.. ... ... . ......•..•..•... (ntake valve seat angie .•..• .. . .. . . Exhaust valve seat angle ....•.••....•. Intake valve seat width . .. .....••.••.• .. . . Exhaust valve seal width .....•..•....... Valve seat runout limil . . . ...••....•....... Valve guide Inside diameter ....... .. .... ...•.••.. . Intake valve face angie .... ••.•..•..• . .. .... Exhaust valve face angle ..•. . . ...••.•..•.. Valve margin width .•... . . • . . • . . •• .•.. • ..•..•.. Valve slem diameter . .. ..•..•..•..•. •.. Valve stem-Io-guide clearance ..••.••. • ..•.. •. Valve spring free length 1972 and 1973 •..•... 19741hrough 1976 With rotatOfS ...••.•..•..•.. Without rotalors 1977 258 2 bbl. only ..... ..... . An others 1978 and later . • . . . . . • . . • . . . . . . . •. .•.. • ..•.. • .. • .. •. .• Ufter/lappet type ......... ....•.. • .. • Valve lash adjustment. . . . . . . • ..•..•.. •. .• ..•. . . UfIer bore diameter 1972 and 1973 ..•.•. . 1974 through 1980 ....•.••.••.• 1981 and later ...•.... Ufter diameter 1972 and 1973 19741hrough 1983 ..••...... Ufter·to-bore clearance 1972 and 1973 1974 through 1980 1981 and later
0.006 in max.
30" 44.5 0 0.040 10 0.060 in 0.040 to 0.060 in 0.0025 in 0.3735100.3745 in 29"
44" 1132 in min. 0.3715 to 0.3725 in 0.001 to 0.003 in Not available 2.00 in (approK.) 2.234 in (approx). 1.987 In (approx .) 2.234 in (approx.) 1.99 in (approx.) Hydraulic Zero Not available 0.905 to 0.906 in 0.9055 to 0.9065 in Not available 0.904 to 0.9045 in Not available 0.001 to 0.002 in 0.001 to 0.0025 in
•
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines Pushrod diameter 1972.1973 and 1975 1974 1976 through 1980 1981 and tater ... Pushrod length 1972. 1973 and 1975 1974 1976 1977 through 1980 1981 and later
2C-5
Not available 0.294 to 0.303 In 0.312 to 0.313 In 0.312 to 0.315 in Not available 9.656 to 9.666 9.595 to 9.615 9.64010 9.660 9 .71010 9.730
In in In in
Oil pump Gear-Io,body clearance 1972 through 1980 1981 and later . Gear end clearance 1972 through 1976 and 1981 throu9h 1966 . . . . . . . 1977 through 1980 . • .. .. . •..•. .
0.0005 to 0.0025 in 0.002 to 0.004 in 0.002 to 0.006 in 0.002 to 0.008 In
Oversize and undersize component code letter definition Code B M P
letter All cylinder bores . . . . . . . . . • • . •• • .••... All crankshaft main beanng JOUrnals .. . .•••.. .•...•.•. All connecting rod beanng journals .. . C All cam shaft beanng bores ....... .
Torque specifications (atl models) Camshaft sprocket bolts Carburetor mountmg nuts Connecting rod cap nuts Cylinder head bolts 1972 1973 through 1980 1981 and laler ...... ... .•..•••.••.. Crankshaft pulley-Io-damper bolt ..........•..•..•.•• • , . Exhaust manifold bolls . . . . . . . . . .. ".,. Fan and hub assembly bolts ........ . .. , . " " , •. Dnveplale-to-torque converter bolts •.•••.... Flywheelldriveplate-to-crankshaft bolts. •• • ....•.•••. Intake manifold bolls ..••.••....• MaIO beanng cap bolts . Oil pump cover bolts .. Oil pump mounllng bolls Short Long 011 pan bolts 1/4 x 20 5116 x 18 . Bndged rocker pivot boll Rocker arm shaft bolts VibratIOn damper boll Ig721hrough 1976 1977 and laler Water pump bolls.
.
.......
42
General information
The In·line six·cylinder engines. used from 1972 through 1986. displace 232 or 258 cu In and are equipped With either a one-barrel or two-barrel carburetor. Beginning In 1984 the 150 cu in four-cylinder. manufactured by AMC. replaced the GM 151 cu in fOl.lr·cylinder as the standard engme. The new lour·cylinder IS based on the Six-cylinder engine design and the maJonty 01 the engine operations 81e IdentiCal to the six-cylinder, The engln'es 81e constructed of cast Iron. With a removable cylin· der head. Intake and exhaust manifolds. The crankshaft IS supported In tile block by live (four-cylinder) or seven (six-cylinder) main bearings.
0.010 in oversize 0 ,010 in undersize 0.010 In undersize 0.010 in oversize Ft-Ibs 45 to 55 12to15
33 80 10 85
105 85 20 to 25 20 to 25 15to 25 20 to 25 10010110 20 to 25
80 6 8 to 12 15 to 18 5 t09 10to 13
"
21 50 to 60
eo
10 to 15
The piwn bearing insens for the crankshaft and connecllng rods are removable. The valves are mounted in the cylinder head and are actuated by a camshaft located In the block via puSh rods , rocker arms and hydraulic lifters. Depending on the year of production. the rock8f arms are mounted in either of two ways . On 1972 and 1974 six-cylinder models the rocker arms operate on a common shaft. All oth8f models use a bridged rocker arm pivot, which Is attached to the cytinder head by cap screws. The camshaft Is driven from the crankshaft by a chain. The distnbl.ltor IS dnven by a gear on the camshaft. which In tum dnves the poSItive displacement oil pump. Along with the cylinder head and manifolds. the watOf pump. tim· 109 chain cover and belihOl.lslng can be unbOlted from the block.
2C
2C-6
Chapter 2 Part C 150 cu In four-cylinder and all in-line six-cylinder engines
""'"
FII ...... ( SUPPORT
COD<
~
)
..,
-
~
y
"u",
Flg.2.21 Oversize/undersize component code location (Sec 43)
43
1 Some engines are built with oVEIf'Size Of undersize cylinder bores, crankshaft main bearing journals, coonecting rod journals or camshaft bearing bores. 2 A code designating the presence 01 ovnze Of undersize components Is stamped on the cylinder block all filler boss located between the distributor and the ignition coil. 3 Refer to the Specifications and compare the letter code with the InfOfTnatlon In the chart to determine which components are oversize or undefSlze.
44
Engine mount n.x1ble cushions - replacement
Inspect the engine mount flexible cushiOf'lS periodically to determine if they have become hard, split or separated from the metal backIng. 2 If it is necessary to replace the cushions, it can be accomplished by supporting the weight of the engine or transmission In the area of the cushion.
45
Fig. 2.22 Typical engine m ount and flexible c ushio n component layout (Sec 44j
Oversize and undersize component designation
engine - removal
Note: The following sequence of operations does not necessarily need to be performed in the order given. It Is, rather, a checklist of everything that must be disconnected or removed before the engine can be lifted out of the vehicle. If your vehicle Is equipped with an automatic transmission, the engine removal procedure will be slightly different from the procedure for a vehicle equipped with a manual transmission, It Is V8ty important that a/l linkages, electrical wiring, hoses and cables be removed or disconnected before attempting to lift the engine clear of the vehicle, so double-check everything thoroughly. Caution: If the vehicle is equipped with air conditioning, DO NOT loosen any fittings or remove any components until after the system has been discharged at an automotive air conditioning facility. Always wear eye protection when disconnecting air conditioning system fittings. 1 Open the hood and tilt it all the way back to provide clearance. 2 Disconnect the negative cable from the banery. Drain the engine 011 by referring to Chapter 1, 3 Remove the air cleaner assembly and disconnect the fuel line from the fuel pump. 4 Raise the vehicle and support it S8l.:urely on jackstands. Unbolt the exhaust pipe from the manifold and disconnect the 5 oxygen sensor, i1 so equipped. 6 Ramove the starter motor. 7 Disconnect the distributor and oil pressure sending unit wires. 8 On manual transmission-equipped models, disconnect the clutch and transmissioo linkage, then ramove the flywheellnspeclion plate.
Remove the bellhousing-to-engine bolts. 9 On automatic transmission-equipped models, mark the relative position of the torque converter-to-driveplate, then remove the anachIng bolts. Remove the torque converter housing-to-engine bolts. 10 Lower the vehicle and support the transmission with a jack. 11 Tag or mark all of the vacuum hoses and electrical connectors and disconnect them. 12 Disconnect the bowl vent hose and mixture control solenoid wire from the carburetor ~f equipped). 13 Disconnect the wires from the altemator. 14 Disconnect the thronle linkage and the choke and solenoid wire from the carburetor (If equipped), 15 Disconnect the coolant temperature sending unit wire from the engine. 16 Drain the coolant Into a suitable container and remove the lower radiator hose. Remove the heater hose. 17 Remove the fan shroud, upper radiator hose, engine fan, radiator and shroud. If equipped with an automatic transmission, disconnect the cooler lines trom the radiator before removing the radiator. 18 If so equipped, remove the power steering pump and drivebelt and position the pump out of the way, Do not disconnect the power steering hoses. 19 Remove the engine mount nuts. 20 Attach a suitable lifting device to the engine. Raise the engine and remove the front engine mounts from the engine, then move it carefully forward to disengage it from the transmission. It may be necessary to raise and lower the transmission with the jack to separate the engine from the transmission. Uft the engine from the engine compartment.
46
External co mpol'l8flts - rem oval
With the engine remol/ed from the vehicle and separated from the transmission, the extemal components should be removed before disassembly of the engine begins. 2 From the right-hand side of the engine, remove the following components: a) The fuel pump b) The engine mounting bracket ' c) The oil filter cartridge d) The ignition coil e) The distributor and spark plug wires 3 From the left-hand side of the engine, remove the following components: a) The alternator and mounts b) The engina mounting bracket c) The EGR valve, back pressure sensor and coolant temperature switch (if equipped)
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
2C-7
<'CV VA L VE ~
OIL FILLER CAP
GROMMET
~~
\Iiil
~~
ff!~::::R ARM
-
$ $ ~ R/PUSHROO
~
KEEPE RS _____ ROTATOR/RE T AINER __ --...........:
til ----- --... tJt _
~
./
V AlV ESPRING--::::i i
CV LINDER HEAD STlJ O -_ _
./
•
H
CY LINDER
.O/~~~CORE
G--------- . ." ,. ."
--=:=
I'! .~~;~~~__
INTA K E
~~l~OER
HEAD
SNAf' R INO
2C
M'.N"FOI.O INTAKE MANifOLD HEATER
MANIfOlD
HEAT STOVE
Fig. 2.23 Typeal cylinder head components (lIb :-cylinder shown) d) The solenoid vacuum valve and connections (if 9QWPped) e) The intake manifold and carburetor ~ The exhaust manifold and air cleaner I10t air inteke 4 Unscrew and remove the vibration damper boll. 5 Draw otlthe damper from the front of the crankshaft using a suitable puller, If necessary.
6 On vehicles with a manual transmission, unbolt and remove the clutch assembly from the flywheel as described In Chapter 7. 7 From the front face of the engine. remove the following components: a) The b) The
water pump thermostat housing cover and the thermostat
2C-8
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
1f.~'""----"",,"':C:7 ROC KER
ARM
-----,r~~-
/ PIVOT /.OCKER A>.
CY LINDER
Fig 2.248 Pry on the four-cylinder engine roeker arm cover only at tile marked locations (Sec 47)
:-- -'r-,L- PUSH HOLl~ ROO / Fig. 2.24b Bridged rocker arm component layout (Sec 47)
47
47.3 Separating the bridge-type rocker arm assembly from the eylinder head
Rocker gear - removal
Remove the rocker arm cover bolls and then lift off the cover and gasket. On fou r-cylinder models remove the cover by prying only al the marked locations. 2 On all models except 1972 and 1974, the rocker arms pivot on a bridge assembly and the pushrods are hollow to serve as oil galleries supplying oil to the rocker assemblies. 3 Remove the rocker arm bridge assemblies by unscrewing the two cap bolts. Keep ali components in their original order (Photo). 4 On 1972 and 1974 models. unscrew and remove the rocker shaft mounting bolts and lift the shaft. complete with the rocker arms. Irom the cylinder head. S Remove the pushrods and keep them in their original order (Photo).
48
Cylinder head - removal
II the cylinder head Is being removed with the engine slill In the vehicle. remember to: a) Drain the cooling sys tem and disconnect the hoses. b) Remove the intake and exhaust manifolds. c) Remove the Ignition coli and disconnect the spark pJug wires . 2 Remove the rocker arm cover and rocker gear. 3 Disconnect the wire from the coolant temperature sending unit. 4 Working from the center out. unscrew each of the cylinder head bolts one tum at a time in a d iagonal sequence. Uft off the cylinder head and remove the gasket. S
47.5 Remove the pushrods and mark them so they can be
returned to Uleir original locations
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
Vi , DEFLECTOR MUST FACE THE PUSH ROO SlOE Of
2C-9
LONG BOLT MUST BE USED AT THIS LOCA TI ON
"i t ®D®D®D®D®D® 1
o~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~o -
,
FRONT
-
•
•
DISASSEMBLED VIEW
~ READY fOR INSTALLATION
Fig. 2.25 Rocker shaft-type valve gear component leyout (Sec (7)
49.3 Removing 8 valve lifter
50 Fig. 2.26 Hydraulic valve lifter -
49
ex~oded
view (Sec (9)
Valve lifters - description and removal
The lifters are hydraulic and consist 01 a body, plunger, spring. check valve, metering disc, cap and lock ring. 2 By means 01 charging and leak-down cycles and the contact of the lifters with the lobes 01 the camshaft. zero lash is maintained. 3 The lifters can be Withdrawn (photo) after removing the cylinder head and pushrods as described elsewhere In this Chapter. Note: Removal of the lifters WIll most hkely require a spacial valve lifter ItmOval tool (available at tool and auto parts stores).
Timing cover, chain and sprockets - removal
1 If these components ere being removed with the engine In the vehicle, remember 10: a) Drain the cooling system. b) Remove the radia tor. c) Remove the fan and pulley. d) Remove the vibration damper and pulley. e) On four..c;yllnder models, remove the alternator bracket. 2 Unscrew and remove the cover mounting bolls and Iha bolts which retain the front of the oil pan to the timing cover. 3 Uft the timing cover to disengage the 011 pan-to-cover 58allng strip. Failure to obS8fVe this operation will cause damage to the oil pan gasket, which will then have 10 be replaced after removal of the 011 pan. 4 Withdraw the timing cover, gasket and the 011 slinger.
2C-10
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
BUILD DATE CODE LOCATION
OIL LEVEL GAUGE (DIPSTICK) AND tUBE
.~
8
L-_--RING SET
~~PISTON
tj ~/PIN
PlUG
~
~~~~~~~~f?~ · ,
.
BLOCK
•/
.,
•
~~~~ct~::--«: a~- •
OIL CHANNEL /PLUG
•
CAMSHAFT
~CONN'CTING ROO
f
PIN
~
__
KEYS
~
LI~!\~'_
...,...........CAMSHAFT SPROCKET
ll~WASHER
"i/ C:--~~DOER
l
@..
~
-.;......_ _
,"-
FLYWHEEL AND RING GEAR (WITH MANUAL TRANSMISSION)
<:>Cl"
ISLINGERI
~,
CRAN ....
AF~
--n . . . . . . CONNECTING ~, ROD BEARING
BUSHING OIL WICK (WITH MANUAL TRANSMISSION)
TIMING
I CONNECTING ROD BEARING /
CRANKSHAFT SPROCKET
CAP
PILOT BUSHING IWITH MANUAL TRANSMISSION)
I
~- --J
MAIN BEARING CAP SEAL KIT IREAR) MAIN BEARING CAP (REAR)
Fig. 2.27 Engine block components - exploded view (six-cylinder)
VIBRATION
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines 5 Tum the crankshaft until the liming marlc;s on the camshaft and crankshaft sprockets are aligned. 6 Unscrew and remove the camshaft sprocket retaining bolt and
..
"-
T
Withdraw the camshaft sprocket. crankshaft sprocket and timing chain as an assembly,
51
rotation 01 the crankshaft. wedge a block 01 wood between the crankshaft web and Ihe Inside 01 the engine block. Alternatively. wedge the starter ring gear by Inserting a screwdriver or pry bar at the starter motor opening. 3 Uft the flywheel (or dnveplate) from the crankshaft nange. 4 Unbolt and remove the engine eodptate. Now IS a good lime 10 check the rear engine block core plug for security and evidence of leakage.
Camshaft· removal If the camshaft is being removed With the engine
In
the vehicle,
remember to: Ii} Remove the radiator and air-conditioner condenser.
Remove the eylmder head, pushrods and lifters. Remove the tlmrng chain and sprockets. Remove the drstributor and fuel pump. Remove the radiator gn/le and 'ront bumper. 2 Withdraw Ihe camshaft from Ihe fronl of Ihe engine. laking great care not to damage the camshaft bearings wllh Ihe lobes or eccentrics as !ney pass through. b) c) d) e)
52
2C-11
011 pan - removal
Raise the front of the vehicle and support it securely. Support the engine With a SUitable lifting device and disconnect the froot engine mounts, 3 Disconnect Ihe steering Idler arm and loosen the sway bar link nuts 10 Ihe end of thOlr Ihreads. Remove the sway bar clamp bolts and lower Ihe sway bar. 4 Unbolt the front frame crossmember; pull it down and wedge it into POSition With wood blocks 5 Remove Ihe righI-hand engine mounl bracket from the engine. 6 loosen the lower control arm strut rod bolts. 7 Drain the engine 011 inlo a SUitable container. 8 Remove the slarter motOf. if necessary. IOf clearance. 9 Remove the 011 pan bolls and lower the pan from the engine.
1
56
Rocker gear - Inspectioo and overhaul
On bridged rocker arm models, Ihis is simpty a matter 01 examining the rocker arms and bridged pivot assembUes lor wear and replacing parts as appropriate. 2 On all other models. examine the rocker arm faces for wear. lilt Is slight. It may be removed by gently rubbing on an oilstone. If the wear is deep or if the shaft If grooved or scored , dismantle the complete rocker assembly and replace parts as necessary. 3 Disassembly can be carried out after driving out the roll pin Irom one end of the shaft and removing the spring washer. 4 Reassemble as shown In the accompanying Illustration. Make sure that the rocker shaft oil holes face toward the cylinder head. 5 Take the time to examine the pushrods for wear and distortion and replace any which require it.
2
53
~b'
The hydraulic Irfters are descnbed In Section 49. Visually examine the lifter surfaces for wear or scoring. lithe cam lobe contact lace has worn concave. the lifter must be replaced. The camshaft Will require changing as well. Never use a worn camshaft With new lifters or vice versa. 3 Checking the leak-down time for each lifter IS a job 10f" your dealer who has the necessary testing device. Ally that take more than the specifted time (20 to 110 seconds) must be replaced . 1
2
58
Timing chain and sprockets· Inspectlon
Examine the teeth of the camshaft and c rankshaft sprockets. If they are worn or chipped, replace the sprocket. 2 Wear In the chain can only be satlslactorily checked by comparIng it With a new one but (when Installed on the sprockets) if it can be deflected more than a total 01 tl2-lnch, then it should be replaced or the timing will be upset.
Lubrlcatioo system - general Information
The 011 pump is a gear type. dnven by an extenslOl1 of the distributor dnveshaft. which In tum IS driven by a gear on the camshaft. The pressunzed 011 passes through the lull-flow 011 filter and then through gallenes and passages to ali moving components. Oil holes in the connecting rod bearlOg caps provide splash-type tubncatlOl1 of the camshaft lobes. distributor dflve gear. cylInder walls and piston pins. The hydraulic valve htters receive oil directly from Ihe main 011 gallery.
All oil Pfessure SWitch is mounted on the right-hand side of the block.
55
Valve lifters - Inapectloo and overhaul
Oil pump - removal
With the 011 pan removed . Ihb oil pump can be unbolted from the engine block. 2 Do not attempt to dismantle or alter the position of the oil pickup tube. If Ihe pressure rehef valve has to be dismantled. then the pickup tube Will have to be moved and will necessitate replacing the tube
54
57
Flywheelldriveplste - removal
Unscrew and remove the bolts which secure the flywheel (or drivoplate) to the crankshaft rear Ilange. 2 II difllculty is e~peflenced when loosening the bolts due to the
59
Camshaft and bearings - inspection and reptacem ent
Examill9 the bearing surfaces and the surfaces of the cam lobes. Surface scratches. If shallow. can be removed by rubbing With fine emery cloth or an oilslone. Any deep scoring will necessitate a new camshaft. 2 The camshafts used in engines Without EGR system!' differ from those installed in engines With EGR systems and they ale nol !flterchangeable. 3 The camshaft runs In four plain Insert-type bearings which have larger wes at the front to permit easier Withdrawal 01 the camshaft. Replacement 01 tho bearings is definitely a job for an automotive 4 machine shop. since special equipmoot Is required. 5 Camshaft end play Is automatically maintained al zero (while the engine is running) by the actIon of the helical cut distributor/oil pump drive gear which holds the camshaft sprocket thrust face against Ihe cylinder block.
2C
2C-12
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
VALVE SPRING
BYPASS
VALVE
RETAINER
--+1
fiLTER
/1 / I
BUSHING SPRINO RETAINER
O!tl\)_'~:r-t::-~~~~~---PVMP-!~¥.~~ <~/r / /1
BODY/ , / /
OIl.'RUSUAI! RELlIF SPRING
IDLEA
SHAFT
IDLER
COTTER PIN
OEAR
~
DRIVE GEAR
ASSEMBLY
1
ll(IlJIJ
/ .~~:::,
BODY
COVER-TO-
GASKET
OIL INLETTUBIE ANDICREEN
AIIEMBLY Fig. 2.28 Typical oil pump and fitter component layout (six-cylinder shown) (Sec 60)
60
011 pump - disassembly. inspection and reassembly
1
Remove the oil pump cover and gasket Place a straightedge across the gears and pump body and use a
2
2 Check I he starter ring gear for worn and chipped teeth. If damage is evident, the ring gear must be replaced with a new one (manual transmission models). On automatic transmission models. the drive· plate must be replaced with a new one if the ring gear Is damaged or
worn.
feeler gauge blade 10 meaSIJre the gear end clearance.
3 Alternatively. place a strip 01 Plasligage across the full width 01 each gear, Install the cover and tighten the retaining screws evenly and securely. Remove the cover and measure the Plastigage with the scale on the envelope. 4 Compare the gear end clearance to the Specifications. 5 Check the gear·to·pump body inner wall clearance and compare this measurement to the SpeclflcaUons. 6 If any of the measurements are out of the specified range, replace the oil pump assembly with a new one. 7 To remove the oil Pfessure relief valve, extract the cotter pin and withdraw the valve and spring. installation Is the reverse of removal and a new pick·up tube must be Installed (Photos). 6 Pack the Interior of the pump with petroleum jelly to provide a sell-priming action and use a new gasket when reassembling the pump.
61
Aywheel and starter ring gear· Inspection and servicing
Examine the clutch contact surface 01 the flywheel (manual transmission models) lor scoring, bum marks, deep ridges and cracks. If any of these condilioos exist, or if the surface is highly polished, have the flywheel resurfaced and balanced at an automotive machine shop.
62
Oil seals - replacement
The timing cover seal and the crankshaft rear oil seal should be replaced as pari of the engine overhaul procedure. 2 Use a suitable diameter piece of tubing or a socket and a hammer to carefully drive the old seal out of the timing cover. 3 Apply a light coat of RTV·type sealant to the outer diameter of the new seal. Place the seal In position with Ihe lip facing in and carefully drive It in until it bottoms in the recess. 4 On four-cylinder engines, the rear main bearing oil seal is a onepiece, single-lip rubber-type seal which fits in a groove in the rear of the block. It can be replaced with Ihe engine in the vehicle, after the transmission and flywheel have been removed, as follows: a) Pry the old seal out very carefully with a screwdriver or similar tool. Do not nick or scratch the crankshaft surface. b) Carefully clean the sealing surfaces of the engine block and crankshaft. Inspect the crankshaft for nicks and scratches. c) Coat the inner lip of the new seal with clean engme oil. d) Insert the seal squarely into the bore and tap it evenly into place until the outer surface is flush WIth the engine block. 5 On six-cylinder engines, drive out the old rear main seal with a brass drift and a hammer until II protrudes sufficiently from the engine
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
2C-13
\
Fig. 2.29 Checking the oil pump gear end c learance with a straightedge and feeler gauge (Sec 50)
Fig. 2.30 Checking the oil pump gear end clearance with Plastigage (A) (Sec 50)
Fig. 2.31 Checking the 011 pump gear-to00dy clearance with B feeler gauge (Sec 50)
2C
6O.7A Insert the relieve valve and spring
60.78 Insert tile spring retainer
6O.7C Push in on the retainer and install a new cotter pin LIQUID ENGINE OIL ON
'"
" '... ON OUTSIDE
RTV SILICONE ON TOP AND BOTTOM OF BOTH SIDES OF SEAL
RTV SILICONE ON CHAMFERED EDGES
Fig 2.32& The rear oil seal (1) on the 150 cubic inch four-cylinder engine fits tightly into a groove in the block (Sec 62) block to be gripped with pliers and removed. Remove the lower seal from the main bearing cap. Clean the main bearing cap and engine block to remove any 6 traces 01 gasket sealer. 7 Coat the lip 01 the seal with engine oil or grease and the upper contact surface with liquid soap. Insert the seal Into the groove in the engine block with the lip facing forward. 6 Coat both sides 01 the lower seal ends with RTV~type sealant, taking care not to apply it to the seal surface. Coat the lip of the seal with engine oil or grease and the curved outer surface with liquid soap.
"'"
SILICONE ON CHAMFERED EDGES
Fig. 2.32b Six-cylinder engine rear main oil seal details (Sec 62)
Insta ll the low8I" seal In the main bearing cap with the lip lacing 9 forward and seat it securely. 10 When installing the main bearing cap, apply a coat of RTV-type sealant to the chamfered contact surfaces.
2C-1 4
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
64.5 Make sure the tab (arrow) on the bearing Insert fits Into the rec ess In the block
64.6 The thrust bearing must be installed in the number three cap and saddle tile block on si x-cyli nder engine s and number two on four-cyli nder engines
83
Main and connecting rod bearing s - selection The crankshaft and bearing Inspection procedures are included In
Chapter 2A. The condition and measured size of the crankshaft journals will determine the bearings to be installed when the engine is
reassembled. 2 If a new or reground crankshaft Is Installed, the size of each journal should be Indicated by a coIor-coded mark on the adjacent cheal< or counterweight, toward the rear (flanged) end of the crankshaft. The bearing Inserts are also color coded (on the edge of the Insert). The accompanying charts (one for main bearings, one for rod bearings) should be consulted to determine the correct bearings to use. Cauti on: Always check the bearing 011 clearance with Plas tig8ge during
final insta/lation of the crankshaft and/or piston/connecting rod assemblies. 3 If necessary to achieve the desired 011 clearance, different size upper and lower bearing inserts may be used on the same journal but the size difference must never exceed 0.OO1-inch. Caution: The odd size Inserts must a/l be eitner In the caps or block (main bearings). In the case of connecting rod bearings, the odd size Inserts must all be
either In the caps or rods. 4 If the original crankshaft Is reground, the automotive machine shop that reconditions the Journals should supply bearings that will produce the desired oil clearance.
64
Crankshaft - In stallation and main bearing 011 clearanc e
,heck Crankshaft installation is generally one of the first steps in engine reassembly: It Is assumed at this point that the engine block and crankshaft have been cleaned and inspected and repaired or reconditioned. Position the engine with the bottom facing up. 2 3 Remove the main bearing cap bolts and lift out the. caps. Lay them out in the proper order to help ensure that they are Installed correctly. If they are still In place, remove the old bearing inserts from the 4 block and the main bearing caps. Wipe the main bearing surfaces of the block and caps with a clean , lint-free cloth (they must be kept spotlessly clean). Clean the back sides of the new main bearing inserts and lay one 5 bearing half in each main bearing saddle in the block. Lay the other bearing half from each bearing set In the corresponding main bearing
cap. Make sure the tab on the bearing insert fits into the recess in the block or cap (photo). Also, the oil holes in the block and cap must line up with the 011 holes in the bearing insert. 00 not hammer the bearing Into place and do not nick or gouge the bearing faces. No lubrication should be used at this time. The flanged thrust bearing must be installed in the number two (2) 6 cap and saddle on four-cylinder engines and the number three (3) cap and saddle on six-cylinder engines (photo). Cl ean the faces of the bearings in the block and the crankshaft 7 main bearing journals with a clean, lint-free cloth. Check or clean the 0(1 holes In the crankshaft, as any dirt here can only go one way straight through the new bearings. Install the rear seal (Section 62). 8 Once you are~certain that the crankshaft Is clean. carefully lay It In position (an assistant would be very helpful here) in the main bearings with the coonterwelghts lying sideways. 9 Before the crankshaft can be permanently installed, the main bearing oil clearance must be checked. 10 Trim several pieces of the appropriate type of Plastigage (so they are slightly shorter than the width 01 the main bearings) and place one piece on each crankshaft main bearing Joumal, parallel with the journal axis. 00 not lay them across any 011 holes. 11 Clean the faces of the bearings In the caps and install the caps In Iheir respective positions (do not mix them up) with the arrows pointing toward the front of the engine. Do nol disturb the Plastigage. 12 Starting with the cen ter main and wor\(ing out toward the ends, tight en the main bearing cap bolts, in three steps, to the specified torque. Do not rotate the crankshaft at any time during this operation. 13 Remove the boils and carefully lift off the main bearing caps. Keep them in O!'der. 00 not disturb the Plastigage 01' rolate the crankshaft. If any of the main bearing caps are difficult to remove, tap gently from side-to-side with a soft-faced hammer to loosen them. 14 Compare the width of the crushed Plastigage on each joumal to the scale printed on the Plastigage container to obtain the main bearIng 011 clearance. Check the Specifications to make sure it is correct. 15 If the clearance is not correct, double-check to make sure you have the right size bearing Inserts. Also, recheck the crankshaft main bearing journal diameters and make sure that no dirt or oil was between the bearing Inserts and the main bearing caps or the block when the clearance was measured. 16 Carefully scrape all traces of the Plastigage material off the maln bearing joumals andlor the bearing faces. 00 not nick or scratch the bearing faces. 17 Carefully lift the crankshaft out of the engine. Clean the bearing faces in the block, then apply a thin, uniform layer of clean , high-quality moly-baSed grease (O!' engine assembly lube) to each of the bearing faces. Be sure to coat the thrust flange faces as well as the joomal face of the thrust bearing. Make sure the crankshaft journals are clean, then
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
tr.nklhaft Con_lng Rod JIMImIII CoIor.nd DiIometw In lnet.. IJournilI Size)
lJpp8r I~ Size
V.llow
-2.0955 to 2.0948ISUlnd8rd)
Rod
-2.0948 10 2.0941 10.0007 Unct.rtlft) -2.094' to 2.093410.0014 Unct.rtlze) -2.0865 to 2.0&48 (0.010 Uno:t.rsIH)
"'..... ""',
2C-15
L_'-,$ln
Vellow Vellow
,,,"""" SUlndlrd
'''''' Rod
.0014nd1 UncMnln .ol~lndI Undtnim
,,,-
V.llow
.0014nch Undtrtlz. .oo,-indl Und8rtiu .o,O-lndl Und8ntu
""'" BlK' RK
Fig. 2.338 Connecting rod bearing selection chart (Sec 83)
Belrlng Color COdi
CrlnluMft MIIi" Buri"g Journal Colo, Code.nd O"met.. i" Inchft (Jou rnal $Iu) VeUow O"nge Bilek G,"" Red
-
Upper I....., $I.,
2.5001102 .4996 (SIInct.rdl 2 .49961024991 (0 .0005 Unde...,u) 24991 102 .4986 (O.OCl1 Under"u) 2 4986 to 2.4981 (0.OCI15 Undfi.,z,1 2 .4901 1024896 10 .010 UncI ..... u )
VeUow V'lIow BllICk BllICk Rod
L_I.-1$1u
- SII" OI,d - S..nde.d .OOHnch Undersize -- .oo' .. nd! U",*,ill - .o,C).jnch Undenizi
Vellow BlICk BllICk
G,_ Rod
-
--
SUinOl.d
.oo, .. nch Unde..," .OO1 .. nd! U...o. •• iu .OO2.jnch Unde.m, .010 .. nch U...o. ..,ze
Fig. 2..33b Main bearing selection chart (Sec 63)
2C
66.1 Be sure to use a new gasket when )nstalllng the 011 pump
lay it back in place in the block. Clean the faces of the bearings in the caps, then apply a thin, uniform layer of clean, moly-based grease to each 01 the bearing faces and install the caps In their respectjve positions With the arrows pointing toward the front of the 9flgine. Install the bolts and tight9fl them to the specified torque, starting with the center main and working out toward the ends. Work up to the final torque in three steps. ,8 Rotate the crankshaft a number 01 limes by hand and check lor any obvious bindIng. 19 The final step is to check the crankshaft end play. This can be done With a feel9l" gauge or a dial indicator set. Rel9l" to Chapter 2A. SectIon '2, for the procedure to follow. 65
AywheeVdriveplate - installation
1 2
Install the engine rear plate 0'191" the locating dowels. Attach the lIywheel (or driveplate) to the crankshaft rear flange
66.2 Installing the 011 pump
and tlght9fl the bolts to the specified torque. Apply a wrench to the vibration damper bolt to prevent the Cf8flkshaft from rotating as tile flywheel bolts are tightened.
66
011 pump and oil pan - Installation
,
Locate a new oil pump gasket on the lower flange of the block
(photo).
2 Install the oil pump/pick-up tube assembly and tighten the mounting bolts (photo). 3 PositIOn a new oil pall gasket on the block and theo bolt on the 011 pan, tightening the bolts to the specified torque. Follow a crisscross pattetn to avoid warping the pan. Make sure the drain plug is tight.
2C-16
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
Fig. 2.34 Before installing the timing chain on four-cylinder engines, tum the tensioner lever (1) to the unlocked position, then pull the tensloner block (2) back and tum the lever to the lock position (Sec 67)
Fig. 2.35 Correct relationship of the cra nkshaft and camshaft sprocket timing marks (Sec 67)
Fig. 2.36a On six-cylinder engines, with the camshaft sprocket tim ing mart( at the 1 o 'clock position, the timing marks must be 15 pins apart (Sec 67)
Fig. 2.36b On four-cylinder engines, with the camshaft sprocket timing mark at the 1 o'clock po sition, the timing marks must be 20 pins apart (Sec 67)
67
Camshaft and timing chain/sprockets - Installation
Lubricate the camshaft and carefully insert the camshaft from the front of the engine. 2 With the engine positioned with the cylinder head surface up. tum Ihe crankshaft so that the keyway is vertical and at the top. Prior to installation. tum the chain tensioner lever 10 the Down (unlocked) position, pull the tensioner block toward the lever to compress the spring and then tum the lever to the Up ~ocked} position as shown. 3 Engage the camshaft and crankshaft sprockets within the timing chain and inslallthem as an assembly so that a line drawn through the sprocket timing marks will also pass through the centers of the sprockets. Obviously the camshaft will have to be rotated and a certain amount of repositloning of the camshaft sprocket within the.loop of the chain Will be required to achieve this. 4 Secure the camshaft sprocket and then check the timing. To do this, set the camshaft sprocket timing Inark to the one o'clock position. There should be 15 chain pins between the sprocket liming marks in six-cylinder engines and 20 chain pins on four-cylinder engines (as shown in the accompanying illustrations). 5 Attach the oil stinger to the front of the crankshaft sprocket (photo). 6 Install a new oil seal in the timing chain cover (Section 62), Ihen
attach the cover to the engine with a new gasket. Tightoo the bolts finger tight at this time (photo). Apply grease to the oil seal contact surfaces of the vibration 7 damper and push it into posiliOn. If necessary, tap the timing cover from side 10 side (or up and down) to center it and enable the damper to be withdrawn and installed easily. 8 Now tighten the liming chain cover bolts securely. Inslall the damper and tighten the mounting bolt to the specified 9 torque. Use a block of wood Inserted between the crankshaft and the engine block to prevent crankshaft rotation . to Locate a new gasket on the front face of the cylinder block (use RTV-type sealant on the gasket). 11 Install the water pump.
68
Valve lifters - Installation
Note: The camshaft must be in place before the lifters are installed. 1 Apply engine assembly lube or moly grease to the lifters, then install them In their original bores. 2 If new lifters are being instaJled, a new camshaft musl also be Installed. If a new camshaft was installed, then use new lifters as well. Never install used lifters unless Ihe original camshaft is used and the lifters can be installed in their original locations.
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
87.5 Remember to install the o il slinger (arrow) before attaching th e tim ing c hain cover to the block
2C-17
67.6 Be careful not to damage the seal when Installing the timing chain covet'"
____ /1>-_ _ _
--- ....... -- ~ --
,,
Q,
, I, "
,,
, , ,
,
, I
----- """If ----
,
, -'
/
Fig. 2.37 Six- cylinder engine head bolt tightening sequence (Sec 69)
69
•
Cylinder head and rocker gear - installation
Note: The valve lifters must be in place before the head is rnstalled. 1 If not already done, thoroughly clean the gasket surfaces on both the cylinder head and the engine block. Do not scratch Of otherwise damage the sealing areas. 2 To gel the proper torque readings, the threads of the head bolts must be clean. This also holds true for the threaded holes In the engine block. Run a lap through these holes to ensure that they are clean. 3 Apply a thin, even coat of AMC Perfect Seal gasket sealer (or equivalent) to both sides of the new head gasket. Caution: Do not apply the gasket sealer to the cylinder head or block and do not allow any sealer to enter the cylinder bores. Place the gasket in position over the engine block dowel pins. Make sure the side marked TOP is facing
"P, 4 Carefully tower the cylinder head onlo the engine. over the dowel pins and the gasket. Be careful not to move the gasket while doing
"" 5 6
Install the head bolts and tighten them finger tight. T1ghten each of the bolts. a little at a time, in the sequence shown f1 the accompanYing illustrations. Conllnue tightening In this sequence untit the proper torque reading is obtained. As a final check, work around the head In a logicat front-to-rear sequence to make sure none of the bolts have been overlooked. 7 Lubricate the pushrod ends with engine assembly lube or moly grease and install them. Make sure they are sealed in the titter cavities. 6 Lubricate the rocker arm contact surfaces. then install the rocker
Fig. 2.38 Four-cylinder engine head bolt tightening sequence (Sec 69)
arms or shaft assembly and lighten the bolts to the specified tOfque. Be sure to lubricate the rock9f" arm pivots with engine assembly lube or moly grease. g Lay a new gasket In place, then install the rocker arm cover.
2C
2C-18
Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines
B
10
"
6
• Fig. 2.39 Six-cylinder engine intake/exhaust manifold bolt tightening sequenee (1982 and earlier models) (Sec 70)
70
External components - installation
Fig. 2.40 Six-cylinder engine intake/exhaust manifold batt tightening sequence (1983 and later models) (Sec 70)
•
1 InslaUthe thermostat (pIn hole up) and COVef using a new gasket. 2 On vehicles with a manual transmission, attach the clutch assembly to the flywheel as described In Chapter 8. 3 Install the Intake and exhaust manifolds.
4
InstaJi the waler pump.
5 Install the EGA valve, the back Pfessure sensor. the coolant tem perature switch and the solenoid vacuum valve and connections (all components of the emissions control system). 6 Install the engine mount brackets.
7 S g 10 11 12 13 the
71
Instalilhe alternator. Attach the air cleaner hot air duct to the exhaust manifold. Install the distributor as described In Chapter 5. Install the Ignition coil. Install the spark plugs and wires. Install the fuel pump. Check that the oil filter cartridge threaded fitting is tight, grease filter sealing ring and screw it on with hand pressure only.
Fig. 2.41 Four-cylinder engine Intake/exhaust manifold bolt tightening sequence (Sec 70)
Engine - installation
Lower the engine carefully into the engine compartment and attach it to the transmission. On manual transmissions, make sure the transmission Input shaft is correctly installed In the pilot bushing and clutch disc. Install the power steering pump, water pump pulley and drivebelt. 2 3 Connect the heater hoses to the heater core. 4 Connect the coolant temperature sending unit. oil pressure sending unit, choke, solenoid and mixture control solenoid wires. 5 Install the carburetor and connect the evaporative system vacuum hoses. 6 Connect the carburetor bowl vent hose. 7 Connect the altemator wiring hamess. 8 Attach the throttle linkage to the carburetor. 9 Place the fan shroud in position over the fan and Install the radiator and hoses. Attach the shroud to the radiator and fill the radiator With the specified coolant. Attach the cooler lines to the radiator (automatic transmission only). 10 Raise the vehicle and support it securely. lIOn automatic transmissions, align the converter-to-driveplate
marks made during removal, then install the attachmg bolts and tighten Ihem to the specified torque. Apply thread-locking compound to the bolt threads before installing them. 12 Inslall the transmlssion-to-torque converter housing attaching bolts and tighten them securely, 13 On manual transmissions, install the flywheel inspection plate and hook up the clutch and transmission linkages. 14 Install the engine mount nuts and tighten them securely. 15 Install the starter motor. 16 Connect the battery cable and solenoid wife to the slarter. 17 Connect the distributor wires. 18 Connect the exhaust pipe to the manifold and install the oxygen sensor wire (i f equipped). 19 Connect the negative battery cable to the battery. 20 Install the air cleaner assembry. 21 Fill the engine to the correct level With the recommended OIl. 22 Refer to Chapter 2A for the Initial start-up and break-in procedures. 23 Have the air conditioning lines hooked up and the system recharged by an air conditioning techniCian.
20-1
va
Chapter 2 Part 0
engine
Contenu
Cemshah - installation ........ . Camshaft - removel ,. Crankshaft - Inspection. Crankshaft - installation and main bearing 011 clearance check . . . . .. . ..... .
.
8~
.. Ch~~t~r
;1
9~ g~~i~~se~a~~~ ~':~::~ing end i~sp~~~i~~ ........... Ch~~t~r ~~
Cylinder head - disassembly.
Cylinder head - installation . Cylinder head - reassembly . Cylinder head - removal Engine block - cleaning . . Engine block - inspection
C . h. '. p.' ." 29~ Chapter .. .. . Chapter Chapter
Engine diuSlIambly - general informallon Engine mounts - replacement Engine Engine Engine Engine Engine
2 7 2 2A
Ch8pler 2A 7
overhaul - general infol1il81ion • . . . . . . . . Chapter rebuilding alternatives . . . •. ....•... Chapter removal - methods and precautions . . . . .. Chapter - disassembly and reassembly sequence.. ...•... - inSUllIl!lIion Engine - removal Generallnformalion Ininal starl'Up and break·in afler oYllrhaul Chapler Intake manifold - inslallalion
2 2 2 7 9 7
7:Z:
2~
Inlake manilold - removal. . . . . . . . . . . . . . . . . . . 7e Main and connecling rod bearings - Inspection ... Chapter 2A Main and connecling rod bearings - selection 96 Oil pan - inslallalion .. . .. .. . .. .. .. . 93 Oil pan - removal .. . . .. .. ......... 77 Oil pump - disassembly, inspeclion and reassembly . . 85 Oil pump - installation . . . . . . . . .. ...... . 87 OH p"mp -
"~.,, .
. . . . . . ..
. ....
84
Oil seal replacemenl . . . . . . . .. Oversize and undersiza component designation Piston/connecting rod assembly - inspection Piston/connecting rod assembly - installation and bearing 011 cle arance check Pistonfconnecting rod asaembly - removal .. Pislon rings - installation .. .. .. .. . .. Aepair operalions possible with the engine in the vehicle .. . . . . . . . . .. ..... TIming chain cover - inSlaliatlon TIming chain cover - removal .... .. Timing chain and sprockets - inSlaliation . TIming chain and sprockets - removal TIming chain wear check . . Valves - servicing . . .
..
73 Chapler 2A Chapter 2A Chapter 2A Chapler 2A Chapler 2A
90
eo
88 82 81 Chapler 2A
92
Specillcations
General Displacement . . .. . . Cylinder numbering IVlewed Irom radiator, Iront· lo·rear) Left blink RighI bank Firing order ComprelllOn pressure Mallimum vallalion between cylinders Oil pressure 600 'pm 1600 rpm and above
Cylinder bore Taper limil Out·ol· round limit Deck warpage limit .
lEn
304 cu in ' · 3·5· 7
I"'H~
CD CD CD CD
2· 4·6 ·8 ' ·8 ·4 ·3 ·6 · 5· 7· 2
ClOClCWI1( It01AT1001
140 psi
' ..... :1-&.6_12
20 PSI
13 PSI 37 PSI mm,mum. 75 psi max
0.005 in 0.003 in 0.008 in
It'OH1'''HIC
CD
(i) (i)
86
CD 'ItOOlTO
Cylinder location and distributor rotation
2D
20-2
Chapter 2 Part 0
va engine
Pistons and rings Plston-Io·cylinder bOle clearanca Standard Pfefeffad Piston ring slda clearance Top ling Standard Pfeferred 2nd ring Standald Prefeffed 011 ring Pfston ling end gap Top and 2nd ring Standard Prelaffed Oil ring PiSlon pln-to-rod clearance. Piston pln·to-bore clearance Standard . Pfelerred
0 .0010 to 0.0018 in 0 .00 14 in
0.00 15 to 0 .0035 In 0.0015 In 0.0015 to 0.003 In 0.0015 in 0.0011 to 0.008 In
0.010100.020 In 0.010 to 0.012 in 0.010 to 0.025 in Pless fit 0.0003 10 0 .0005 in 0.0005 in
Crankshaft and flywheel Main Journal diameter 1.2.3and4 Rear main (5) Main beaflng oil clearance 1.2.3end4 Standard Prefened Rear main 15) Standard Preferred Connecling rod journal Diametel Tapel limit Out·of round limit Connecting lod bearing oil clearance Standard Prelaffed Connecting lod and play .. Crankshaft and play
2.7474 to 2.7489 in 2 .7464 to 2.7479 In
0.001 to 0.003 In 0.0017 to 0.0020 in 0.002100.004 in 0.0025 10 0.003 in 2.0934 to 2.0955 10 0.000510 0.0005 In 0.001 to 0.003 in 0.0020 to 0.0025 ,n 0.006 to 0.0018 in 0.003 to 0.008 11'1
Camshaft Beaflng journal diameter 1
2 3 4 5 Bearing oil clearance Standard Pleferred Lobe lift End play TimlOg chain total allowable deflection
2.1195t02 .1205in 2.0895 to 2.0905 in 2.0595 to 2.0605 in 2.0295 to 2 .0305 in 1.9995 to 2.0005 In 0.001 to 0.003 in 0 .0017 to 0 .0020 0.266 in Zero 7/8 in
III
Cylinder heads and valve train Head warpage limit Valve seat angle Intake Ellhausl Valve seal Width Valve seat IUnoUt limit Valve lace angle Intake Ellhaust Valve stem diameter Velve guide diameter Valve slem-Io-guide clearance Valve margin width Valve lifter type Lifter diameter Lifter bore diameler L1fter-Io-bore clearance. .
0.008 In mu.
30" 44.5° 0.040 to 0.060 In 0.0025 In mu
29' 44' 0.3715 to 0.3725 In 0.3735100.3745 In 0.001 to 0 .003 In 1/ 32 in minimum Hydraulic 0 .9040 to 0.9045 In 0.9055 10 0 .9065 In 0.001 to 0.0025 in
•
va engine
Chapter 2 Part D
20-3
Oil pump Gear end clearance Gear-to·body clearance Oil pressure relief valve opening pressure
0.002 to 0.006 in 0.0005 to 0.0025 in 75 pSI
Oversize and undersize component code letter definition Code letter 8 Cylinder bore M Main bearings . F Connecting rod bearings PM Main and connecting rod beaflngs . C Camshaft bearing bores
0.010 0 .010 0.010 0.010 0.010
Torque specifications Camshaft gear screw Carburetor adapter Carburetor mounting nuts Connecting rod nuts 1972 through 1975 1976 through 1983 Crcmkshaft pulleY'lo-damper bolts . Cylinder head boils. Drrveplate·to-torque converter bolts Exhaust manifold bolts 318 in 5116 in . Exhaust pipe-to·manlfold bolts Fan and hub assembly Flywheel or driveplate· to·crankshaft bolts Intake manifold Main bearing cap bolts Oil pan screws 1/4 in 5/16 in Oil pump cover Oil relief valve cap Rocker arm boll Spark plugs . Starter motor bolts Thermostat housing bolts Timing chaIn cover -Io·block bolts Vibration damper bolt' 1972 through 1975 1976 and 1978 1977 and 1979 through 1983 Water pump bolts
...
in in in in in
oversize undersize undersize undersize oversize
Ft·lbs 30
Nm 41
12to15 12 to 15
16 to 20 16 to 20
28 33 17 to 28 110 22
38 45
25 15 15 to 25 12 10 25 105 43 100
34 20
5 to 9 9 to 13
4.5 28
7" 12 12 to 18 6.0 38
16t026 22 to 33 13 to 25 10 to 18 18 to 33
22 to 35 30 to 45 18t034 1410 24 24 to 45
24 10 38
149 30
20 to 34 16 to 34
142 58 136
76 55 108 60 122 90 4 to 5 510 6 'Note: The vibration damper bolt on 1978 through 1983 models should be lubricated before instill/arion.
•
72
General information
3 Refer to the Specifications Sect 100 and compare the letter code with the information in the charI to delermine which components are oversize or undersize.
The 90 degree VB engine is made of cast iron and features overhead valves. The camshaft is located in the V of the cylinder block and ac· tuates the valves through hydraulic lifters. pushrods and rocker arms. The rocker arms are fastened to the cylinder head in pairs by bridged pivots. The positive displacement. gear-type oil pump is incorporated into tha timing case cover and is dllven by the distributor shaft. The crankshaft Is supported by five two·piece insert· type main bearings.
73
Oversize and undersize component designation
Some engines may have ovtlrsize or undersize cylinder bores. crankshaft main bearing journals, connecting rod journals and/or cam· shafl bearing bores. 2 A code designating the presence of oversize or undersize com· >Klnents is stamped on the tag located on the 'ight bank rocker arm cover. The oversize/undersize code is located adjacent to the engine build date code on the tag.
rr--
Fig . 2.42 Thll lIogloe build date and oversize/underslza codes are loceted on the right sida rockar arm cover (Sec 131
2D
20-4
Chapter 2 Part 0 t21 ~'6 INCH · 12 Nun
V8 engine
... .
~
LJII'ItEA TAUNNIOH
IE ... 'UNG
"VOTOA SLEEVE
•
'~H
D •• HD"
N.
~
"""'......
..O"~
I .
''''N'
MOUNTING BRACKETS
FRAME SUI'PORT
~~ "
2 X 2XIINCH
HARDWOOD
0···,c~': Y~:::~~DN , (. ~ 1
2 I( 2 It'" INCH HARDWOOD BLOCK
121 liZ INCH HOLE S
Fig . 2.43 Typical Inginl Wfting'lupponing fixture which can be fabn.c.tad and v.,d when r,placlng engine mount cu5hlon. (See 74)
74
Engine mount. -
r.pl.c.~nt
Rubber engine mounts SUPPOIt the engine 81 three points. These mounts should be inspected periOdically to make sure they haven't become hard, split or separated from the metel backing. 2 The mount cushions can be replaced after supporting the engine/transmission weight with 8 jack, hoist or holding , jxture.
75
Engine - removal
Not.: The foNowing sequence of operatIOns d~s not necessarily nHd to be Pflrformed in the order given. It is, rather, e chlJCklist of everything th., must be disconnected or remo...cJ befol'8 the engine can be lifted out of the vehicle. If \'Our vehicle is equipped with an aUlomeric tmnsmission, the engine removal procedure will be slightly different from the procedure for vehicles equipped with e manual trensmission. It is very important that aI/linkages. electric.' wiring, hoses and cables be removed or disconnected before attempting to lift the engine clear of the vehicle, so double·check eVflrything thoroughly. 1 Open the hood and tilt it completely back. 2 Remo\le the air cleaner assembly. 3 Drain the coolant into a suitable container. then remove the heater hoses and radiator hoses. 4 On automatic transmission equipped models. disconnect and plug the transmission fluid cooler lines. S Remo\le the radiator and engine cooling fan. 6 Disconnect and plug the pOW1lr steering hoses and remove the power steering pump assembly. 7 If the \lehicle is equipped with air conditioning, ha\le the system discharged by a dealer ser\lice department or properly trained teChnicien. Caution: Do not ettempt to disconnlJCt the air conditioning system components until the system h8s been s. f./y discharged, as serious in;ury could result. 8 Remove the air conditioning compreasor. 9 If equipped with cruise con trol, remove the se,...,o bellows end mounting bracket as an assembly. 10 Disconnect the negati\le battery cable from the battery. 11 Disconnect the fuel supply and ,eturn lines et the chassis connactlons. 12 Olsconnect the engine wiring herness and move it out of the way. 13 Disconnect the vacuum line hom tha pOW1lr brake unit. 14 Disconnect the heater damper door vacu um line at the intake menifold. 15 On automatic transmission equipped models. disconnect Ibut do
Fig . 2.44 T,!,plcal engine mount component Ia'!'out - uploded view (Sec 74)
not remO\le) the filler tube at the light cylinder head. 16 Remove the nuts from the liOn! engine mount support cushIOns.. 17 Connect a suitable lilting device to the engine and raise il suffi ciently to support the englne's weight 18 Remove the left front engine support cushion and bracke t. 19 On four wheel drive models equipped with a manual transmission, remO\le the transfer case shift le\lar boot, 11001 mat and transmission access covar. 20 On automatic transmiSSion eqUipped vehicles. remove the upper torque converter·to·engine bolts. 21 On manual transmission eqUipped models. remolle the upper clutch houslng-to-engine 601ts. 22 Unbolt and disconnect the exhaust pipes Irom the manifolds and support bracket. 23 Remove the SlaMel motOI. 24 Support the transmiSSion wllh a jack. 25 On eutomotic transmission equippad models, remove the inspec· tion cover and mark the relati\le position of the con\lerter and dllveplate. 26 Remo\le the convertel ·to·dri\leplal8 bolts by rotating the crankshaft pulle,!, nut with a wrench to prOVide access to each bolt. 27 Remo\le an,!, remaining boilS retaining the engine to the transmis· sion. On manual transmission equIpped models. remove the clutCh houS' Ing lower cover for access to the remaining bolts. 28 Withdraw the engine forward and tift it up at an angle to ramove the engine from the vehicle.
76 Engine - dlsessembly .nd , ••ssembl,!, sequence To completely disassemble the engine. remove the follOWing Items in the order given: Oil pan Intake manifold Cylinder head/valve train components Timing chain cover Timing chain end sprock~ts Camshaft PiSlonJconnecting rod assemblies Crankshaft Oil pump 2 Engine reassembl,!, is bUlcaU'!' the ,everse of disassembl,!,. InSll1l tha following components In the order gl\lon: Oil pump Crankshaft PiSlon/connecting rod assemblies
Chapter 2 Part 0
va engine
20·5
IENOI~E ACCESSOAY OAIVE I'VlllEY
~.~ .",,,,;000 DAMPEA COVIE" Oil SEAL
Fig. 2.46
I Fig. 2.45
)
nmlng chein cove r components 15K 80)
•
Rocur arm assembly components (Sac 791
elCploded view
Timing cham and sprockets Camshaft Timing chain COYer Cylinder head/Va/ve train components Intake mamfold 011 pan Fig . 2.47 77
011 p.n -
80
Remove the carburetor and linkage (Chapter 41. Remove the retaining bolts and lilt the manifold Irom the engine. Remove the metal gasket and the end seals.
81
79
ChKking timing ch.n
_.t
2D (deflection) (Sec 81)
removal
Remove the bolts attaching the oil pan to the engine block. 2 Tap on the pan with a solt-Iaced hammer. to break the gasket seal. and 1,lt the 011 pan off the engint 3 Remove the oil pan neoprene seals. 4 USing a gasket scraper. remove all traces 01 gasket Itom the oil pan and engine block gasket surfaces. 5 Clean the oil pan with solvent and dry it thoroughly. Check the gasket sealing surfaces for distortion.
1 2 3
e:llploded view
Cylinder head -
removal
Remove the rocker arm covers. The cover. are installed with a formed · in-pl.ca ATV· type gasket and it m.y be necassary 10 tap Ihem sharply With a soft -faced hammer 10 breek Ihe le.1. 2 Remove the intake manifold. 3 Remove the rocker arm assembly bolts/nuts. 4 Remove the rocker arm assemblies .nd pushrods, keeping them in order so they c.n be reinstalled in thel' oligin.1 locations. 5 Loosen the cylinder head bolts 1I4-tu,n at • time. working Irom the inside out. Remove the boilS, then lift all the cylinder head and gasket. It may be nacassary to tap the head sharply with a soft-faced hammer around Its circumference to bra.k the gaskel seal.
nmlng chain cover -
removel
1 Remove the vibration damper bolt. 2 Using a suitable puller, remova the vibration damper. 3 Remove the timing COvel mounting bolts. Since these bolts are of varying lengths. mark the location of each one at tha time of removal so Ihey can be reinstalled in the sama locations. 4 Ramova the cover by pulling it atraight out. off the locating dowels. 5 Pry the oil seal out and cle.n the bC/fe. Cle.n the gasket surfaces of the timing cover and engille block.
Timing chain _ar ct..tk
1 Remove the timing chain CoYer. 2 Rotete either the cranksheft or c.msh.ft sprocket until there Is no sl.ck in the right side of the ch.ln. 3 To determine. reference point for deflection measurement, move 314 01 an Inch up from the dowel on the right side of the engine .nd make. mark at this location. PI.ce • streightedge across the timing chain from. point at the lowest root 01 the c.mshaft sprocket to the marked position. Grasp the ch.in at this point to use as • reference. move the chain in tow.rd the centerline of the engine and mark the point 01 m.ximum deflection. Move the ch.in out to the point of m'lIimum deflection .nd make .nother mark. 4 Me.sure the distance between the two merk. to determine the total deflection (as shown in the .cCompenying illustration). 5 If the deflection Is beyond the malClmum .1I0wed in the Specifications. replace the chain with a new one. If the chain is replaced, new .prockets probably 8hould be used as well.
20-6
Fig. 2 .49
Fig. 2 .48 Thil ml,k, on the Iprocket' mUlt be Illgned belo,.. removing the eh"'" end sprockets 15K 821
17'
F:;:.:fJ (~
IOLIER I!iAFT
Fig. 2 .51 Checlllng oR pump g"r end elelr.nc. with PIa.tlgeg. (Sec 85)
t-' ~I
~iJ
'O"'G"'~
OIL !'''lAURIE IULIEf VALVE ....1. . Ly
A
~~
~
Cam, haft componenta - Ixploded view (Sec 831
Fig. 2 .52
Checking oU pump gear end
cle.r.nce with • I..ler gauge and Itralghtedge (Se<: 85)
DRIVE SHAFT
"NOGE""
,1
Fig. 2.50 Oil pump components IltpkKted view (Sec 85)
Fig. 2 .53
Checking 01 pump g ••, -to-
body clur8ncl (S.C 85)
Chapter 2 Part 0
82 ,
Timing chain and sprockets -
ramoval
Remove the vibration damper and pulley.
2 Ramova tha timing chain cover. 3 Remove the camshaft retaining screw and washer. distributor drive gear and fuel pump eccentric. 4 Rotate the crankshaft until the ~ero timing mark on the sprocket is aligned with. and closest to. the ~aro timing mark on tha camshaft sprocket as shown in the accompanying illustration. 5 Remove the crankshaft and camshaft sprockets and tha timing chain as an assembly.
20-7
VB engine
tween Ihe gaar tooth end and the pump body inner wall opposite the point of gear mesh as shown in the accompanying illustration. Select a gauge which fits snugly, yet can be insarted freely. Rotate the gears and measure the clearance of each looth in lurn. 7 If the geaHo-body clearance is greater than specified. replace the gears and idler shaft. B Slide the gear and idler shaft assembly into the pump body and 'nsert the pressure relief velve and spring. secure it with the cap. Note: The oil pump must be pecked with petroleum ;ally (not grease) prior to installa tion to ensure self·priming action.
86 011 seal replacement 83 Camshaft - removal Remove the pushrods and valve lifters. 2 Remove the distributor. 3 Remove the vibration damper' and timing chain cover. 4 Install the vibration damper screw and two washers and use a wrench to rotate the crankshaft until the timing mark is aligned with the centerline of the camshaft sprocket. 5 Remove the retaining screws from the camshaft and crankshaft. 6 Remove the fuel pump eccentric and distributor drive gear from the camshaft. 7 Remove the crankshaft and camshaft sprockets and timing chain as an assembly. 8 Remove the camshaft from the engine block. laking care not to damage the lobes or bearing surfaces. 9 Inspect the distributor drive gear and fuel pump eccentric for wear and damage. Inspect the camshaft bearing journals for eJ(cessive wear and evidence of seizure. If the journals are damaged, the bearings in the block are probably damaged as well. Both the" camshaft and bear· ings will have to be replaced with new ones. Check the cam lobes for pitting, grooves, scoring or flaking. Inspect the valve lifter facas lthat rida on the cam lobes) for concave wear. Note: Never install used liftelS on a new camshaft. If the original camshaft and lifters are installed, make sure the lifters are returned to the bores they were removed from. I! they get mixed up. new lifters must be used. 1
84 Oil pump - removal
Front timing chain cover seal I The seal should be replaced with a new one whenever the timing chain cover is removed. 2 Remove the old seal and clean the cavity. 3 Apply a gas kat sealant such as Permatex No.. 2 or equivalent to the outer circumference of the seal. 4 Install the seal evenly in the timing case, using a large socket or block of wood and a hammer to seat it completely in the cavity. 5 Prior to installing the crankshaft vibration damper. apply a light coat of engine oil or grease to the seal·to-damper contact surface.
Rear main bearing oil seal Remove the rear main bearing and discard the old lower seal. Clean all traces of sealer from the main beaflng cap. a Gently drive out the upper seal. USing a hammer and brass drift, until it protrudes sufficiently to be grasped with pliers and pulled out. S If the crankshaft is in place, wipe the contact surface area clean and apply a light coat of engine oil. 10 Coat the lip of the seal with engine oil or grease and the upper contllct surface with liquid soap. Insert the seal into tha groove in the engine block with the lip facing forward . 11 Coat both sides of the lower seal ends with RTV·type sealant, tak· ing care not to apply it to the saalsurface. Coat the lip of the seal with engine oil or grease and the curved outer surface with liquid soap as shown in the accompanying illustration. 12 Install the lower seal in the main bearing cap with the lip facing forward and seat it securely. 13 When installing the main bearing cap, apply a coat of RTV-tvpe sealant to the chamfered contact surfaces.
6 7
The oil pump is an integral part of the timing chain cover with the cavity in the cover forming tha pody of the pump. 2 Remove the retaining bolts and lift the oil pump cover. the gasket and the oil filter as an assambly away from tha timing chain cover.
ENGINE OIL ON
'"
LlOUIO SQAPON OUTSIOE
RTV SILICONE ON TOPANO BOTTOM OF BOTH
85 011 pump - disassembly, inspection and raassembly
SIOESO~SE"'L
Slide the dflve gaar assembly and idler gear from the pump body. Unscrew the pressure relief valve cap and remove the valve and spring. 3 Check the operation of the relief valve by insening the poppet valve and making sure it slides back and forth f reely. If it does not, raplace the pump cover and the valve with new components. 4 The distance between the end of tha pump gear and the cover is the gear end clearance. This can be checked in either of two ways. I
2
a)
m SILICONE ONCHA/llFEREO EO(IES
~ace
a strip of Plastigaga across the full width of each gear, install the pump cover and tighten the bolts to the specified torqua Remove the cover and measure tha Plastigage with the scale on the container to determine if the clearance is within the Specifications. b) Place a straightedge across the gears and the pump body and select a feeler gauge which will fit freely but snugly between the straightedge and the body. Make sure the gears are push· ed as far up into the body as possible. 5 If the clearance is ellcessive. check the gears for ellcessive wear. n the gear is obviously not badly worn and a thinner cover gasket will not bring the clearance within the specified limit, replace the gears and idler shaft. 6 To check the gear·to·body clearance, Insert a feeler gauge be-
Fig. 2.54
87
Rear meln bellling 011 seal installation detail, (Sec 86)
Oil pump - lnstallitlon
Pack tha interior of the pump with petroleum jelly to provide I self-priming action. Caution: Do not use grease for this purpose. 2 Using a new gasket, place the pump and filter assembly in posi tion and install the retaining bolts. TIghten them to the specified torqua
2D
20-8 88
Chapter 2 Part 0
Timlnll c hain end sprocket. - Installation
Assemble the timing chain, crankshaft and clNTlsha ft sprockets with the timing marks ehgned el shown In the accompanying illustration, 2 Install the Iprockets and chain o nto the crank.&halt and camsha f t. 3 Install the fuel pump eccentric and distrib utor drive gear wil h the eccentric REAR Itamping facing the camsha ft sprocket. 4 Install the camlhaft washer and $Crew. Ttghten the screw to the specified torque. 5 Rotate the crankshaft until the camshaft Iprocket timing mark is at the 3 o'clock position. COUf1ling from the pin directlV adjacent to the timing mark, there must be 20 pins bet ween the cams hal t sprocket mark and the crankshaft sprocket mark as shown in the accompanving illustration. 6 Install the crankshaft oil seal and timing chain cover. 7 Install the vibra tion dampar and pullev.
89 Cam. haft - Inltanatlon Lubricate the camshaft very thoroughlv wit h engine assembly lube or molV-based grea$8. 2 Carefully inllrt the camshaft into the block, I8king care not to contact the bearing surfacel with tha cam lobes. 3 Install the timing chain and sprocket assembly. 4 Install the oil slinger on the cranksha l t. 5 Install the fuel pump eccen tric and drive gear on the camshalt. tightening the retaining screw to Ihe specified torque. 6 Install the liming chain case using a new gasket and oil seal. 7 Install the vibretion damper and pullev. tightening the retaimng boits to the specified torque. B Coat the hydreulic lifters w ith engine assembly lube or moly-be sed grease. Install each lifter into the bore from w hich it was originallv removed . 9 Lubricete the ends of each pushrod with engine assemblv lube
VB engine
or moly-based grease and ,nstall them in their onginal locations. 10 Install the rocker arm assemblies. 11 Install the rocker arm cove,s. 12 Install the fuel pump. 13 Rotate the crankshaft until the number 1 piston II at lOp dead center noel on the comprl!ssion stroke. nils can be determined by piecing your finger over the number 1 cylinder spark plug hole and turning the crankshaft pulley boll with a wrench in a clockwise direction until pressure is felt. The liming mark on the vibration damper should be aligned with the TOe rndell mark on the tIming degree scale. 14 Insert the dislributol so Ihe rotor IS alIgned with Ihe number 1 terminal of the cap when fully in place ,Chapter 51. Install the dlstnbulOf
co. 90
Timing chain cov • • - Installation
1 Remove the lower locating dowel, I8king care not to damage it. 2 Cut both Sides 01 the oil pan gasket off flush with the engine block. 3 ApplV RTV-type gasket sealant to both sides 01 the new liming cover gaske t and attach the gasket to the cover. 4 Attach the new froni oil pan seal to Ihe bottom of the liming chain cover. S If a new oil pan gasket is used. use the old gaskets as a guide and trim them to correspond to the amount cut off in Step 2. Une up the tongues of the new gasket piece; wi th the oil pan seal and cement them into place on the cover with RTV-type gasket sealant. ApplV gasket sealant to the cut-off edges of the original pan gasket. place the limIng cover in position and in"allthe bolts. Tighten the boits slowlV and evenly untit the cover aligns with the upper dowel. Insen the lower dowel and carefullv drive it IOtO position. Install the 10_ bolts and then tighten all of the cover bolts 10 the specified torque. 6 II RTV-lVpe sealant is used. apply a l /Blnch bead to the timing cover flanges. Place the cover In position and install the boilS in their marked posit ions. Insert the lower lOCating dowel into the block and drive It inlo position. Install the remaining boilS and IIghlen them to the specified lorque. ApplV a bead 01 RTV·type sealanlto the pan· to-
Fig. 2 .56 Timing chain co ....r end oM pan s.al InSllllation datalls (5 K 90)
~ ~ @
@ Fig. 2 .55 F~ pro~ valve timing. th .... must be 20 pk,. betwMn the sprodwt timing martu !Sec 88)
0 0
Fig. 2 .57
0
0
0
/"'.
0
(]
0
~ ~ 0
0 0
@
Cylindar head bolt tightening .equence (Sec 91)
Chapter 2 Part 0 cover joint and press it into place with your finger. ApplV a thread· locking compound to the oil pan bolts and install them. 7 Install the vibration damper and tighten the bolt to the specified torque.
91 Cvlinder heed -
installation
ApplV an even coal of non·hardening gasket sealanllO both sides of the new cylinder head gasket. 2 Place Ihe gasket in position on the engine block with the stamped TOP designation facing up. 3 Prior to installing the head bolts. clean the threads with a wire brush so the bolts will not bind when installed. 4 Place the cvlinder head in position on the engine block. S Install the bolts finger tight. making sure they thread smoothlV into the block with no binding. 6 Tighten the bolts evenlv to the specified torque in the sequence soown in the accompanying illustration. 7 Install the intake manifold. S Install the pushrods and rocker arm assemblies in their original positions. Make sure tha push rod ends are lubricated with a dab of &ngine assemblv lube or molV· based grease and that the boltom end of each rod is centered in the valve lifter plunger cup. Tighten the rocker arm baits/nuts one turn at a time. alternatelV, to avoid bending or break· ing the bridge (if so equipped), 9 ApplV a lI8-inch bead of RTV-tVpe sealant to the gasket surface of the rocker arm cover. 10 Place the cover in position on the cylinder head, install the bolts end tighten them evenly and securely.
92
Intake manifold - installation
If a new intake manifold is to be installed, transfer the EGR valve and back pressure sensor, thermostat housing, coolant temperature sensor and CTO valve from the old unit. 2 Coat both sides of the manifold gasket with RTV· type sealant, 3 Place the gasket in position on the alignment locators at the rear of the cvlinder heads. Hold the rear of the gaskat in place and align it with the front locators. 4 Install the end seals and applV a coat of Permatex No.2 sealant. 5 Lower the manifold into position and install the retaining bolts finger tight. 6 After making sure the bolts are properlv started with no binding. tighten them to the specified torque in a crisscross pattern.
93
011 pan - installation
va engine
20 -9
95 Crankshaf1; - Inll1allatlon and main bearing oil clearance cha<:k Crankshaft installation is generally one of the first steps in angine reassembly; it is assumed at this point that the engine block and crankshaft'have been cleaned, inspected and rapaired or reconditioned . 2 Position the engine with the boltom facing up. 3 Remove the main bearing cap bolts and lift out tha caps. Lay them out in the proper order to help ensure that they are installed correctly. 4 If they are still in place. remove the old bearing inserts from the block and the main bearing caps. Wipe the main bearing surfaces of the block and caps with a clean, linHree cloth (they must be kept spotlessly clean). 5 Clean the back side of the new main bearing inserts and lay one bearing half in each main bearing saddle in the block. LaV the other bearing half from aach bearing set in the corresponding main bearing cap. Make sure the tab on the bearing insert fits into the recess in the block or cap. Also, the oil hotes in the block and cap must line up with the oil holes in the bearing insert. Do not hammer the bearing into place 8nd do not nick or gouge the bearing faces. No lubrication should be used at this time. 6 The flanged thrust bearing must be inatalled in the number three (3) (center) cap and saddle. 7 Clean the faces of the bearings in the block and the crankshaft main bearing journals with a clean, lint·free cloth. Check or clean the oil holes in the c rankshaft, as any dirt here can only go one way straight through the new bearings. 8 Once you are certain I hat the crankshaft is clean, carefully lav it in position (an assistant would be very helpful here) in the main bear· ings with the counterweights lying sideways. 9 Before the crankshaft can be permanentlv installed, the main bear· Ing oil clearance must be checked. 10 Cut five pieces of the appropriate type of PlBstigage slightlv shorter than the width of the main bearings. Place one piece on each crankshaft main bearing journal, parallel with the journal axis. Do not lay them across any all lines. 11 Clean the faces of the bearings in the caps and make sure the caps are not mixed up. Install the caps in theif respective positions with the arrows pointing toward the front of the engine. Do not disturb the Plastigage. 12 Starting with the center main and working out toward the ends, tighten the main bearing cap bolts, in three steps, to the specified tor· que. Do not rotate the crankshaft 8t any time during this opefation. 13 Remove the baits and carefullv lift off the main bearing caps. Keep them in order. Do nut disturb the Plastigage or rotate the crankshaft. If any of the main bearing caps are difficult to remove, tap gently from side·to·side with a soft· faced hammer to loosen them. 14 Compare the width of the crushed Plastigage on each journal to the scale printed on the Plastigage container (photo) to obtain the main bearing oil clearance. Check the Specifications to make sure it is correct. 15 If the clearance is not correct. double·check to make sure that
Install tha front oil seal in the timing chain cover. Coat the ends of the seal with RTY·type sealant. 2 Coal the rear oil pan seal curved surfaca and the end seal tabs with RTY· tvpe sealant and install the seal in the rear main bearing cap. Make sure the seal is completelV saatad. 3 Cement the oil pan side gasket to tha engine block sealing sur· faces with gasket sealant. Apply a generous coat of RTV· tvpe sealant to the gaskeT ends. 4 Install the oil pan and bolts and tighten the bolts to the specified torque in a crisscross pattern.
94
Crankshaft -
ramoval
Before remov ing the crankshaft. you must remove the flywheel /driveplate, the rear oil seal housing, the cylinder heads, the oil pan. the timing chain cover and the timing chain and sprockets. 2 With the engine upside·down, remove the oil pick· up tube and 5(:reen assemblv. 3 Remove the piston assemblies from the engine block as de· scribed in Chapter 2A . 4 Refer to Chapter 2A for the remarnrng crankshaft removal steps.
95.14 Comparing the width of the crushed Plastigage to the scale on the container
2D
"
20-10
Chapter 2 Part 0
VQU hBVe the right size beering InserlS. Also, make sure that no dirt or oil was between Ihe bearing inserts and the main bearing caps or the block when the clearance was measured. 16 Carefully screpe all traces 01 the Plntigage material off the main bearing journals and/or the beering faces. 00 not nick or seuneh the
4
beering leces.
97
17 Carefully lift Ihe crankshaft out 01 the engine. Clean Ihe bearmg face. in the block, then apply 8 thio, uniform layer of clean, hlgh-qual,ty moly-besed grease 10f engine assembly lube) to each of the bearing faces. Be SUIe 10 coal Ihe thrUSI flange faces as well as the journal face of the thrust bearing in the number three (center) main. Make sure the crankshalt journlls Ire clean, then cerelully ley it back in piece in the block. Clean Ihe Ilces 01 the bearings in the caps, then apply a thin lever 01 cleen, high-quelity moIy·based grease to each of the bearing feces end install the capi in their respectIve posilions with the arrows pointing toward the Iront of the engine. Inllall the bolts and lighten them to the specIfied torque, starting WIth the center maIn and work· Ing out toward the ends. Work up to the finel torque in three lIeps. 16 Rotate Ihe crenksheh a number of times by hand and check fOf env obvious binding. The final step is to check the crenkshaft end play. ThIS can be done with a feeler gauge or a dial indicator set. Refer to Chepter 2A. " Section t2, for the procedure to follow.
96
VB engine
If the original crankshaft is reground, the !lUlomotJve maenine shop thai reconditions the journals should supplV beaungs Ihat Will produce the de~med 011 clearance.
Engine - lo,"halion
1 wwer the engine slowly and c81elully ,nto the eng,ne compartment. Align the transmission input shah with Ihe engIne. On manuel transmISSIon models this will reqUIre aligning the sphnes of the input shaft and clutch plete. Instell the trensmlssion hOUSing retaining bolts and tighten them securely. 3 Remove the jack supporting the transmission. 4 On automatic transmission eqUipped models. align the marks made on the converter and driveplate and install the retaining bolts. Be sure to lighten them to the specified torque. 5 Instanthe automatic lfansmiSSlon inspection covel or the menual transmiSSIon lower cover. 6 Install the starter motor. 7 On four wheel drive models, ettech the left Iront engine suPPOrt cushion and bracket to the cvlinder block end tIghten the bolts securety. 6 LDwer the engine weight fully onto the engIne supports and remove the lifting deVICe. Install the front engine mount support cushion reuuning nuts and lighten them secul8ly. • 10 Connect the e"haust pIpes to the manifoldS and bracket 11 Connect the eutomatic transmIssion filler tube brecket to the cylinder head. Install the cruise control vacuum servo bellows and bracket assembly. 13 Connect the electrical harness, throttle linkage and vacuum and fuel hoses to the engine. 14 Install the aIr conditioner compressor. Install the power ste8fing pump and hoses. Refill the reselVOir to the speCIfied level. 16 Install the radialor. hoses and cooling fan . On automatic rransmis· sicn equipped models, connect the trensmlssion HUld cooler hnes to the radiator. 17 Fill the radiator with the specifIed coolant. Add the correct en10unt of the specified type of oil to the engIne. 16 Install the air cleaner assembly end connect the battery negatIve cable. 19 Refer 10 Chapter 2A fOl the InitIal stan·up and recommended break'ln procedures.
,
•
M ain and co nneetlng rod bearings - s.l.ctlon
1 The crenkshaft and bearing inspection procedures are included In Chapter 2A. The condition and meesured size of the crankshaft jour· nals will determine the bearings to be installed when the engine is reassembled. If a new or reground crankshah is installed. the size of each lournai should be indic.ted by a color coded mark on the adjacent cheek or counterweight, toward tha reer (fIangedl end of the crankshaft. The bearIng inS8fts are al,o color coded (on the edge of the insenl. The accompanying charts (one for main bearing., one for rod bearings! should be consulted to determine the correct bearings to use. Caution: Always chllClr. the bearing oil clearance with Plastigege during final in · stallation of tha crankshaft and,or pistonA;onnecting rod 8s5emblies. 3 II necessary to achieve the desired oil claarence, different size up· per and lower bearing Inserts may be used on the same journal but the sIze difference must never e"ceed O.OOl·inch. Caution: The odd size msefts must,,11 be either in the caps Of block (main belJringsJ. In the case of connecting rod /Hanngs. tha odd size inserts must all be 8/thlt' In the caps or rods.
,
"
,.
.
a..ring Color Coda
Cranksh.ft Connecting Rod Jour,..t Co/Of".nd Oiam.ter in l net- (JourNlI
Yellow Ortnge Blxk
Rod
- 2.0955 -2.0948 -2.0941 -2.0855
Si ~.1
U",* Insert Sizl
to 2.0948 (Standerdl to 2.0941 10.0001 Undl...,z.) 102.0934 10.001 4 Uncl...... z.) to 2.084810.0 10 Undllfslzt) Fig. 2.58
Rod
-
-- Standard Standard - .(XI1·lnch UncI,••ilt - .010·lnch Undllfsllt
Y,lIow Yellow Black
Rod
Yellow 818(:k Bleck
" "
-
RoO
"
Standard .OCt -mch Under,.ze OOH"ch UnderSIze .010·i"ch U"dersllII
Connecting rod bearing selection chart ISec 96)
Bur;no Color Code
C'e"ksMfI MIIin BN, intl Jou. ,..1 Colo. Code end Diameter in I nches (Jou. ,..1 Si ze) Yellow Orange Bleck Green
Lower Insert Sizl
Upper I nwrt Size
2.7 489 to 2.7484 IStsndlrd) 2.7484102.7479 (0.0005 Undenizel 2.7479102.7474 (0.001 Unde",It) 2.7474102.746910.0015 Underllle) 2 .7389 10 2.7384 10.010 UnderSIZe) Fig. 2.59
Yellow Yellow BllICk BI&e:k
Rod
- Slandard Standard Underslle - .001"nch .00t·lnch UnderSlll - .OIO·inch Unde'''l1 "
"
Main bearing selection chert (Sec 96)
Lower Insert S.u Yellow Black BlitCk Gree"
Rod
" " "
Standard DOI ' I"ch DOI 'I"ch D02'lnch OIO'I"ch
UnderSlu UnderSIze Underl"e UndersIze
2E-1
Chapter 2 Part E
V6 engine
Contents Camshaft - removal and installation Clutch and flywheel - removal and installation ..•. Crankshaft - inspection .•...•..•..... Crankshaft - installation and main bearing oil ~ clearance check ............ _ . Crankshaft - removal Cylinder head - cleaning and inspection Cylinder head - disassembly Cylinder hllad - reassembly . . . . . . . . . Cylinder head - removal and installation ... .. .... Engine block - cleaning. . . . . . . . . . . . . . . . • . . .. Engine block - inspection . . . . • . . . . . . Engine - disassembly and reassembly sequence. Engine disassembly - general information Engine external components - installation . . . . . . • . Engine external components - removal Engine - Installation . . . • . . . . • . • . .. . ... . Engine overhaul - general information Engine rebu ilding alternatives . . . . . . . . . . . Engine - removal .. .. .. . . .. . . ••.. Engine removal - methods and precautions General information . . . . ............ _ .
108 10' Chapter 2A
115 112 Chapter 2A Chapter 2A Chapter 2A 106 Chapter 2A Chapter 2A 101 Chapter 2A • . • •. 116 102 1 17 Chapter 2A Chapter 2A
100 Chapter 2A
'8
Initial start-up and break-in alter overhaul ....•... Main and connecting rod bearings - inspection Oil pan - removal and installation •.•. __ . __ . _ . Oil pump - inspection and installation .. _ . Oil pump intake pipe and screen - removal and ..... __ . _ ........ _ .. _ • installation Oil pump - removal .. _ . _ . _ . __ . . . . . . •. . ••.•. Piston/connect ing rod assembly - inspection •... _ Piston/conn ecting rod assembly - installation and bearing 0;1 clearance check ..... .. __ Piston/connecting rod assembly - removal . Piston rings - installation __ . _ . _ ...... __ Pushrods and v alve lifters - removal. inspection and installation .. _ .. _ . __ . _ . _ .. . .•.... Rear main bearing oil seal - replacement •..... Repair operations possible with the engine in the vehicle ... _ . _ . . .. _ . _ .•.. _ ....•. Timing chain cover - removal end installatio n Timing chain and sprockets - removal and installation .......... _ . Undersize/oversize compo nent designation Valves - servicing. _ . ...... . _ .
Chapler 2A Chapter 2A
110 113 111 103 Chaptar 2A Chapter 2A Chapter 2A Chapter 2A
107
114 Chapter 2A
104 105
99 Chepter 2A
Specifications
General Type Displacement .......... • Bore and stroke . . Compression ratio Federal California Normal oil pressure . Cylinder numbering (front -to -rearl Right bank • left bank
90 0 V6 225 cu in
3.750
K
3.400 in
9 .0 : I 7.4 : 1 33 psi at 2400 rpm
IC
FIRIHC ORDER 1-6-S-4-3-2
2-4-6 1-3-5
Engine block Cylinder bore Taper limit Out-of-round limit Piston -la-cylinder bore clearance Standard . Service limit •.
0 .005 in 0.003 in 0.00 1 in 0.0015 in
Cylinder location and distributor rotation
2E
2E-2
Chapter 2 Part E V6 engine
Pistons and rings Piston ring side clearance Standard Top ring
2nd ,ing Oil'ing
0.002
In
0.003 in 0.0015 In
Service limit
Top ring 2nd ,ing O,l,ing PiSlon rIng end gap Standard Compression rings o.llIog
0.0035 In 0.005 in 0.0085 in
0.010 In 0.015 in
Service limit
Dilling Piston pin diameter.
0.020 in 0.035 In 0.9334 to 0.9397 in
Piston pin·lo-piston clearance Standard ......... . Service limit Piston pin-Io-connecting rod clearance
0.004 in 0.0017 ,n 0.0007 to 0.0017 in
Compression rings
Cylinder heads Valve seat angle Valve seat width Standard Service limit
45' 1/16 in
5/64 in
Valve Slem diameter Intake Exhaust
0.3415 to 0 .3427
Top
0.3402 to 0.3412 0.3397 to 0.3407
Bottom Valve head diameter Intake
Exhaust Valve stem-la-guide clearance Intake
Exhaust Top BoHam
Valve mSlgin width Val ... e s tem installed height, Valve spring pressure (length 81 specified pressure) .
1.625 in 1.3750 in 0.0012 10 0.0032 in 0 .0015 to 0.0035 in 0 .002 10 0.004 in 1/32 in minimum 1.925 in above cylinder head 1.640 in at 59 to 64 Ib/l.260 ,n at 168 Ib
Crankshaft and flywheel Main journal Diameter Teper limit OUI-ol-round limit Meln bearing oil clearance Slandard Service limil Connecling rod journal Diameter Taper limit ... . ... Out-of·round limit Connecting rod bearing oil clearance Standard . . . . . . Servica limit .. ..... . .. ..... . ...... . Connecting rod end play .................. •.• ... •.. Crankshaft end play. . ...............•..•... Flywheel clutch face runout limit ....... . ...... .
2.4995 in 0 .002 to 0.0023 in 0.0015 in 0.0005 in 0 .0021 in 2.000 in 0.003 in 0.0015 In 0.020 In 0.0023 In 0.005 to 0.0012 in 10lel fo r two rods 0.004 10 0.008 in 0 .0015 in
Camshaft and valve train Bea"ng journal diameter 1
2
3 4 Bearing oil cleerance Slandard . Service limil Lifter type.
1.7 55 1.725 1.695 1.665
to to to to
0.00 15 in 0.0040 in Hydraulic
1.756 1.726 1.696 1.666
in in in in
2E-3
Chapter 2 Part E V6 engine Lifter -Io-bore clearance Standard Service limit Rocker arm-to-shah clearance .......... .
0.0015 in 0.0030 in 0.0017 to 0.0032 in
Oil pump gear end clearance .....
0.0023 to" 0.0058 in
Oversize and undersize component code letter definition Code letter A Main and connecting rod bearings ........ . .. . . . . B Pistons .
AB R
S
Torque specifications Main bearing cap bolts .. . ..... . Connecting rod cap nuts . . ... . . • . . . . ......•. Cylinder head bolts. . ...... . . Fan pulleY-IO-lIibration damper bolts ...... _ . _ ......... . Flywheel-to-crankshaft bolts. . ............. . . ............. . Vibration damper bolt . Oil pan bolts ..... Oil pan drain plug .. .... . .... • .... Oil pump COller·to·timing chain cOllar .......... . Oil pump prassura ralief lIallie ................... . Oil scraen housing .. . .. .. . . • ... •. Oil pan baffle. . ...... . Oil gallery plugs ...... . Oil filter ........... _ ..... . . Timing chain cOlier bolts . Water pump bolts. Fan drillen pulley bolt .. . ..... . . .. Tharmostat housing bolts Intake manifold bolts ..... ............ • . . . .. Exhaust manifold bolts . ...... . Carburetor-to-intake manifOld bolts .. Fuel pump bolts . . .. . ........... . Engine mount-to-block bolts ......... .... . ........ . Fuel pump eccentric and timing chain sprocket -to -camshaf t bolt. . . . . . . . . ... . ... . Rocker arm cOlier bolts . Rocker arm shaft bracket bolts .................... . Alternator bracket -to-cylinder head bolts ........... . Alternator pillot bolt . . ......... . Alternator bracket-to-liming chaJn cOlier bolt .. Starter motor bolts .... .. ....... . . ..... . Starter motor brace Distributor hold-down clamp bolt .................... . .............. . Spark plugs Bellhousing-to-block bolts ...... . Timing chain damper-Io·block bolts ........... _ Mailable timing chain damper bolt .
,
0.0 10 in undersize 0.0 10 in over5i~e Combination of A and B Short block Service engine Ft-Ib 80 to 30 to 65 to 18 to 50 to
Nm 129 to 162 41t054 SS to 109 25 to 34 68 to 88
110 40 85 25 65
'90
'40 10to 16 30 to 40 8 to 12 25 to 30 6 to 9 9 to 13 20 to 30 10to15 25 to 33 6 to 8 17 to 23 17 to 23 45 10 55 15t0 20 10to15 17 to 23 50 to 75
14 to 22 41t054 l1to17 34t041 8 to 12 12 to 17 27 to 41 141020 34 to 45 8 to 11 23 to 32 23 to 32 61 to 75 20 to 27 141020 23 to 32 68 to 102
40 to 55 3 to 5 25 to 35 30 to 40 301040 18 to 25 30 to 40 9 to 13 10to15 25 to 35 30 to 40 6 to 9 10 to 15
54 to 75 4 to 7 34 to 48 41t054 41 t05 4 24 to 34 41 to 54 12 to 17 14 to 20 34 to 4S 41 to 54 8 to 12 14 to 20
Undersize/ovellli~e
98 General Information
99
The 90 degree V6 engine used in these lIehicles is made of cast iron and features oller head lIallies. The aluminum rocker arms are mounted on tubular steel shafts which are secured to the cylinder heads by brackets. A camshaft. mounted in the block and drillen by a chain off the crankshaft, operates the vailies through hydraulic li fters. push rods and the rocker arms. The crankshaft is supported by four main bearings. Th e number t wo bearing is flanged to control crankshaft end play. The crankshaft and connecting rod bearing shells are replaceable. The lull-skirt aluminum pistons are cam ground and tin plated and feature two compression and one oil control ring. The piston pin is press fit in the upper end of the connecting rod . The oil pump is located at the front of the engine, under the timing chain COlier. and draws oil from the crankcase-located pick·up and Icreen assembly through a drilled passage in the cylinder block.
Some engines have oversize or undersize main and connecting rod becuings andlor pistons. 2 A code letter denoting the presence of oversize or undersize com· ponents, as well 85 other import ant information, is stamped on the engine block Iront face. below the right rocker Brm cOlier. 3 Reier to the Specifications and compere the code letters on the engine block with the chart to determine which components are under· size or ollersize. 100
component dasfgnsUon
Engine - removal
Note: The fol/owing sequence of operstions does not neceSS8rify need to be performed in the order given. It is, rsther, II checklist of everything that must be disconnected or removed before the engine clln be lifted
2E
Chapter 2 Part E V6 engine
2E-4
out of tflll ~hlc1e. II is very impom"" that lilt linkages. electrical wiring, hoses lind c(JIbJes be removed or dlsconnftCted bflfore attemptmg to hit the engine des' of the vehICle, so double-check. everything thoroughly. 1 Remove the hood end disconnect the battery cables (negative first, Ihen positive). 2 Remove the air cleaner assemblV. 3 Drain the coolant from the radiator end the engine in to II suitable
container, 4 Drain the engine oil into 8 suitable container. 5 Disconnect the alternator wiring harness Irom the regulator. 6 Disconnect the fuel evaporative purge valve 8t the PCV valva 7 Remove the radiator hoses and suppon be,.. Remove the r&diatot 8 Unplug the engine wiring harnesses at the firewall. 9 If so equipped, remove the exhaust emissions conuol 811 pump, d,str,butIOn manifold and anti-backflte valve. 10 Disconnect the cables and wires and remove Ihe starter. 11 Disconnect and plug the fuel hOS81 at the right frame rail. 12 Disconneci the choke cable from the carburator and remove the bracket.
Ag _ 2 _6 0 I
Bolt and washer
2 Fan assambly 3 Drivtlbelt 4 Fan driven pulltly 5 Water pump Hose clamp 7 Thermosta t bypass hose 8 Bolt Water outlet elbow 10 Gasket II Thermostat 12 Water pump gasket 13 Wa ter pump Impeller and insert 14 Water pump seal
•
•
13 Unbolt the exhaust pipes from the manifolds. 14 Support I he transmission with a jack. 15 Remove the front englne-Io-mount bolts. 16 Attach a lifting devIce to the engme and raIse it suffiCIently to remove the slack in the hoist cham or cable. 17 Remove the engine-to-bellhousing bolts. 16 Raise the engine sligh tly and slide it fo rward to release It from the transmission shaft and clutch assembly. 19 Raise the engine slowly and carefully to remove it from the vehICle.
101
Engine - di. e ... mbly end rea ...mbly sequem;:e
To completely dIsassemble the engine. remove Ihe following items In the order given. Engine external components Oil pump Timing chain cover Timing chain and sprockets
Engine extamal components
15 Dowel pin
"18 20 " 17
21 22 23 24 25 2. 27
Werer pump cover Bolt Wa rer pump sha ft and bearing Fan hub Oil suction pipe gasket Oil suction housing, pipe and flange Bolt 0;1 pump sCfflen Dipstick Oil pan gasket Oil pan Dmin plug gasket
28 2' 30 31 32 33 34 35 3. 37 38 3. 40
Dram plug Bolt and washer Oil pump shaf t and gear Oil pump cover gasket Valve bypass and cover assembly Oil PfflSSUffl valve Valve bf'pass spring Oil PfflSSUffl valve cep gasket Oil PfflSSUffI valve cap $CfflW (114-20 JC '-3/8-inl SCfflW (114 -20 JC 1-1/8-inl Fan drive pulley Bolt
2E-5
2E
Flg. 2 .B1 I Connecting rOd
2 3 4 5
~ssembly
Piston pin Piston lind pin IIssembly Piston ring set Connecting rod bo" and nut Connecting rod baaring 7 Damper spring 8 DlImper bolt Timing ch';n dllmper 10 Engine block II Camshaft 12 Woodruff key 13 Camshaft bearing (front) 14 Cttmshaft bearing (numbar 2) 15 CttmshlJft bfJaflng (number 3)
•
•
"
17 18 I. 20
21 22 23 24 25 2. 27 28 2.
Exoloded view of engine inlemal componenll Cttmshttft bellring (rttllr' Rettr ClImshllfr plug Flywheel Starter ring gear Crsnlcshllf t bellring set Raaf mllin ba~ring oil sf/a' Crsnkshaft Rear main beafing neoprene oil ua' Main buring cap bolt Woodruff leey Timing chllin dllmpllr Damper bo" Timing chain Cttmshaft sprocleet
30
31 32 33 34 35 3. 37 38 3. 40 41 42 43 44
C~nlcshllfr sprocker CTtlnleshllft oil slinger CTtlnlesh.ft oR shtHider Front c~nJahaft sHI fHlClcing riming ch';n coYBr gasket riming ch';n COVfN Vib~rion dlJmper
80' WsSh~f
80h DOWf/lpin ClImshllft throst ffJreiflflr lind Ws.sher Distributor drive gellr Fual pump eccentric
bo"
2E-6
Chapter 2 Part E V6 engine
Cylinder heads
14 Remove the bolt and washer ret,l!nmg the vibration damper to the
Pushrods and valve fifttJ~ Camshaft Clutch end ffywheel Oil pen Oil pump intake pipe and screen PisronA::onnecting rod assemblies Crsnksheft
crankshaft. Tep around the circumference of the damper with II soft· faced hammer and withdraw it from the crankshaft (8 puller may be reQuired for this procedurel.
2
Engine assembly is basically the roverse of disassembly. Install the
following components in the order given. Crankshaft
103
011 pump -
removal
Remove the five retaining bolts and lift the oil pump and cover away from the timing chain cover. 2 Remove the oil pump gears.
Piston rinys PfstonA:;onnecting lad assemblies Oil pump intake pipe lind screen Oil pan Clutch and flywheel Camshaft Pushrods and valve lif ters Cylinder heads Timing chein and sprockets Timing chain cover Oil pump
Engme ex/ernel components
102
Engine exlemel componenu - removal
Disconnact tha vent hose. distributor vacuum hose and fuel line from the carburetor. 2 Disconnect the distributor wires from the ignition coil and the coolant temperature sending unit wire. 3 Remove the bolts and lift the intake manifold from the engine. 4 Unbolt and remove the exhaust manifolds. 5 Disconnect the vecuum hose and wiring harness from the distributor end remove the hold-down bolt. Carefully lift the distributor and bracket from the timing chain cover. 6 Remove the spark plugs, wires and brackets. 7 Disconnect the hose and unbolt end remove the fuel pump. a Remove the altarnator, brackets and drive belt. 9 Remove the fan assembly end water pump. 10 Unscrew and remove the all filter. l' Disconnect the oil pressure sending unit wire end unscrew the sending unit from the engine. 12 Remove the oil dipstick end tube. 13 Remove the etteching bolts and withdraw the crankshaft pulley.
Fig. 2 .62 In.talilng the di.tributor drive gear and fuel pump eccentric on the cam.hah !Sec 106)
104
Timing chain COll1lr - removal and installation
Remove the retaining bolts and separate the timing chain cover and gasket from the engine. 2 Ramova the old oil seal and shedder. 3 Ramove all traces of old gasket material. taking care not to damage the sealing sur face. Wash the cover thoroughly with solvent and dry it with compressad air or clean,lint -fraa cloths. Inspect the covar. particularly the gaskat saaling suriaca, for damage, cracks and nicks. 4 Roll up a length of new packing malarial in the seel cevity. working from the back of the cover. Overlap the ends of the packing at the top. Drive a new oil shedder irlto place and stake it in position at three or four locations. 5 Rotate a large wood dowel or hammer handle around Ihe opening to size the packing and shedder and produce a snug fit around the cren kshaft vibration damper hub. 6 Make sure the contact surface of the engine block is clean and free of nicks and other damage and install the cover, using a new gasket. Inslall the rataining bolts and lighten them in a crisscross pattern to the specified torque. 7 If the oil pump has not been removed. the cover must be removed and the cevity packed with petroleum jelly as descrobed in SectIon 113.
105
Timing c hein~and .procket. - removal end instellation
, Remove the pulley bolt and oil slinger from the crankshaft 2 Remove the bolt and washer and slide the fuel pump eccentric and distributor geer off the camsheft. 3 Use two pry bers or large screwdrivers to pry alternataly on the camshaft and crankshaft sprockets until the camshaft sprocket is loose.
fig . 2 .63 Timing chain sprocket marks properfy ellgned [Sec 105)
2E-7
Chapter 2 Part E V6 engine UII the sprocket and chain assembly from the engine. 4 Wash the sprockets, c hain, eccentric and distributor gear thoroughly with solvent and inspect them lor wear and damage. S Puor to installation, rotat8 the cfankshel1 '0 the number one III pilton is at lOP dead cen ter. Instalithe camshaft sprocket temporarily and turn the camshaft untillhe timing marXs are aligned as shown in the accompanying illustration. S Remove the camshaft sprocket, attach the liming cham to the tpfockals and inSlall the entire assembly. makmg sure the Ilm,ng marks .ra aligned. Have en assistant hold the spring-loaded chain dampers out 01 the way while slodlng the assembly into place. 7 InSlelithe oil slinger on the crankshaft with the concsve side roWlJrd
the engme. S Slide the fuel pump eccentriC and Woodruff key onto the camahah with the oil groove facing the frOM. 9 Install the distributor drive gear, washer and bolt. Tighten the bolt to the specified torque.
106 1 2
CyHndflf heed - removal end Inilellllion Remove the rocker arm cover. loosen the rocker arm assembly boilS 1/ 4 -lUrn 81 a lime until they
Fig. 2 .64 Cylinder head end valve geer componenls - a_plodad view (Sec 106) I Right rocker arm COVfJr 2 Rock.r arm cOYer bolt 3 Gesket 4 Bolt 8affle LAfr rocker arm COVfJr 7 Rocker arm shefl 8 Plug Rocker arm spring 10 Cylinder head Heed gllsk.t 12 Pushrod 13 VlIlve lifrer 14 In tllke valve I. E_hllUst valve DOW#t1 pin Valve spring 18 Valve spring retBinBr I. Velve keftPers
•• •
"
16
""
2E
2E-8
Chapter 2 Part E V6 engine
FIg.2.65
Cylinder head bolt tightening sequence ISec 106)
Fig. 2 .66 Proper rocker arm shaft ellgnmenl (Sac 106)
Fig.2.67
Valve lifter componenls - u:ploded view (Sec 107)
IIfB completely 100s8. Leave the bolts in place so the assembly can be lifted from the head. Remove the pushrods (Section 107). 3 lDosen the cylinder head bolts l f 4 -tu rn at til lime. in a crisscross panern, then remove them. 4 Remolle the cylinder head end gasket. It may be necessary to tap around the outer edge of the head with a soft-faced hammer to break the gasket seal. Repeat the procedure fOf the remaining cylinder head. S Prior to installation, clean the cylinder head bolts tho roughly end coat the threads with Perfect Seal sesling compound (or its equivalent). Make sure the 98skel surfaces of the head(s) end block are clean. 6 Coat both sides of the new head gaskets with a suitable aerosol spray sealant, then position the gaskets on the block. The alignment dowels will hold them in position. Carefully lower the cylinder heads into position. Make sure they fit properly over the dowel pins. 7 Install the bolts and tighten Ihem to the specified torque. one turn at a lime. following the sequence shown in the accompanying illustration. 8 Install the pushrods (Section 107). 9 Place the rocker arm assemblies in position with the notches at the end of the shefts positioned as shown in the accompanying illustration. Tilt the rocker arm assembly loward the puahrod to securely seat Iha rod and in Ihe arm seal. Inslall the retaining bolts. 10 Draw the rocker arm assembly down evenly by tightening the bolts a little at a time until the specified torque is reached . 11 Install the rocker arm covers and gaskets. 00 not overtighten the bolts or oil leaks mey result.
tion in their original positions. Clean the push rods and lifters thoroughly With solvent and dry them with compressad air or clean. lint-free cloths. 4 Inspect the contact surfaces of the push rods for wear. damage and roughness. To determine if the pushrod is bent. roll it on a lIat surface such as a piece of glass. Replace any worn. damaged or bent pushrods with new ones. 5 Inspect Ihe lifters for galling. pitting. wear on the contact surfaces and grooves or scoring along the sides. If there is excessive varnish on the lifter, disassemble it and submerge it in a suilable solvent for at least an hour to dissolve the deposits. Clean the varnish from the lifter(s) and reassemble them. Replace any excessively worn or damaged lifters wit h naw ones. 6 Lubricate the lifter bores with clean engine oil and the cam contact faces with engine assembly lube or moly-based grease. Install the lifters in their original locations. Note: If new lifters are being installed, a new camshaft must also be installad. If a new camshaft was instlllled, then use new lifters as well. Never install used lifters unless th, original camshaft is used and the lifters can ba installad in their origl"'" locations. 7 Insta!! the cylinder heads ISection 106). 8 Lubricate the ends of the pushrods with engina assembly lube or moly-based grease and install them in their original locations. 9 Install the rocker erm assemblies and rocker arm covers ISeclion 1061.
3
108 107
Camshaft -
removal and instellation
Pu.tlrod. and valvtlilft.... - removal, inapectlon end Inatallalion
Remove the rocker arm covers and rocker arm assemblies (Section 1061, then remove the pushrods one at a time and place them in a merked piece of cardboard to ensure rei nstalletion in their original locations. 2 Ramove the cylinder head(sllSection 1061, then remove Ihe lifters one at a time and place them In a marked container to ensure reinstalla -
Remove the liming cheln end sprockets ISection 105). the cylindfll' head s ISection 106), and the pushrods and lifters (Section 107). 2 Carefully withdrew the camshaft from the engine block, taking cere not to damage the bearing surfaces by striking them with the cam lobes. 3 Before installation. lubricate the cam lobes and bearing journall with engine assembly luba or moly-based grease. 4 Refer to the note in Seclion 107, Step 6.
Chapter 2 Part E V6 engine
2E-9
'-
,
3
Fig. 2.68 011 pump and oil pan componenta - axploded view ISec 110) , 2 3 4 5 6 7 8
11
9 10 11 12 13 14
•
15
Dipstick Oil pan baffle Gasket Oil pen Drain plvg gasket Drain plug Ol~ pump screen Ol~ suction housing, pipe and flange Oil svction pipe gasket Oil pump idler gear Valve bypass and cover assembly Oil pressura valve Spring Gasket Oil pressure relief valve
'"P
16 Oil filter 17 Oil pump cover gasket 18 Oil pump Shaft and gear
109
Clutch and flywhael - ramoval and instanation
Mark the location of the clutch cover to ensure reinstalla tion in the ume position. LDosen the retaining bolts, one turn at a lime, follow· jng a crisscross pattern, unlil all si~ bolts are loose. Remove the boilS and the clulch cover assembly. 2 Remove the relaining boils and separale the flywheel Irom Ihe crankshafl. 3 Inspect the clutch contact surface 01 the flywheel for cracks and score marks and the starter ring gaar for brokan and damaged teelh. A properly equipped shop can resurface the flywheel or replace the starter ring gear if they are badly damaged. 4 To install, place the flywheel in posi tion, install the retaining bolts and tighten them in a crisscross pattern to the specified torque. 5 Check the flywheel runout to make sure it is within the Specifications by mounting a dial indicator on the engine with the stem on thll clutch contact surface. Rotate the flywheel several revolutions to determine the runout . 6 Attach the clutch cover to Ihe flywheel, aligning it with the marks made during removal, and install the bolts. TIghten the bolts a little at a time, following a c risscross pattern, to Ihe specified torque.
110 Oil pan - removal and installation With the engine invened, remove the bolts securing the all pan to the engine block. 2 Tap on the pan with a soh-faced hammer to break the gasket seal, then lift the oil pan off the engine. 3 Using a gasket scraper, scrape all all traces of the old gasket from the engine block, the timing chain cover and the oil pan. Be especially careful not to nick or gouge the gaskel sealing surface of I he liming chain cove r lit is made of aluminum and is quite soh). 4 Clean Ihe oil pan with solvent and dry it thoroughly. Check the gasket sealing surfaces for distortion. S Before installing the oil pan, apply a thin coat of RTV-type gasket sealer to the engine block gasket sealing surfaces. Lay a new oil pan gasket in place and carefully appl.,. a coa t of gasket sealer to the oil pan gasket surface. 6 Gently lay the oil pan in place (do not disturb the gasket) and In· stall the bolts. Start with the bolts closest to the center of the pan and tighten them 10 the specified torque following a crisscross pattern. Do not overtighten them or leakage rna.,. occur.
2E
2E- 10 111
Chapter 2 Part E V6 engine
011 pump Intake pipe and acr ••n - ramoVllI and Installatio n
Remove the two anaching boIls and lift the intake pipe and screen assembly away from the engine. 2 Pry the SCfeen from the housing and wash the whole 8516mbly thoroughly with solvent. Dry it with compressed air or clean, lint-free cloths. Install the screen. 3 To instell the intake pipe,. place the assembly in position with e new gasket end install the retaining bolts. TIghten the bolts to the specified torque.
112
Crankshaft - removal
Before removing the crankshaft, you must remove the flywheel, the cylinder heads, the oil pen, the on pump intake pipe and screen. the timing chain cover and the liming chain and sprockets by re ferring to the appropriate Sections. 2 Remove the piston/connecting rod assemblies from the block as described In Chapter 2A. Be sum to marle. each connecting rod and bearing cap so they will be properly mated during reassembly. 3 Refer to Chapler 2A for the remainder of the crankshaft removal procedure. Note: It may be necessary to use a special tool (available at automotive parts slores or a daaler) for trlmOVlJ1 of the rear main cap bacause of tha tight fit. As an alternative, a IIJrge wood dowel can be inserted into the bearIng cap bolt hole end used es II {8IIf1r to loosen the cap.
petroleum jelly is fo rced into every part of the cavity between the gear teeth. 7 lubricate the pressure relief valve plunger and spring with clean engine oil. Install the assambly in the cover and tightan the valva cap to the specified torque. 8 Place the oil pump cover in position and install the retaining bOIIl. Tighten them to the specified torque following a crisscross pattern.
114
The braided fabric seals are pmssed into the engine block and main bearing cap grooves. A neoprene stick-type seal is also used in the grooves in the sides of the rear main bearing cap. This seal is under· size when installed and swells whan exposed to oil and heat. 2 Remove the old seah, from the bearing cap and engine block. 3 Posit ion the new braided seals in the grooves and use a wooden dowel or hammar handle to push them down until they project 1116-indt above the cap and block surfaces. Cut off the ends of the seal flush with the bearing cap and block. Just prior to installation of the main bearing cap, lubricate the seal with clean engine oil. 4 After the rear main bearing cap is installed, the neoprene seals ara inserted. Soak the seals in kerosene for approximately 1-1/2 minutes. insert them into the bearing cap grooves and soak the ends with kerosene. Use a hammer to peen t"a seal ends over to make a good seal at the upper parting line of the bearing cap and engine block.
115 ' 13
011 pump -
Inspection and Inst allation
Wash the all pump cover and gears thoroughly with solvant and dry them with compressed air or clean, lint- fme cloths. 2 Inspect the gears for wear. scoring and dam age. The gears should always be replaced in pairs. 3 Remove tha oil pressure relief valve cap, spring and plunger. Do not remove the oil filter bypass valve plunger and spring IJS thay are stIJked in place. 4 Wash the valve components thoroughly wit h solven t . Ory and inspect the relief valve plunger for wear and scoring. Check the spring to see if it is worn or collapsed. Insart the relief valve plunger into the bore and make sura It Is an aasy slip fit with no slda·to·side movemant. Replace the plunger andlor the cover if the side movement is excessive. Check Ihe oil filter bypass to make sure it is lIat with no nicks, cracks or warping. Replace any wom or damaged components with new onas. 5 Tamporarily install the oil pump gears in the timing chain cover and usa a faeler gauga and straightedge to Check the gear end clearance. 6 Remove the gears end pack the oil pump cavity in the timing chain cover with petroleum jelly to provide a self'priming action when the angine is started. Do not use greasa. Install the gears, making sure tha
Fig. 2.69 InstalUng the rear main bearing all H al (Sec '14)
Re., main bearing oil Hal - replacement
Crankshaft - In st allation and m ain bearing oil clearance check
Crankshaft installation is generally one of the first steps in engine reassembly. It is assumed at this point that the engine block and crankshaft have been cleaned and inspected and repaired or reconditioned. 2 Posit ion the engine with the bottom facing up. 3 Re move the main bearing cap bolts and lift out the caps. lay them out in the proper oryer to help ensure that they are Installed correctly. 4 If they are still in place. remove the old bearing inserts from the block and the main bearing caps. Wipe the main bearing surfaces of the block and caps with a clean. lint-free cloth (they must be kept spotlessly clean). 5 Clean the back sides of the new main bearing inserts and lay one bearing half in each main bearing saddle in the block and the other bearing half from each bearing set in the corresponding main bearing cap. Make sure the tab on the bearing insert fits into the recess in Iha block or cap. Also. the all holes in the block and cap must line up with the oil holes in the bearing insert. Caution: Upper bearing halves have an oil groove, while lower halves are plain. They mUSI not be interchanged. Do not hammer the bearing into place and do nOl nick or gouge the bearing faces. No lUbrication should be used at this time. 6 The flanged thrust bearing must be installed in the number two
Fig. 2 .70 Intake manifold .nd s.aI installation (Sec 1'6)
Fig. 2 .7 ' Int ake mllnlfold galket Inltellatlon (Sec '16 1
Chapter 2 Part E V6 engine cap and saddle. Install the upper all seal in the black (Sec tion 114). 7 Clean the laces of the bearings in Ihe black and the crankshaft main bearing journals with a clean, lint-free cloth. Check or clean the ail hales in the crankshaft, as any dirt here can only go one way straight through the new bearings. 8 Once you ere certain that the crankshalt is clean. carefully lay it i!"l position Ian assistant would be very helpful hera) in the main bearings with the counterweights lying sideways. 9 Before the crankshah can be permanently installed, the main bearing oil clearan ce must be checked. 10 Trim four pieces of the appropriate type of Plastigage (slightly shorter than the width of the main bearingsl and place one piece on each crankshaft main bearing journal, parallel with the journal axis. Do nat lay them ecross eny oil holes. 11 Clean the faces 01 the bearings in the caps and install the caps in their respective positions (do not mix them upl with the arrows pointing toward the front of the engine. Do not diSlUrb the Plastigage. 12 Starting with the number twa main and working out toward the ends, tighten the main bearing cap bolts, in three steps, to the specified torque. Do not rot8te the crankshaft at any time during this operation. 13 Remove the bolts and cerefuly lift off the main bearing caps. Keep them in order. Do not disturb the Plastigage or rotate the crankshaft. If any of the main bearing caps are difficult to remove, tap gently from side-to-side with a soft-faced hammer to loosen them. 14 Compare the width of the crushed Plastigage on each journal to the scale printed on the Plastigage container to obtain tha main bearing oil clearence. Check the Specifications to make sure it is correct 15 If the clearance is nat correct, double-check to make sure that you have the right size bearing inserts. Also, recheck the crenkshaft main bearing joumal diameters and make sure that no dirt Of oil was between the bearing inserts and the main bearing caps or the block when the clearence was measured. 16 Carefully scrape all traces of the Plastigage rflaterial off the mein bearing journals andlor the beering laces. 00 not nick or scratch the bearing laces. 17 Carefully lift the crankshaft out of the engine. Clean the bearing faces in the block. then apply a thin, uniform leyer 01 clean. high-quality moly-based grease (or engine assembly lube) to each 01 the bearing faces. Be sure to coat the thrust flange faces as well as the journal face of the thrust bearing in the number two main. Make sure the crankShaft journals ere clean, then carefully lay It back in place in the block. Clean the fa ces of the bearings in the caps, then apply a thin, uniform layer of clean, high-quality moly·based grease to each ollhe bearing laces and install the caps in their respective positions with the arrows painting toward the Iront 01 the engine. Install the lower rear main ail seal ISection 114). InSli!ll the bolts and tighten them to Ihe specified torque, but leave the number two (thrusO bearing cap bolts finger tight. Pry the crankshaft back and fonh several times to align the thrust bearing surfaces, then tighten the number two bearing cap bolts. Work up to the finel torque in three steps. 18 Rotate the crankshaft a number of times by hand and check for any obvious binding. 19 The final step is to cheCk the crankshaft end play. This can be done with a feeler gauge or a dial indicator set. Refer to Chapter 2A, Section 12, for the procedure to follow.
116
Engine eldemal components -
installation
Lubricate the outer surface of the crankshaft vibration damper hub to prevent damage to the front oil sea! and place the damper in position an the crankshaft. Install the bolt and washer and ti ghten the bolt to the specified torque. 2 Install the crankShaft pulley and the six retaining bolts. Tighten the bolts to the specified torque. 3 Install the oil dipstick and tube.
2E-11
4 Install the oil pressure sending unit in the cylinder block 5 Install the staner motor and bracket. 6 Lubricate the gasket with ~ film of engine oil and install the oil filter. 7 Install the coo ling fan. hub drive pulley and water pump. 8 Install the fuel pump and tighten the retaining bolts to the specified torque. 9 Install the alternator and dnvebelt. 10 Install the spark plugs, wires and brackets. 11 Install the distributor (Ch aptar 5). 12 Install the exhaust manifolds and tighten the retaining bolts to the specified torque. 13 Anach a new rubber intake manifold seal to the front and rear rails of the engine block with the pointed ends installed snugly against both the block and cylinder heads. Place the intake manifold in position and install tha two cap bolts through the manilold and into the cylinder heads to act as guides. Raise the manifold slightly and place the two gaskets in position between the manifold and each cylinder head. The gasket must be installed with the three hales aligned with the manifold and cylinder head ports. Install the bolt in the open-sided hale on tha right Side of the manilold, followed by the two long bolts at the front. Install the remaining bolts and tighten them to the specified torque in the sequence shown in the accompanying illustration. 14 Connect the distributor, ignition coil and coolant temperature sending unit leads. 15 Attach the vent and distributor vacuum hoses and fuel line to the carburetor.
2E Fig .2.72
117
Intake manifold bolt tightening sequence (Sec 116)
Engine - In8l11lation
Lower the engine carefully into the vehicle. align it WIth the bellhousing and engage the transmission shaft and clutch plate splines as the engine is moved to the reaf. Install the engine block·to-bellhouslng bolts and tighten them to the specified torque. 2 Install the front engine mount bolts. 3 Remove the lifting device and connect the exhaust pipes to the manifolds. 4 Connect the choke cable bracket to the carburetor. 5 Connect the fuel hoses and lines to the engine. 6 Connect the wiring harness on the firewall to the engine. 7 If equipped, instIl! the exhaust emission air pump, the pump manifold lind anti·backfire valve. 8 Install the radiator, suppon rods and hoses. 9 Install the air cleaner Issembly. '0 Connect the battery cables (posi!ive first, then negativel and install the hood . 11 Reier to Chapter 2A lor the initial stan·up and break·in procedures.
2F-O
Chapter 2 Part F L- and F-head four-cylinder engines Content. Camshaft - installation Camshaft - removal . . . .... . . . Clutch and flywheel - installation .. Clutch snd flywheel - removal ...... . Crankshaft - inspection ........•.•.•..•. . Crankshaft - installation and main bearing oil clearance check . . .. . .. . . ... . Crankshaft rBBr main oil seal - replacement. Crankshaft - removal ...•.... Cylinder head (F· heed engine) - cleaning and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head IF·head engine) - disassembly . . . Cylinder head IF·head engine) - installation. Cylinder head iF-head engine) - reassembly. Cylinder head If-head engine) - removal Cvlinder head (l· heed enginel - cleaning and inspection. . ....... . Cylinder head (l·head enginel - installation. Cylinder head (l·head enginel - removel . . Engine block - cleaning . . . . . .. . . . . Engine block - inspection . . .. .. .. . Engine block valve seats end guides - servicing. Engine disassembly - general information Engine - disassembly and reassembly sequence. Engine external components - installation Engine external components - removal Engine front plate - installation ....... . Engine front plate - removal ............ . Engine - installation ................ . Engine overhaul - general information . . . . . . . .
143 13' 146
132 Chapter 2A 14' 141
133 . . Chapter 2A •. Chapter 2A . . . . . . .. 150 Chapler 2A 125
139 151 124 Chapter 2A Chapter 2A
138 Chapter 2A
121 153 122 147
131 154 ..
Chapter 2A
Engine rebuilding alternatives . .. . ...... . . . . . Engine - removal ... . . . . . . . .. . . .. . . . Engine removal - methods end preceutions Floating oil intake - removal, "inspection and installation. . . . . . . . . . . . . . . .. . ........ . General information . . . . .. . .... . . . Initial start-up and break-in after overhaul .. Main and connecting rod bearings - inspection Oil pan - removal and installation ...... . Oil pump disassembly, inspection and reassembly . Oil pump - installation ... . .. . . . . . . . . . . . ...... Oil pump - removal .. .. . .. .. .. . . . . ... . Oversi~e and undersi~e component designation . . .... . .. Piston/connecting rod assembly - inspection . Piston/connecting rod assembly - installation and bearing oil clearance check Pistonlconnac t1 ng rod assembly - removal. Piston rings - inslallation ...... . ... . ..... . . . Repair oper8tions possible with the engine in the vehicle . . . ............ . Timing gear or chain cover - install8tion ...... . Timing gear or chain cover - ramoval . ........ Timing gears or chain and sprockets - installation . . Timing gears or chain and sprock.ets - removal Valves and springs On block) - installation ..... . ...... Valves and springs lin block) - removal . . . . .. . ...... Valve liftars - inspection ..... . Valve lifters - installation Valve lifters - removel Valves - servicing ............ .. .. .
. .
.
. .
General Type . . . . . . . . . . . .. . ........ . . . Oisplacement ..................... .... . Firing order .... . . . . . . . . . . . . . . . . . . . . •...• . Cylinder numbering (from fronl-Io-back) .. . .. . . . . . . Bore and stroke .. .. . ..................... . Oil pressure l -head to SIN 44417 l -head SIN 44417 and on . F-head
In-line four-cylinder with F134 cu in
1·3·4-2 '·2-3-4 3-1 /8 x 4 · 31B in
Of
l -head valve configuration FIRING ORDER 1-3-4-2
50 psi at 30 mph 35 psi at 2000 rpm 35 psi at 2000 rpm
Valve timing Inlake valve Opens. Closes Exhaust valve Opens . Closes .............. _ .
go BTC 50· ABC
47° BBC 12°ATC
Cylinder location and distributor rotation
Chapter 2 Part F L- and F-head four-cylinder engines
2F-1
Engine block 3. 125 0.005 0.005 0.010
Cylinder bore diameter Taper limit Out·of·round limit Deck warpage limit .
to 3 .127 in in in in
Pistons and rings 3 . 1225 10 3 . 1245 In 0 .003 in (see Chaptel 2A)
Piston diameter (near bottom 01 skirtl Piston to cylinder bore clearance Piston ring side clea/ance Top ling 2nd ring Oill;ng Piston ling end gap Ring ,Ize Cylinder bole oversize Standald Standald to 0 .009 in 0 .020 in 0 .010 to 0.019 in 0 .020 to 0 .024 in 0,020 In 0 .030 In 0.025 to 0.029 in 0,030 in 0.030 to 0.034 in 0,040 in 0.035 to 0 .039 in 0 .040 in 0 .040 in
0 .002 to 0.004 in 0.0015 10 0.0035 in 0.001 to 0.0025 In End gap 0.007 to 0.007 10 0.007 to 0 .007 to 0 .007 to 0 .007 to 0 .007 to
0.045 0.017 0.029 0.017 0.029 0.017 0.017
in in in in in in in 0.81 19100.8121 in
Piston pin diametel . Piston pin· to· piston clearance Standard Selvice limit Connecting lod end play
0.0001 In 0 .0003 in 0 .004 to 0.010 in
Crankshaft and flywheel Main journal Diametel Tapel limit Out·of· lound limit Mam beallng oil clearance Standard Service limit Connecting rod journal Diametel Tapel limit Out·of-Iound limit Connecting rod bearing oil c learance SUlnd8ld Service limit Crankshaft end pley Flywheel clutch lI,ce runout limit
Camshaft
•
.
2.3331 10 2 .3341 in 0 .001 in 0 .001 in 0.0003 In 0 .0029 In 1.9375 to 1.9383 in 0 .001 in 0 .001 in
2F
0 .001 In 0 .0019 in 0 .004 to 0.006 In 0 .005 in
Bearing journal diameter 1
2 3 4 Bearing oil clearance Standard . Service limit .. End pltlV
2.1860 2.1225 2.0600 1.6230
to to to to
2.1855 2.12 15 2 .0590 1.6225
In 1n In in
0 .00 1 in 0 .0025 in 0 .004 to 0.007 in
Cylinder head and valve train Head warpage limit
l·head . . F·head Valve seat angle . Valve seat width Valve seat runout limit Valve face angle Valve margin w idth Valve stem diameter Intake. . . hhaust Valve stem·to·gulde clearance Intake .. Exhaust Valve spring free length lintake and exhaust I l·head F'head
1/32 in 0 .010 in
45' 3/32 to 118 in 0 .002 in 45' 1f32 in minimum 0.3733 to 0.3738 In 0.371 100.372 in 0.0007 to 0.0022 In 0.0025 to 0.004 5 In 2 . 50 in 1.97 in
2F-2
Chapter 2 Part F L- and F-head four-cylinder engines
Cylinder head and valve train (continued) Valve spring pressure (lbs 8t specified length) Open Standard .. Service limit .. Closed Standard ....•.•.•..• Service limit . . . . . . . . . . . . . • . . • . Lifter type Ufter diameter . . . . . . . . . . . . . . . . . . . . . , ...... . Ufter-Ia-bore clearance ........ .
1 208t 1.750 in 110 at 1.750 in 53 &1 2.109 in 47 8t 2 . 109 in Mechanical 0.624 5 to 0.6240 in 0.0005 to 0.002 in
Oil pump Early model l-head engine (to engine SIN 44417) Rotor end play ................. .. .. . .. 0 .002 to 0.005 Pump shelt end play . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 to 0.004 Late model l·head engine (engine SIN 44417 end on) and all F-head engines Rotor lobe cleerancce . .. ..... .. .. .. . .. 0.010 in or less Rotor end play ................... 0.004 in Outer rotor-Io-pump body clearance . . . . . . . . . . 0.012 in or less Rotor thicknass variance . . . . . . . . . . . . . . . 0.001 in or less Driven gear-to-pump body running clearance L·heed . . . . ......... . ....... . . 0.003 to 0.010 F-head . . . . . . . ......... . 0.022 to 0.051 Pump cover warpage limit ............... . . . . 0.001 in
in in
in in
•
Oversize and undersize component code letter definition Code letter A Main and connecling rod bearings . . . . . . . . . . . . . . 8 Pistons.. . . . . . . . .. .. . .. .. .. A8 .. .. . .. . .. .. .•. . ..•. .. .. ..
0.010 in undersi ze 0.010 in oversize Combination of A and B
Torque specifications
Ft-Ib
Nm
Camshaft thrust plate bolt ........•..... Camshaft gear or sprocket bolt ........... . Main bearing cep bolts. . . . . . .. . .. Connecting rod cap nuts. . . . . .... . . . Cylinder head bolts. . .•.••... . Flywheel bolts ....................•. Manifold assembly bolts .......... . . . Oil pen boh s ...................... ..... . Piston pin lock screw ............. . .................. . Spark plugs Rocker arm cover nuts (F·headl Rocker arm assembly nuts (F-headl ... ..•.. _ . Valve lifter cover bolts (aliI .. Water outlet bolts ......................... . Water pump bolts ........................ .
26
35
30 to 40 65 to 75 35 to 45 60 to 70 35 to 41 29 to 35 9 to 14 35 to 41 25 to 33 7 to 10 30 to 36 7 to 10 20 to 25 12 to 17
41 to 55 88 to 101 48 to 61 82 to 95 48 to 55 33 to 48 12 to 19 48 to 55 34 to 48 9.5 to 13.6 41 to 48 9 .5 to 13.6 27 to 34 16 to 23
118
Glnerallnformation
The F- and L·head engines used in these models are four-cylinder in· line dasigns of cast iron construction. The c rankshaft is supported by three insert-type replaceable bearings. Earlier models were L·head types with later models featuring an Fhead design . On the L-head !flathead) engine, the valves and velve gear are located completely within the engine block with only the combustion chamber located in the removable cast iron cylinder head. The intake valves of the F-head design are located in the cylinder head and are actuated by the camshaft through a conventional rocker arm and pushrod arrangement . The F-head exhaust valves are located in the engine block as on the earlier L·head. Other than tha cylinder head design, the F- and L-head engines are virtually identical in layout and construction.
119
DVI,.l:ut and unde,.lze component deslgnltlon
Some engines have OV1lrsize or undersize main and connecting rod bearings and for pistons. 2 A coda letter denoting the presence of oversize or undersize com-
ponents is stamped on tha eng ina block immediately following the serial number. 3 Reier to the Specifications and compare the letter code on the engine block with the chart to determine which components are uncler· size or oversize.
120
Engine - removal
Note: The following sequence of operetions does not necesS8rily need to be performed in the order given. It is, rather, e checklist of everything that must be disconnected or removed before the engine can be lifted out of the vehicle. It is very important that aI/linkages, electrical wiring, hoses and cables be removed or disconnected before atrempting to lift the engine clear of the vehicle, so double-check everything thoroughly. 1 Open the hood and tilt it completely back . 2 Drain the cooling system through the petcocks located at the bottom of the radiator and at the tower right side of the engine block. 3 Disconnect the positive cabte from the battery. 4 Remove the radiator and heater hoses. 5 Remove the engine cooling fan assembly. 6 Remove the radiator brace iiI so equipped) and the radiator.
Chapter 2 Part F L- and F-head four-cylinder engines 7 Disconnect and plug the fuel hose at the fuel pump. S Remove the air cleaner assembly and disconnect the windshield wipe. motor hose. 9 Disconnect the choke and throttle controls from the carburetor. 10 Disconnect the starter cables and remove the staner motor. 11 Disconnect the wires from the generator. 12 Remove the ignition coil primary wire. 13 Disconnect the wires from the oil pressure and coolant temperature sending units. 14 Unbolt the exhaust pipe from the manifold. 15 On the F-head engine, disconnect the spark plug wires, then remove the braCket and the rocker arm cover. 16 Remove the two nuts and bolts from the front engine mounts and remove the supports. which will lower the engine sufficiently to pro· vide access to the top two bolts on the bellhousing
2F-3
17 Attach a lifting device and raise the engine sufficiently to remove the slack in the hoist or cable. 18 Remove the flywheel bellhousing·to·engine bolts. 19 Carefully pull the engine fOI ward until it is clear of the bellhousing end lift it from the vehicle.
121
Engine
~
disassembly and reassembly sequ ence
To complete ly disassemble the engine, remove the following items in the order given: Engine external components Oil pump Cylinder heed Oil psn Floa ting 011 pick·up Piston,f;onnecting rod assemblies Timing geer COVfJf Timing geers Of sprockets end chein Engine f ron t ple te Clutch end fl ywheel Cn:m/(sha fr WJ/vtls and springs lin block} Cemshaf t Velvtl lif ters
2 Engine assembly is basically the reverse of disassembly. Install the following componen ts in the order given: Velvtl lif ters Cemshaft Valves and springs (in block! Cr1Jnksha f t Clutch and flywheel Engine f ront plata Timing geers or chain Timing geer COvtlr Piston rings Pis ton/connecting rod essemblies Floating oil pick·up Oil pen Cylinder head Oil pump Engine ex ternel components
122
,
Fig. 2.73
Oil pump end pen com ponents
Oil filler cap
2 Gssket 3 Oil filler tube
, 5
• • 7
9
10
"13" ""
80/r 8r/Jcket Crankcase·to·cylinder hesd oilline Scr8w Oil line brscket FflSlener G8sktlf
Pi"
a,l pump driven gesr Oil pump Sheff and rotors Cover gasket
,.
." IS
20
"
22
23 2' 25 26
27
2. 29
30
Oil pump cO'tler Oil pan gssket Oil pan Or/Jin plug gssket Dr8in plug Lock wssher Fen pulley Shield Spscer Oil filttlr bracket stud Lock washer Rtltsine, Gtlsktlt Shim Spring Plunger
~
exploded view
31 Gasket
32 Oil float suppon 33 Flost sssembly 3< Cotter pin
35 Elbow f itting 3. Oil filter inlet
Engine external componenll
~
2F
remo val
1 Unbolt and remove the water pump . 2 On L-head enginas, remove the crankcase ventilator tube (if so equipped). Remove the attaching nuts and pull the intake and exhaust manifolds from the engine. Remove the gaskets. 3 On F·heedengines, remove the five retaining nuts and pull the ex' haust manifold off the studs. Remove the gaskets . 4 Wrap a piece of wire around the oil filler tube and a suitable pry bar. Pull the tube from the crankcase by prying on the engine block with a bar while tapping the base of the tube to (oosen it from the crankcase. 5 Unbolt and remove the wa ter outlet and thermostat. 6 Remove the crankshaft pulley nut and use e puller to remove the pulley. 7 On crankcase ventilator·equipped models. remove the bolt and gasket which secure the valve to the block . Remove the crankcase vent body and valve cove r plate.
tubtl
37 Oil filrer outler tub8
3. Jsm nut 39 Bracket ' 0 Oil lilt8r bsse Filter brace Oil filter sssembly <3 CIsmp
""
123
011 pump -
removel
The oil pump is located on the left sid e of the engine and is driven off the camshaft by a spiral gear. The distributor is driven off the oil pump by a slot in t he end of the sh aft. The tongue in the distributor and slot in th e pump shaft are machined off·center so the two shafts can mesh in only one position. Consequently. when removing the oil pump with the distributor installed, always remove the csp end mark the location o f the distributor ro tor so the pump can be reinstalled in
2F-4
,
Fig. 2.74
F-head IInglne cylinder head
compone nts -
~~
IIIIIploded
view 1 Rocker 81m cover 2 Gasket 3 COllflf stud 4 Connector
5 Pipe plug 6 Cylinder head
®-
7 Gasket 8 Pipe plug 9 ThermostBt 10 Gasket 11 Werer outlet fitting 12 SCfew lJnd lock
:v-
..
washer
13 Carburetor mounting srud
14 Pipe plug
Crankcase vent
Flg. 2.75
F-haad valve gellr
compone nts - exploded view
1 Nut 2 Left rocker 8rm J Rocker rum shaft spring 4 Rocker shillt fock screw 5 Rocker shaf'
6 Nut 7 Right rocker 8rm 8 9 10 11
Roder /I,m shaft bflfCket Intake valve lifter adjustment screw l"tlJke valve keepers 011 sea/
12 Intllke valve spring 'erainer 13 14 15 16 17 18
Intake valve spring Imelell valve pushrod Intake valve In(IIke v/Jlve lifter C.msh8ft Cllmshllft front beating
19 Camsh.', rhrost plate spacer 20 21 22 23 24 25 26 27 28 29
30 31 32
33 34 35 36
Cllmshafr thrust plate 80lt end lock washer Bolt Lock washar Camshaft gaar washer Crankshaft gear Camshaft gear Woodruff key Exhausl villve lifter Uttar adJusting screw Exhaust valve keepers Valve rotalor assembly Exhaust valve spring Exhaust valve Rochr shaft support stud Washar Rocker arm cover stud
2F-5
Chapter 2 Part F l- and F-head four-cylinder engines the same position without disturbing the Ignilion timing. 2 II the engine is In the vehicle and is not going to be dismantled. position the number one 111 piston 8t top doad center on the compression stroke. If the distributor is already removed, sigh t through the in• t8111110n hole and verify thst the oil pump slot is in the near vertical position. 3 Remove the altaching boilS lind carefully shde the oil pump lind dflvesheft out.
1 Remo\le the relalning nuts and bolts from the cO\ler . 2 Remove the liming gear cover, the timing indicator and the gasket You may have to tap Ihe COll8r lightly With a soh-faced hammer to break the gasket seal. 3 Remove the oil slinger and the spacer from the crankshaft_
124
130
CyHnder head (L-hsed anglnel femov al
Remove the spark plugs, Ihe cylinder head retaining nuts end the coolant temperature sending unit. 2 Remove the cylinder head and discard the gasket. It may be necessary to lap around the outer circumference 0 1 the head with a soft-laced hammer to break the gasket seal .
129
Cylinder head IF-head englnel -
remo\l81
I Remo\le the rocker arm CO\ler Irom the cylinder head. 2 Remo\le the rocker arm shaft suppon nuts and lift the assembly from the cylinder head. Remove the intake \lal\le pushroos one al a time end tag them or place them In e marked rack to ensure reinstallation in their original positions. 3 Remo\le the bypass hosa from the front of the cylinder heed. Disconnecl the oil line at the flare nut and remove the rocker arm studs. 4 RemO\le the cylinder heed bolts, including the one located below the carburetor, inside the intake manifold. 6 Lilt the cylinder head from the engine block. It may be necessary to tap lightly around Ihe Circumference of the hal d with a soft· faced hammer to break the gasket seal.
126
011 pan - remo\lal and Installation
With the engine upside-down. remo\le the bolts securing the 011 pan to Ihe engine block. 2 Tap on the pan with a soft-faced hammer to break the gasket saal aoo loft the oil pan off the engine. 3 Using a gasket scraper, scrape off allllaces of the old gasket from the engine block and the 011 pan. 4 Clean the oil pan With sol\leh t and dry it thoroughly. Check the gasket sealing surfaces for distortion . 5 Before installing the 011 pan, apply a thin coat of RTV-t ype gasket l8eler to the engine block gasket sealing surfacas. lay a ne w oil pan gasket In place and carefully apply a coat of gesket sealer to Ihe eKposed side of the gasket. 6 Gently lay the 011 pan In place Ido not dillurb the gasket) and in· I tall the bolts. Stan With the bolts closest to the center of the pan and tighten them to the splllClfied torQue uSing a crisscross pattern. Do not OIIartighten them or laakage may occur.
127
Floating 011 Intaka -
remo\lal. Inl pectlon and Inllalletion
1 Remove the two retaining bolts end li't off the oi' intake assembly. 2 Claan Ihe float, scraen end tube thoroughly with sol\lent. 3 Inspect the float suppon flange and the engine block cont act alea to make sure they are lIat and flee of nicks, which could cause air leaks and fl uct uating oil pressure, 4 Ins!ali the oil intaka assembly and retaining boilS (usa a new gasketl.
Pillon(connect ing rod ....mbly -
Timing gearl or chain Ind . procket. -
remO\lal
Engine front plat. - remo\lal
Remo\le the retaining boltS and separate the engine front plete from the block. Discard Ihe old gasket.
132
Clutch eod flywh' " -
ramo\ll l
1 Unbolt and remo\le Ihe lIywheel bellhousing. 2 Ma rk the relati\le position of the clulCh end lIywheel for reinstalla tion in their original positions. 3 Remo\le the four clutch retaining bolts which are diagonallv opposed to one another. Loosen the t wo remaining boilS one turn at e time until the clulCh spring pressure is relieved . 4 Remove the clutch assembly, taklllg care not 10 let the clulch plate fall. 5 Remove the ret.ining bolts and care fully pry the flywheel from the crankshaft. 6 Inspect the llywheel for scoring .nd weer on the f riclion face and warpage an d dam.ge to the sta rter ring gear.
133
Crank.haft - ramoval
Slide the thrust washer and end play edjuSling shims from the end of Ihe cranksha ft. 2 RemO\le the t wo pieces of main bearing cap packing from bet· ween the sides of the bearing c ap and Ihe engine block. 3 Re fer to Chapter 2A l or the remaining steps in this procedure.
134
Vllv,. and I prlngl (In block) - remo\lal
The inlake end elthaust \lal\le5 on the l-head engine and the eKhaust \lalves on the F-head are located In the engille block 2 Afler remO\ling the \lalve spling CO\ler , use clean, lint- free clOlhs to block off the three eKhauSl valve chamber holes so the \lal\le keepers cannot accidentallv fall in. 3 Use a \lal\le spring compressor to compress the springs on the \lel\les which ere closed (seeted against the \lal\le seat). 4 Remove the \lalves , springs, retainers and keepers. Rotate the camshalt 10 closelhe remaining \lalves and repeal the operation . If a \lel\le cannot be easily remO\led, remo\le the Ipllng and clean the carbon deposits from I he val\le Item. M ark ell of the \lal\le components or keep them in a rack so Ihey will be reinst alled in thei r original locations.
135 128
remo\lel
Remo\le the atlaching bolts and use a puller to remo\le Ihe tlmlllg gears or sprockets and chain. 2 Remove the Woodruff keys from the camshaft and crenksheft.
131 126
Timing g.et or chain CO\ler -
Cam,hm - remolllli
remo\l.1
Prior to remo\ling Ihe pillon/connecting rod assemblies, remo\la tha manifolds, Ihe oil pump, the cylinder head, the oil pan and the floating oil pick-up by referring to Ihe appropriate Sect ions. 2 Refe r to Chapter 2A for the remaining SllllpS in th is procedure.
Push the \lal\le liftars all the way lnlo the block so Ihey will not contac t the camshaft lobes. Use a clothespin (or equi\lalentl to hold Ihe lifters up in the \lal\le chamber. 2 If so equipped, remove Ihe camshaft thrust plale, screWI and spacer,
2F
2F-6
2
11 31
'l----il0
30 FIg.2.76 FI.,whHI. bellhoutlng and timing gear coye r companen" - exploded view , 2 3 4
Dowel bolt Boft Flywheel ring geer Flywheel
5 Clutch pilat bushing
6 Lock washer 7 Nut 8 Belfhol./sing 9 Cable
10 Rile, engme plats
2
11 Woodruff key 12 CJmshaft thrust plilte 13 Specer 14 Cllmshaft ge81
15 W,ul!et 16 17 18 19 20 21 22 23
Cranksheft shim Crankshaft throst WlJ$hllf Crankshaft geer Spece! Oit slinger Crllnksheft f,on, oil seal Pttcking ring .GlJllf COVf!f gesket
24 Gllar C(JVf1f
25 Pulley 26 Crenksheft pulley fUJI
27 Timmg indicator 28 Enginll support front insufl/ltor
29 Front engine plate 30 80lt 31 Front plate gasket
Chapter 2 Part F L- and F-head four-cylinder engines 3 Pullihe cam.heh dIrectly out 01 the engine block. takmg care not 10 Icrepe the bearing surlaces with tha cam lobes.
Ramove the valve IIlters from the bottom (crankcase sidel 01 the engine block. 2 Mark the lilters or place them in a rack which is marked so they win be ralnllalled in their original locatIons_
137
Valv. 11ft." - Inapection
Clean tha lihers thoroughly with solvent and dry them with a clean. lint-Irae cloth or compressed eir. 2 Inspect the contact surfaces 01 eech lifter for wear. cracks and other dlmage. Make sure the adjustment screw can be turned only with a wrench as they are self-locking. 3 Measure each lifter diameter and its corresponding bore diameter to detarmine the lifter-to-bore clearance. If it is excessive, new lifters WId block service will be required.
138
Engln. bloock valve ••at. and guides -
servicing
Alter cleaning and inspecting the engine block (Chapter 2AI, the valve seau and guides must be inspected and repeired, if necessary. 2 Inspect the valva seats for cracks, Pits, burned areas and ridges. 3 Maasure the width of each seat and compare it to the Specifications. 4 Check the valve seat runout with a dial indicator to determine il it i, out-aI -round. II a dial indicator is not availeble, apply a light layer 01 pencil lead to the lace 01 each valve and insert the valves, one at I time. into position. Press on each valve and rotete it one-quarter 01 • turn. Remove the valve and check to see if the pencil lead transler· red eventy to the valve seat. II it did not, the seat is In need of service. 5 Melsufl the inside diameters 01 the valve guides (at both ends and the center 01 each guidel with a smell hole gauge and a O-t0-1 inch ~clometer. Record the measurements fOI future reference. These
•
,
2F-7
."..asuflments, eJong with the velve stem diameter measurements. wi. 8f\able you to compute the valve stem -to-guide clearance. This clearance. when compared to the Specifications. will be one factor thet will determine the e)(tent of the valva .. rvice worX required . The guides are measured at the ends and at the center to determine if they are warn in a bell-mouth pettern (more wear 81 the ends). If they are. guide reconditioning or replecement is an absolute must_ 6 Carefully inspect each valve face for crecks, pits and burned spots. Check the velve stem and neck for crack,. Rotete the valve and check for any ObviOUS indication that it is bent_ Check the end of the stem for Pits and excessive weer. The presence ollny ollhe above condi tion s indicates a need for valve service by I profeSSIOnal. 7 Measure the width of tha valve margin (on each vllve) end compere it to the Specifications_ Any valve with I margin narrower than specified will have to be repleced WIth a new one. 8 Maasure the valve stem diamet8f. By subtrecting the stem diafn8tlf from the valve guide diameter, the valve stem -to-guide clearance II obtelned . Compare the results to the Specifications. Jf the stem-to-guide clearance is greater then specified. the guides will have to be recondi tioned or repleced and new vllves may have to be installed. depending on the condition of tne old ones. 9 Check the ends of each valve spring for weer and pits. Meesure the free length and compere It to the Specifications_ Any springs that ere shorter then specified have sagged and should nOt be reused _Stand the spling on a flat surlace and check i t lor squareness. 10 Check the spring retainers and keepers lor obvious wear and cracks.. Any questionable parts should not be reused beceuse extensive damage Will occur in the event of lailure dUfing engine operation.
139
CyllndlK head (L-head .ngln.1 - cleaning and inspection
Scrape all any traces of old gasket material and sealing compound from the head gasket sealing surlace. 2 Remove any scale thet may have built up around the COOlant passages. 3 It is a good idea to run an appropriate Size tap into each of the threaded holes 10 remove any corrosion or thread sealant that may be present . II compressed air is available, use 1\ to clear the holes of debns produced by this opelation _ 4 Clean tne cylinder head With solv8f\t and dry it thoroughlv. Com-
•
Fig. 2.71 Crankaheft components - .xploded view
. •,
~,,
, •
, Bearing dowsl 2 Front main bean"ng 3 Center main beering 4 Rllar main bearing 5 Flywheel 6 Cranksheft 7 Flywhttel dowel bolt B Crankshaft shim 9 Thrust washer 10 Woodruff kt:y II Crenkshaft gllllr
12 Gear spacer 13 Oil slinger 14 Front ofl selll
2F
2F-8
Chapter 2 Part F L- and F-head four-cylinder engines
pressed air will speed the drying process and ensure that all holes and recessed araBS are clean. 5 Inspect the head very carefully for cracks, evidence of coolant leakage and other damage. If cracks are found, 8 new cylinder head should be obtained. 6 Using II straightedge and a feeler gauge. check the head gasket surfaces for warpage. If the head is warped beyond the limits given in the Specifications, it can be resurfaced 8t 8n automotive machine
shop . 140
011 pump - diI8118mbly. Inspection and r'."embl.,.
Early models were equipped with an oil pump of slightly different design, which used gears to pump Ihe oil. The latsr modsl pump amploys en inner and outer rotor within the pump and feetura9 an oil pressura relief velve mounted on the pump body instead of in the cover as on the early model pump. 2 To disassembla either pump, file off the end of the driven gear rstaining pin, drive it out with a hemmer end small punch end remove the gear. Remove the pump cover end withdrew the gears or rotors end she It. 3 To check the cleerence of Ihe rOlors on late model pumps, metch tha rotors together with one lobe of the inner rotor pushed completely rnto the outer rotOI notch. Insert e leeler geuge as shown in tha accompanying illustration and measure the rotor lobe clea rance. Replace the rotors if the clearance exceeds the Specificetions.
Fig. 2.78
4 Insert a feeler geuge between the outer rotor and the body of tha pump to determina tha cfeenmce. If the cleerence exceeds the Specifications, replece the pump body. 5 Inspect the pump cover of both model pumps for weef end scoring end check it with e streightedge and feeler gauge to make sure the fletness is within the Specifications. 6 Measure the thickness of the late model pump rotors and make su.e both roto.s are within the specified tolerance. 7 Install the pump cover without the gasket and verify that the pump shelt cannot be turned because of intartarence between the gears and the cove r. Remove the cover, install the gasket end reinstall the cover and bolts. The shaft should now turn treely showing that the end play at the pump shaft is within the Specifications. 8 Install the driven gear on the pump shaft and check the running clearance between the geer and the pump body with a leeler gauge. 9 Reassemble the oil pump, remove the cover plug end fill it with engine oil to provide a selt-priming action. Replace the plug.
141
Crankshaft raar main oil seal - raplacament
On early L-head engines, wick packing is used to seal the rear crankshaft main bearing . On later L-head and ali F-head engines, a steelbacked lip seal is used. 2 Install tha wick packing into IIjp machined groove in the block end main bearing cap. Use a round pieca of wood Of a steel fod to roll the packing securely into the groove, starting at one end and working
Early-type 011 pump compo nenu - exploded view (Sec 1401
, Cover-to·body screw 2 Covel-la-body screw gasket 3 Cover plug 4 Cover 5 Geer 6 Rotor disc 7 Shaft assembly 8 Shaft gflsket 9 Cover gasket
TO Oil pump-la-block gasket 11 Driven gear pin 12 DriVfln gNr 13 Oil pump body 14 Oil relief spring retainer 15 Oil relief spring retainer gaskets 16 Relief spring shims 17 Rfllief plunger spring 18 Relief plunger
L • Fig . 2.79
Late-type oil
pump componant. exploded view (Sec 1401
1 1
i~o lI_
11
n
10
)
•
I 2 3 4 5 6 7 8
. 9 10 11 12
Cover screw Cover Cover geske r Shaft and rotors Body assembly Driven gear Pump gesker Gear retaining pin Relief valve retainer Reliflf valve retainflr gasket Rfllief valve spring Relief valve plunger
Chapter 2 Part F L· and F·head four-cylinder engines toward the center. Stert at the oPPOsite end and then roll toward the center until the packing is firmly seated. Cut off the protruding ends of the pecking flush with the cap. 3 Lubricate the tip-type seals wilh I light film of grelse to ease instillation Ind then slide the seals inlo place in the block Ind bearing cap. 4 Apply I lighl coat of gasket sealent to the sides end face of the bearing cap and install it. 5 Insart the two rear bearing cap packings Into tha holes bat ween the belring cap Ind the block. 00 nOl cut these packings off IS they Ire designed to protrude so that they will be crushed and form I tight lell when the oil Pin Is installed.
damage Ihe beariflg surfaces. 00 not allow the end of the camsheft to sharply suike the expansion plug II the back of the bore. 3 Install the camshaft thrUlt plate and slide the thrust plate spacer onto the lind of the Cllmshaft with the beveled Inner edge facing Ihe Cllmshaft. 4 Install eny shims which were removed . Thele lire pieced between the shoulder end specer. InSlall the thrust plate atteching bolts and tighten them to the specified torque. 5 Check the end play of the camshaft with a dlel indicator at Ihe rear face of the camshaft gear and thrust plate. If there is too linle end play. it can be corrected by removing the Inlms.
144
142
Velves and springs Un blockl - Instanation
Vllv. IIft.r. - Inl1ll1atlon
lubricate elch lifter with engine assembly lube or moly-based grease. 2 With the engine inverted. begin at Ihe rear of the block and inslall the lifters in sequence. Hold Ihem in position with clothespins.
143
2F-9
Camshllft -
Insllllilltion
lubflcllte the camshaft bearing and loba surfaces and Ihe camshaft bearings in the block with eng.ne assembly lube or moly·based grease. 2 Cerefully insert the camshaft inlO the engine. taking care not to
Oil the stems and insert the valves into the gUIdes from wnleh they wer. ,emoved. 2 Install the valve springs and retainers on each valve. 3 Slide Ihe top end of the spllng ontO the bottom end of the valve guide and use a large screwdriver to snap the apring and retainer over the lifter adjusting screw. The twO closely wound coils of each spring should be seated against the block at the top. 4 Rotate the crankshaft to bring each lifter to its lowest point lin tum) and use a compressor tool to hold the valves down and install the keepers. 5 Remove any rags used to seal off the engine block openings. 6 The valves should be adjusted to Ihe specified clearance as de· sCllbed In Chapter 1. 7 InSlell Ihe valve lifter cOYer luse a new gasketl.
•
2F
Fig. 2.80
Measuring tha leta model 011 pump rOlor lobe clearanc. lSec 140) Checking tn. Ilia model 01 pump outar rotor·to·pump body dearance (Sec 140)
fig. 2.81
Fig. 2.82 Checking tha 011 pump cOYer flatness with a straightedge and feeler gauge ISec 140)
Fig. 2.83
Installing earty·tV'" relf main bearing seal packing wltn a woocMn do_I IS.c 1411
2F-10
Chapter 2 Part F L- and F-head four-cylinder engines
Fig. 2.84 Timing gear markl (arrOW1lJ property aligned (Sec 148)
Fig . 2.85
The flvwheel TC mark aligned with tha covar hole (indlceting that tha number Dna and four plltons are at Top
Fig. 2.86 Timi ng chain sproc ket' properly aligned (Sec 148)
Dead Center) )Sec 1481 145
Crenkshah - Inst allation end main bearing all cle8rance c heck
Crankshaft installation is generally one of the first steps in engine reassembly; it is assumed 8t this point that the engine block and crankshaft have been cleaned and inspected and repaired or reo conditioned. 2 Position the engine with the bottom lacing up. 3
Remove the main bearing cap bolts and lift out the caps. Lay them
oul in the proper order to help ensure that they are reinstalled correctly. 4 If they are still in place, remove the old bearing inserts from the block and the main bearing caps. Wipe the main bearing surfaces of the block and caps with a clean, lint-free cloth Ithey must be kept spotlessly clean). 5 Clean the back sides of the new main bearing inserts and lay one bearing half in each main bearing saddle in the block and the other bearing half from each bearing set in the corresponding main bearing cap. Make sure that the tab on the bearing insert fits into the recess in the block or cap. Also, the all holes in the block and cap must line up with the oil holes in the bearing insert. Do not hammer the bearing into place and do not nick or gouge the bearing faces. No lubrication should be used ar rhis rime. 6 The flanged thrust bearing must be installed in the number one lfront) cap and saddle. Note: It is possible to incorrectly install the front main bearing. The bearing must be installed in the cap with the narrower of the two radial 011 grooves toward the front edge of the cap. /( this bearing Is not properly installed, the oil grooves in the two halves of the bearing will not ma tch at the parting /ine and prematuff! failure of rhe bearing will result. Install the upper and lower rear main oil seal sections as described in Section 141. 7 Clean the faces of the bearings in the block and the crankshaft main bearing journals with a clean. lint-free cloth. Check or clean the oil holes In the crankshaft; any dirt here can only go one way - straight through the new bearings. 8 Once you are certain that the crankshaft is clean, carefully lay it in position in the main bearings with the counterweights lying sideways. An assistant would be very helpful here. 9 Before the crankshaft can be permanently installed, the main bearing oil clearance must be checked. 10 Trim three pieces 01 the appropriate type of Plastigage (slightly shorter than the width of the main bearings) and place one piece on each crankshaft main bearing journal, parallel with the journal axis. Do not lay them across any oil holes. 11 Clean the laces of the beatings in the caps and install the caps In their respective positions Ida not mix them up) with the arrows pain· ling toward the front of the engine. Do not disturb Ihe Plastigage. 12 Starting with the center main and working oulloward Ihe ends, tighten the main bearing cap bolts. in three steps. to the specified tor· que. Do nOf rotate the crankshaft at any time during this operation. 13 Remove the bolts and carelully lilt off the main bearing caps. Keep them in order. Do not disturb the Plastigage or rotate the crankshaft. If any of the main bearing caps are difficult to remove. tap gently from slde-to-side with a soft-faced hammer to loosen them.
14 Compare the width of the crushed Plastigage on each journal to the scale printed on the Plastigage container to obtain the main bear· ing oil clearance. Check the Specilications 10 make sure il is correct. 15 If Ihe clearance is not correct, double check to make sure that yOlJ have Ihe right sl2e bearing inserts. Also. recheck the crenkshaft main bearing journal diameters and make sure that no dirt or oil was bet· ween the bearing inserts and the main bearing caps or Ihe block whef\ the clearance was measured. 16 Carelully scrape ell traces of the Plastigage material off the main bearing journals andlor the bearing laces. Do not nick or scratch tha bearing faces. 17 Carefully lift the crankshaft out of the engine. Clean the bearing laces in the block, then apply a thin, unilorm layer of clean, high-quality moly·based grease (or engine assembly lube) to each 01 the bearing faces. Be sure to coat the thrust flange laces as well as the journal face of the thrus to bearlng in the number one (front) main. Make sura the crankshaft journals are clean. then carefully lay il back in place in the block. Clean the faces of Ihe bearings in Ihe caps. then apply a thin, uniform layer of clean. high-quality moly-based grease 10 each 01 the bearing laces and install the caps in their respective positions with the arrows pointing toward the Iront 01 the engine (reler to Sec· tion 141 and note the special instructions related to the rear main bear· ing capl. Install the bolts and tighten them to Ihe specified torque, star· ting with the center main and working out toward the ends. Work up to the final torque in three steps. 18 Rotate Ihe crankshaft a number of limes by hand and check for any obvious binding. 19 The final step is to check the crankshalt end play. This can be done with a feeler gauge or a dial indicator set. Refer to Chapter 2A, Sec· tion 12, for the procedure to follow.
146
Clutch and flywheel - installation
Make sure the mating surfaces of the crankshaft and the flywheel are clean and free of nicks and damage which could affect alignment. 2 Place the flywheel in position on the alignment dowels. install the retaining bolts and tighten them to the specilied torque in e crisscrou pattern. 3 Attach a dial indicator to the engine plate with the stem resting on the flywheel clutch contact face. Rotale the crankshaft and check the runout. Compare it to the Specifications. 4 Use a clutch alignment tool to align the clutch plate, place the pressure plate assembly in position and install the retaining bolt.. Tighten the bolts a little al a time in a crisscross pattern so as not to distort the pressure plate. Remove Ihe alignment tool. 5 Place the belJhousing in position and inslall the retaining bolts. The tong bolts that go through the lugs on the crankcase and the ones below are installed with the nuts on the bellhousing side. The other bolts 81'11 installed from the rear. except for the screw attaching the top of the starter molar.
Chapter 2 Part F L- and F-head four-cylinder engines 147
1
Engln. Iront plate - Instellation Placa tna gasket In position on the engine plate.
2 Attacn the plate to the angine wltn tna gasket raacning all tna way down to tha bottom of tne crankcase. Install tne bOlts and tighten them l&Curely.
148 Timing gears or chein and sprockets - Installation On timing gear-equipped engines, inSla1l the clankshaft gear. 101Iowad by the camshaft gear. The timing marks on the gears must be aligned as shown in the accompanying illustration. whiCh can ba accomplisned by tUIOIng tha camshalt or crankshaft. 2 Onca the marks on the gears are in alignmant. remove tha cam.haft gaar. install the Woodruff key and rainstall the gear, using the retaining bolt to draw It into POSition. Do nor II/tempt to drive the gear 0Il/0 the camshaft, as it could damaga tha plug at the rear of the shaff. Tightan tha bolt to the specified torque. 3 Prior to installing the sprockats on timing Chsin-equipped engines, fatale the cran kshaft until the number one and number four pistons 81a at top dead canter. ThiS can ba verified by sighting th rough the nspectlon hole in the flywheel cover and making sure the TC mark on the flywheel is alignad with tha covar. 4 Install the sprockets so the punch marks on Ihe rims are directly OPPOsite each other. turning Ihe camshaft 85 necessary. 5 Remova the camshaft sprocket_ Pla ca the timing ch ain on the crankshaft sprocket and the camshaft sprocket In the chain and inltaH the assembly Wilh the liming marks proparly aligned, as shown In the illustration, Install the camshaft sprockat bolts and tighten them to tha spacified torque. 6 Install th a oil slinger and spacer on the cr/ nkshaft and Of removad) the timing gear oil jet in Ihe tappad hola in tha front of the eogina block. The oil jet hole should be directed so the oil will go against ma camshaft driyan gear, just ahead 01 whela it angages with the crankshaft gear. Nota: A new timing gear ojt jet entered production with L-heed engme SIN 3J-166871 (F-head engine SIN 4J-250095J. The earl,er jet hes II O.07D-inch diameter ap/mura; the fa ler jet has a O.040-lnch llperlure. The Jater jer reduces oil pressvre vanation allha fH.Imber one connec ting rod bearlng_ It IS recommended that the O.OI/O-inch jet be Installed in angintls wrth serrllf numbers fower thlln lIbove whenever It has been necessery to rapface tI scored or burned number one connecting rod bearing
.
149 Timing gear or chain cover - Inllallllllion Apply e coat of RTV-Iype gasket sealant to Iha conlact surface 01 Iha tlmlOg cover and place the gasket ,n POSiIIOn. 2 Carafully place the cover and timing poinler In posilion and inSlali the attaching bolts. TIghten tha bolts evenly and securely.
150
CyRnder head IF-head engine) - inlllllliltlon
Apply alhin coa l of sealant to both SIdes of the cylinder head gasket and place the gasket in position on thaenglne block with the crimped ladges down.
2 lower the cylinder head inlO position, install the bolts and lighten them to the specified torque in the sequence shown in Iha accompanying iIIustration_ 3 Insert the ball ends of tha ~ushrods securely into tha intake valve hflars in the block. 4 Instal! the rockar arm assembly on the mounting studs, making sura Ihe liftars, pushrods and rocker arms are In alignment_ 5 Install the nuts on the rockar arm assembly studs and t ighten tham aV1lnly to tha specifiad torqua. 6 Adjusl tha yalve clearances IChapter 1). 7 Coat both sides 01 tha rocker arm cover gasket with RTV-type sealanl and anach the gaskat to tha cover. 8 Place the rocker arm cover In poaltlon and install the retaining boits_ TIghten the bolts to the specified torque.
151
Fig. 2 _88 Cylinder head bolt· tightening sequence for the L-head ang;na (Sec 161 )
152
Oil pump - Installetlon
Rotate the crankshaft and tim ing gear 01 sprockets so the timing marks are aligned. 2 Attach the gaskat to the pump. 3 Begin Inserting the oil pump shah inlo the laft side 01 tha engine wltn the wider side of the shaft on top and the bolt holas aligned. Insert a long screwdriver into the distributor shaft opening on tha opposite side of the block and turn the slot 10 the oil pump shaft until it is in the 9:30 o'clock position. 4 Ramove the screwdriver and use a flashlight to make SUfa that the slot is In the proper position. 5 Insert the screwdriver and use It to guide the oil pump shah gaar into engagement with the camshaft gear as the pump is lowered into position. 6 Remove the screwdriver end make sure that the ad pump dlSlnbutor tang slOt IS now in the 11 o'clock poSition. If it IS not. repeat tha operatIon. 7 Coat the thraeds of the attaching bolts WIth gasket seatant and lO5Iall tham.
1 2 3 4 5
F-haad engine cylinder helld bah -tightening sequence (Sec 150)
Cylinder head (l-heltd engine) - Inltallatlon
Without using any gasket sealer, place the head gaskat in posit10n on the block. 2 lowar tha cylinder head into position. In81all the retaining bolts and lighten them to the spacified torque, in threa steps. following the seQuence shown in the accompanying illustration.
163
Fig . 2.87
2F-11
Engine extemal camponen" - InstallatIon
Install the clankcase ventilator valve assembly. Install the distributor (Chaptel 51_ Instell the crankshaft pulley and nut. Inltal1 the thermostat and water inlel (Chapter 3). Install the water pump (Chapter 3). 8 Insart the oil filler tube into the block with the bevelad and lacing away from the CTllnkshaft_ Tap the tube into place with a hammer. using a piece of wood to protect the and. 7 On F-helJd engines. install th a exhaust manifold, using a new gasket. and lighten the retaining nuts to the spacified torque B On L-head engines, Install tha manifolds, using new gaskets, and the crankcasa ventilator tuba.
2F
2F-12
1 2
Chapter 2 Part F L- and F-head four-cylinder engines
lower the 80gi081010 the vehicle and connect it to the t ransmission. Install the ffont engine mounts and remove Ihe lihing device. Connect the 8:J1heu.t pipe to the manilold.
3 4 Connecllhe spark plug, o~ and coolanllempersture sending unit, ignition coli and generltor wires. 5 Inslell the starter motor and connect Ihe wires.
6 Connect t he choke and throttle controls to Ihe CilrburBlor. 7 Connect the windshield wiper molor hose and install the air elaane!" assembly. Connect the fuel hose to the fuel pump. 9 Inst8111he cooling fan, the radiator end brace and the radlalor and
a
heeltel hoses. 10 Fill Ihe coohng 5ystem and crankcsse with the specified coolant and oil. 11 Connect the positive battery cable.
3 -1
Chapter 3 Cooling, • heating and air conditioning systems Contents Air conditioning components - removel lind installallon
. . . . . . . . . . . .. .
Air conditioning system - check
-
Antifreeze - general in forma tion Coolant levlIl check . . . . . . . .. . . . .. . . Coolant tempe rature sending unit - remollel end installation . . ... Cooling system check .......... . .. . .. .. . .
.. .
.
10 5 6 Chapter 1
9 Chapter 1
Cooling system se rvicing Idraining. f lush ing an d
refillingl
.. . .. .. .
. ..... .
Oril/ebel! check and adju stment .•......•.•...... General information . •.• . , ....•.•.•..•. Heater system - general info rmation . . . . .. . .....
Radiato r - remOllll1 lind installat io n . ..
Chapter 1 1
8
2
Radiato r - servic ing . . • . . . . • . . . . • . . . .. •. 7 Thermostat - removal and insta llation . _ . . . . . . .. .. J. Underhood hoses - chec k and replacament Chapler 1 Water pump - removal and installation. _ . 4
Chapte r'
Specifications
Therm ostat rat ing
3
F- and L-head four-cylinder engines V6 engine • In-line six~cylinder engines 1971 and 1972 ........ _.. 1973 1974 through 1986 en9ine ....... _.. 150 and 151 cu in four-cylinder engines . . .• . .• _.• .
190"F 190"F
Radiator cap pressure rating (all models)
15 psi
Torque specifications
Ft-Ib 15 1020 20 1025 15 1020
Nm 20 to 27 27 to 34 20 to 27
20 to 25 17 to 23 10to 18 10 to 18 22
27 to 34 23 to 31 14 1025 141025 30
12 10 17 6108 9 to 18
171029 8 to 11 121024
18 1033 4 25
6
va
Alternator adjusting bol t Generator adjusting bolt Fan-Io-hub bol t .•....•... Thermostat housing bolts F- and L-head four-cylinder engines. _. _. __. __. __ . __ . V6 engine. 150 cu in lour-cylinder and in-line six-cylinder engines . .•• . •.. .• V8 engine .••.•.•..•..•... 151 cu in lour-cylinder engine . . •. Water pump bolts F- and L-head four-cylinder engines _. V6 engine .......• . .... . ............ . 150 cu in lour-cylinder and in-line six-cylinder engines .. . .. . .. _. VB engine Water pump-Io-block . .. . .. . . Waler pump-lo-Iiming cover 151 cu in lour-cylinder engine . . ... . . . .. . .... .
195°F 205°F 195°F 195°F 195Q F
24 to 44
30
3-2
Chapter 3 Cooling, heating and air conditioning systems 2
Oeneral Information The cooling system on aU moder, eonslst, of II radiator, belt -driven waler pump,. fan, thermoltat and associated hoses. Coolant is circulated through the radiator tube. and is cooled bV eir passing through the cooling fins. The coolant is circulated bV II pump mounted on the front of the engine and turned by II crankshaft-driven drivebell. The fen is bolted 10 the waler pump pulley .md draws air through the r'dleter at low speeds and when Ihe lIehicie is stopped. A then'l'lostal allows the englfl8 to warm up quicldy by remaimng closed until the coolant in the radiator, heater, intake manifold and cylinder head is 8t operating temperature. The thermostat then opens, allowing lull circulallo n of coolant throughout the cooling system. Some models are equipped with a coolant e"pansion reservoir. As tha radiator coolant expands, a preasura relief valve in the cap allows Iha coolant to flow through the overflow hose into tha raservolr. When the system cools and contracts, there is a pre5lure drop and the coolant is drawn back into the radiator.
Fig . 3.'
Radiator - removal and Instalhl1lon
Caution: The engine must be completely cool when this procedure is performed. , Remove the radiator cap and the drain cock and dreln the coolant into a suitable container. 2 Disconnect the upper radiator hose and coolant overflow or recovery tube. 3 Remove the fan shroud hf so equippedl. 4 Remove Ihe upper radiator mounting screws or bolts. 5 On lIutomatic tnmsm;sslon-equ;pped models. disconnect and plug the transmission fluid cooler lines at the radiator. 6 Di sconnect the lowar radiator hose, remove the lower moun ting screws or bolts and lift the radiator carefully out of the vehicle. Refer to Section 7 for radiator servicing information. 7 To inSlall, place the radiator in position snd install the mountir'lg screws 01 bolts. B Install the Ian shroud (, f so equipped).
Typical engine compertment cooling system component layout Ive engine . hownl
, Flln 2 FIJn shroud 3 Overflow tube
4 Redietor Clip 5 Upper rlldiator hose 6 Water pump drivebelt
7 Wllte, pump 8 Heater hose 9 Thermosrat hOUSing
3-3 Fig. 3.2
,
F- end l -heltd lo ur-cylind8f' engine cooling Iy.lem co mponen .. - exploded vie w
Redietor cep
2 Redietor 3 Fan retaining bolt 4 Hose clamp 5 Upper redill tor hose
6 F.n 7 Fen spece, 8 Drivebelt 9 Double groove pulley '0 SinglB g,oove pulley WlIter pump bearing and shalt 12 Pipe plug '3 8earing 'etlliner spring 14 Wster pump body 15 The,mostet 16 GlIsket
"
"'8 19
20 21 22 23
Wet., outle, housing Gesket Wa tsr pump impeffer Weter pump seel Selll wllshsr Lower rlldie tor hose RlIdilltor drllin cock
' " T
, ;.,
•
13
?
.
.?-
~
rJ:\'
0
18 11
3
12
4
@
Fig . 3 .3 V6 envIne cooling 'yltem component' - e xploded vie w
,
,
Rediator cap
2 Hose cflJmp
3 Upper (inlet) redistor
~. \
J<
hose 4 Lo_r (outlet) radilltOf
"""
5 FlIn retaining bolt 6 WlI te, pump assembly 7 Cop
8 ThermDstllt bypsss
1.
'~ 15
'®
.!,
«
hose
9 Water outlet housing '0 Water outlet housing
"'2'3 14 15 16
"'9 '8
20 21
gasket ThsrrTlOstat Wilt., pump gllsket Dowel pin RlIdilltor shroud FlIn pulley FlIn specer Drivebelt Fon Fen bolt lock washer RlIdilltOf RlldilltOf dftlin cock
3
3-4
Ag. 3 .4
Six-cylinder in-line engine cooling
'yltem component. - exploded view
•
_. ..
....,
, '''"':;:,
Fig. 3.5
va
engine cooling system
component, - exploded view
"'UCOH~
CH .. _lR
HUll)
Ch apter 3 Cooling , heating and air c onditioning systems 9 Install the drain cock and overllow or recovery hose. 10 Remove the plugs Itnd reconnect the automatic transmiSSion Ifuid cooler lines to the radiator " Connect the hoses, fill the radiator with the specified coolant end Inllal! the cap. 12 Start the engine and allow rt to ~ach normal operatmQ temperature. then check carelullv for leaks 13 Allow the engine to cool completely, then chack the coolant level tadd more coolafll if reQuiredl.
3-5
8 Place the new Ihermostat in pOSIUon tbe sure to seat it securelv In the recess or groove). 9 Apply RTV'IYPI geskat sealan t to bot h sides of a new gesket and place it in position on the housing. 10 Allach the housing to Ihe engine and lighten Ihe retaining bolts to the specified torque. 11 Recontiect the upper radiator hose to Ihe thermoslat haUling. Reconnect any other hoses that were removed. 12 Fill the radistor to the specified level. 13 Start the engine. allow it to reach normlll operating temperature snd Check for leaks.
3 Th ermost at - removal end Inllellatlon Watll pump -
removal lind Inllallation
C.utlon: The engine must be completely cool when thiS procedure is ptJrform&d.
4
1 On all mod "Is, the thermostat is located under Ihe water outlet housing tlo which the upper radiator hose is allached, on Ihe front of the engme. If the thermoStat is functioning propetly, tht! temperature gauge should rise to the normal oparatlng temperature QUickly and then • tay therll, onlv rising above the normal position occasionallv when the engine gets unusuallv hot. II the engine does not rise to normal operating temperature qUickly. or if it overheats, the thermostat should be removed and checked or replaced. 2 Remove the radiator cap, Ihen drain coolant from Ihe radiator until the lovel is below the level of the thermostat. 3 Remove the upper radiator hose from Ihe water oullet or housing On some models it Will be necessary to remOlle the intake manifold or thermostat bvpass hoses from the housing to facilitate remollal of the hOUSing. 4 Remolle the retaining bolts, grasp the housing firmly and sepal ate it hom the engine. 5 Note Ihe pOSItion of Ihe thermostat so the nJ w one can be in· .talled in the same direction. 6 lift the thermostat ' rom the engine. 7 Use a gasket scraper to remove all traces of gasket material from the housing and the engine Rasket mating surfaces.
Cllutlon: The engine mus' be completely cool when t his proc&dure is perfOlmed. Drain the radiator coolant into a SUitable container. Oisconnect the negative battary cllble from the battery. 2 If so equipped, unbolt the fan shroud and separate it f rom th e radiator. 3 Oisconnect the hoses from the water pump. 4 Remove the drivebeills) and fan allemblv. 5 Some models may require the removal of lOme air conditioning components to prOllide access to Ihe water pump (Sect ion 101. 6 Unbolt and remove the water pump. It mav be necassary to grasp Iha pump securely and rock it back-and-forth to break the gasket seal. 7 Use a gaskat scraper 10 cle an all traces of gesket me terial from the water pump and engine surfaces. 8 Note: Some la tal six-cylinder models use II ser,wntine ddvebelt which drives the watef INmp In the I'II\VtSe of normlll rota tion. RflPlacement watel pumps and fans fOf these vehicles must be of the correc t type and fifE! mafk&d REV Of REVERSE. 9 Apply fI thin coat of RTV-tyPB gasket Maler to the new gasket and 10llsllil on the water pul'Tlp. Place the pump Iota posit ion and secure " wllh the bolts Make sure the accessory brackets are installed in their
3
FIg,3. 6
15 1 c ubic Inch four-cylinder engin e cooling SYl tem components - e . ploded view
VIICOUSOAIV. U," ! .. ~ .. VY D\lTY t;OOlllOO USn"'OI'IlVI
3-6
Chapter 3 Cooling, heating and air conditioning systems
original positions. 10 TIgnten the water pump bolts to the specified torque. " Inslall the engine components in the reverse order of removal. 12 Adjust all drivebelU to Ihe proper tension IChapter 1). 13 Connect the negative battery cable and fill the radiator with the specified coolant. Stan the engine and allow it 10 idle until the upper ,.dietor hose gets hot. Check for leaks. With Ihe engine hot Icap It!1I removed). fill the radiator with more coolant miltlVre until the level i, 112·inch below the bottom of the filler neck. Install the radiator cap and check the coolant level periodically during the r'l8l1t few mile. of driving. adding coolant ' I necessary.
6
Air conditioning syltem - check
Maintenance consill' of keeping the system cherged with refrigerent, the compressor drivebelt tensioned properly and meking sure the con· denser is free of leaves end debris. Do not use II screen in front of tM condenser beeeuse fr wiN resrric r rM eir "ow. The receiver/drier features a sight gless which provides e visual check of the refrigetant le\lel. A continuous slream of bubbles In the gless Indlcetes the system is not cha rged properlv with refrigerant. Check the sight glass with the engine running at a fast idla and with the eir conditioning controls se t for mell' imum cooling. Have an assillant cycle tha fan blower switch from OH to High. If a short buret of bubbles appears when the switch is turned on snd disappeare when it is turned oH. the system is ploperlv c~rged.
Fig . 3 . 7 The tece!\ler/dryer (light gillS arrowed) is located In the right front comer of the engine compartment ISec 5) If no bubbles are observed, the system is empty and mUSt be taken to a deeler or properlv equipped shop for recharging. Caution: Any work on the air conditioning system should be do". only after the system has been diSCharged by a deeler service depart· ment or properly equipped shop. Some components, such as Ihe com· pressor, cen be unbolted and moved OUI of Ihe wav fOI Becess pur· poses with the hoses lIill connectea ,Section 10).
VIEW INDICATED BY ARROW
Fig. 3 .8
1 2 3 4
e.tV model Uhrough , 971) CJ -5 and CJ -6 hAtar and defrolter
He"rer assembly Hose clamp Delroster nozzle Air duct screen Air duct and hellte, coller Air duct inteke tube 7 Hose clemp Straight hot weter hose 9 Heater tube elbow
•• •
10 Heater hose support brecket 11 Defroster hose 12 Hot water hOlst/l 13 Heate, nipple 14 Reducing bushing Inverted flaf6d tube nut Tube nut COnmte tof 17 Heater control tube
" "
,.
/'Ifill/fir conuol tube
19 Clip 20 Grommet 21 thlroster bushing 22 Heat distributor assembly 23 HealtH control tube
24 2' 2' 27
Heater control tube Heatar control assembly Fuse holder assembly Control panel-to-heate, Bowden wire 2. Blower end e;r fnlet assembly
3-7
Ch apter 3 Cooling, heating and air conditioning systems 8
Antifreeze -
general Information
It il recommended that the cooling sYltem be filled with a w.ter/ethylene glycol b(lsed antifreeze solution which will give protection down to .lle.sl -200F (It elilifTles. This provides proleclion egeinst corrosion .nd Increases the coolant boiling point. When handling antifreeze. do not spill it on the vehicle's paint, Blnce it will cause damage II not removed immediately. The cooling system should be drain ad. flushed end refilled (It laast I!\I8ry other year. Tha use of antifreeze solutionl for parieds of longer thsn two years IS likely to cause damage and encourage the formetion of rust and scale in the system. Before adding antifreeze to the syStem, check all hose connections .nd the lightness 01 the cylinder heed boits. since antifreeze tendS 10 Harch OUI and leak through ellen Ihe mOil minute openings. The exact miKlure of antifreeze to water which you should use depends upon the reletive weather conditions. The mixture should contain at leBst 50 percent antifreeze. The mixture should never contain more th.n 70 percent antifreele.
5 Any neeespry radiator repairs should be performed by a repulable radia tor repair shop.
8
Heater I Vl tem - general Informetlo n
These models are equipped wi th heater/defroster units which use a blower motor to circulete lir through. duct system under Ihe dash . Engine coolant directed by valves through Ihe heater core provides heel for the system. Air Is drawn th rough the cowl intake into the heater core Ind duct system. A system of doors conttols air mi xture and movemenl within Ihe ducts. The various svstems used are basicelly similar and component replacemen t can be accomplished with simple hend tools end the help of the .ccompanying illustretions. AJw~s disconnflCt (he "flgatiVfJ baltery cllb~ before begi""i"g work. Also, prior to removing the heater core, the cooling system should be cold to avoid the possibility of burn •. Drain the coolant level to below tha heater core.
9
Coolent temperature .. ndlng unit - ramoval end inst.llatlon
7 Radiator - lerv lclng The radiator should be kept free 01 obstructions such as lelNes. paper, insects, etc. which could affect cooling efficiency. 2 Penodically Inspect the radiator for bent cooling fins. signs of coolant leakage and cracks around the upper end lower tanks. Carefully Itraighlen any bent lins. using Ihe blade ola screwdriver. 3 Check the filler neck sealing surface for dents, which could affect the seahng effectiveness of the radiator cap. Check the pressure rating of Ihe cap and have it tested by a service Itatiq.n. 4 The radiator can be f lushed liS described In Chapter 1.
Caution: The t!flgi"e must be completely cool whe" this procedure is performed. 1 II Ihe COOlant temperature sending unit has been determined to be faulty, ob tain a replacement . 2 Disconnect the wire from the unit. 3 Apply le.lant to tha I hreads of th. replacement unit. 4 Use a wrench to remove the old unit and immediately install tha new one. Because the unit threads into e coolen! passage, there will be some coolant spillage. Check the IlI\Iel after the replacement ha. been Installed.
HEATER
A IR OUC T
,
HEATER
OEFROSTER NOZZLE
OEFROSTe.1
HOS'
Fig . 3 .9
Heater and detrolt.r .ssembly 11973 through 1977 modelal -
exploded view 15ft 8 1
3
3-8
".cSt
SCREW
~
BLOWER
CLAMP
/
~
\
HOSE
CLAMP
'CAM':"'~I :::;,
, ~_
I . . :'~::~;O"
.HEATER HOUSING
Fig. 3.10
Heater an d defroster IISSllmbIy !1978 through 1981 models) - .lIploded view ISec 8)
Fig. 3.11 1982 and later medel hSClter . aSSB mbly components - ell: ploded view (Sec 8)
Chapter 3 Cooling, heating and air conditioning systems
3-9
PANEL
DRAINAGE HOSE_--\ HOSE
,,~,
\ DUCT
'
, "'-
CONTROL~
FRESH AIR VENT
Fig . 3 .12
later mc:Jdel lir inteke eilimbly components -
IlIploded view (Sec a)
3
FIg. 3.13
10
F· Ind L-held eng)ne coollnt tlmparatura sending unit location (Sec 9)
Air conditioning components - removel and Installation
Caution: The 8;r condirioning sysrem is under high pressure end should be discheryed by e deafer sarvice dep8rtment or air conditioning technician before any work is performed or hoses disconnected. Some components cen be unbolted and moved out 01 the way to provide access with the hoses still connected. Do not stretch or pinch the hoses during these operations.
Fig. 3.14
va engine elr conditioning compressor installation (Sec' 0)
drive belts. Remove the <merna tor adjusting bolt and upper mounting bolt and loosen the lower mounting bolt. Remove the idler assembly. Remove the retaining bolts and separate the compressor from the engine. 6 On 1981 through 1983 si:x.-cylinder models using the serpentine drivebelt. remove the drlvebelt and alternator. Unbolt and remove the compressor from ,he engine mounting bracket. 7 Installetion on all models is the reverse of the removal procedure. Adjust the drivebelt tension and have the air conditioning system recharged. Connect the negative battery cable.
Compressor 2 Disconnect the negative battery cable from the battery. 3 Have the system discharged. disconnect the lines and plug the openings. 4 On VB models, disconnect the comprassor clutch wire and loosen and remove the drivebelts. On some models it will be necessary to remove the alternator and the coii. Unbolt the compressor and mounting bracket and remove them as an assembly. 5 On six-cylinder models, remove the compressor and alternator
Condenser and receiver/dryer assembly 8 With the system discharged, drein the radiator, remove the fan shroud and radiator (Section 2) and disconnect the pressure line from the condenser. Make sure all disconnected lines and hoses are plugged. 9 Remove the retaining bolts and tilt the bonom of the condenser toward the engine. 10 From under the vehicle. disconnect the evaporator hose at the receiver/dryer.
BLOWER MOTOR _~~_ _
I
BLOWER HOUSING
UPPER HOUSING
Lj-
,NSUCATOR
LOWER HOUSING
I TEMPERO~T~N~B
CONTR
,I I
DRAIN _ _ _ _ TuaE
\
~NEL
LOUVER
Fig. 3 .15 Evllp..... ....... "or housing an d related compo nents - ellp loded v w ISec 101
"
Chapter 3 Cooling, heating and air conditioning syst em s
3-11
11 Remove the condenser and receiver/dryer assembly from the vehicle. 12 To install, place the condenser in position and connect the evaporator hose to the receiveridryer. Install the retaining botts and connect the pressure line to the condenser. 13 Instell the radietor, fan end shroud. 14 Fill the radiator with the specified coolant end have the air conditioning system recharged.
COMPRESSOR I DL ER MOUN T ING BRACKET
Receiver/dryer 15 Remove the condenser as described above and disconnect the evaporator and condenser lines at the receiver/dryer. 16 Remove the screws and separate the receiver/dryer from the condenser. 17 Installation is the reverse of removal. Fig. 3.16 Typical 49-state In·llne six-c ylinder air conditioning co mpreasor installation ISec 10)
SC :EW I 4 1 ~ FIg.3. 17
Evapora tor housing panel installatlon (Sse 101
Evaporator housing assembly 18 With the system discharged, disconnect the inlet line from the compressor and the receiver/dryer-to-evaporator hose. 19 Remove the hose clamps and the dash grommat retaining screws, followed by the evaporator housing-to-instrument panel and mount· ing bracket screws. 20 lower the housing from the instrument panel and pull the hoses th rough the opening. 21 The evaporator assembly components can now be removed . The blower motor can be replaced without discharging the air conditioning system. 22 To install, push the hoses up through the grommel opening and then push the grommet into placa. Install the screws. 23 Raise the evaporator into position and install the retaining screws. 24 Install the hose clamps and the grommet retaining screws. 25 Connect the receiver/dryer-to-evaporator hose and inlet-tocompressor line. 26 Have the system recharged .
3
•
4-0
Chapter 4 Fuel and exhaust systems Contents Air filter replacement . . . ..•..•... . . .Chapter 1 AutollteIMotorcraft 2100 and 2150 carburetors (Va anginal-overhaul and adjustment ....... 13 Carburetors - application . . ... _ . ................ 7 Carburetor choke cneck ~ate models only) •.••.......... Chapter 1 Carburetor mounting torque check • • •.••.••...•...... Chapter 1 Carburetor - removal and installation ...•..•...... . 9 Carburetor - servicing .•.....•.••. . . . • . . . . . . . B Carter BBD carburetor [in-line six-cylinder engine)- overhaul and adjustment . . ... ........ 14 Carter YF carburetor (F- and L-head four-cylinder engines)overhaul and adjustment . • . . • . • . . • . . •. •.. .••..•. 10 Carter YF carburetor [in-line six-cylirn::ler engine)- ovemaul arn::l adjustment ... . . _ . • . . • .. . ..•........... 11 Carter YFA carburetor (ISO cu in four-cylinder engine)overhaul and adjustment . . . ••.••••• _. .. 16 Engine idle speed adjustment . _ . . . .• _.... Chapter 1
Exhaust heat valve check Exhaust system - check and component replacement Fuel filter replacement . . Fuel 'Ines and hoses - check and replacement Fuel pump - check .....
Fuel pump - general information Fuel pump - removal and installation
Carter YF Carburetor (F- end L-heed four-cylinder engines) L·head engine -
3/8 in 5/16 In 5116 in 17/64 in 118 in 17/64 in 118 in
Rochester 2G carburetor Non-emission controlled Float level . . . . . . . . • . • . . • . • . . . . •. . ...•. Float drop . . . . • . ••• . . . .. . ••.. Accelerator pump rod edjustment .•• .......• ,_ . • Initial idle spe6d adjustment screw setting .....•.• _ . • . Imtial Idle fflIxture screw setting •..•...••.•. Daahpot setting. Emission controlled Float level . Float drop . . . ..... . Accelerator pump rod adjustment ..•. . . , .. _ . Inilial idle speed adjustment screw selling ........ _ . Imtial idle mix/Ure screw setting .•.•..... . ........ Dashpot selling. . . . . . . . . . . . • . • . • .. . ...•......
19 .Chapter 1
6 4
3 5
Chapter 1 Fuel system check Fuel tank - removal and installation 17 18 Fuel tank - cleaning and repair 1 General information . . . . .. .. .Chapter 1 Oil bath-type air cleaner service . Rochester 2G carburetor (V6 engine) - overhaul and adjustment .. 12 Rochester 2SE and E2SE carburetors (15 1 cu in four-cylinder engme) - overhaul"and adjustment 15 Throttle linkage - check and adjustment 2
Speelflutlons
floet level CJ-2A, CJ -3A . .... ... . ........ . CJ-38, CJ-5, CJ-6 ..... . F-heed engine Inon-emission controlled) Float lavel Early {CJ·28) . . . . . . . .. . ..... . Late (CJ-38, CJ-5. CJ-6 Dashpot aetting.. ..• .. F-head engine (emission controlledl Float level . .. . •••. Dash pot setting.
Chapler 1
1·3/32 in 1-7 /8 in 1·5/32 in 3 turns in 2 turns out 118 In 1-5132 ,n 1-7 /8 in
1-5/32,n 3 turns in 2 turns out 118 In
Chapter 4 Fuel and exhaust systems
4-1
Carter YF carburetor (in-line six-cylinder engine) Float level 1973 1974 through 1978 Float drop 1973 1974 through 1978 Initiel choke plate-tO-air horn cleerance Fast idle cam setting 1973 .............................. . 1974 through 1978 ...... . Choke unloeder ......... . Automatic choke setting Standard .. Altitude compensator equipped ..... . ...... ........ . Oashpot setting ... .. ... . Fast idle speed ...... , . Idle drop Automatic transmission . Manual transmission
0.450 in 0.476 in 1.25 in 1.38 in 0.215 in Inde)( mark (choke closed) 0.195 in 0.275 in 1 notch riCh 2 notches rich 0.075 to 0.095 in 1600 rpm 25 rpm 50 rpm
Autolite/ Motorcraft 2100 and 2150 carburetors Dry float lavel 1973 ............................... . 1974 and 1975 ..... . ......... . 1976 through 1979 .. . .. . .. . 1980 and 1981 Wet float level 1973 1974 and 1975 1976 through 1981 • Initial choke plate clearance 1973 through 1975 ........................ . 1976 through 1978 Manual transmission Automatic transmission 1979 through 1981 Manual transmission (49·sta tes) .............. . Automatic transm ission (49·stetesl ...... . . California lall models) . Fast idle cam setting 1973 through 1975 . 1976 through 1978 Manuel transmission • Automatic transmission 1979 through 1981 Automatic choke setting . Oashpot 1973 and 1974 1975 .. 1976 1977 ........ . Choke unloader .. Bowl vent clearance .......... . Fast idle speed ..
3/8 in 0. 4 00 in 0.555 in 0.375 in 3/4 in 0.78 in 0.93 In
0.130 In 0.130 in 0.140 in 0.125 in 0 .128 in 0.120 in 0.130 in 0.120 in 0.1261n 0.1131n 1·1 /2 to 2·1/2 notchea rich 0. 140 in 0.095 in 0.075 in 0.093 in 0.250 in 0. 120 in 1400 to 1600 rpm
Carter BBD carburetor (In-line six-cylinder engine) Float level Vacuum piston gap 1977 and 1978 1979 through 1986 Initial choke plate clearance 1977 and 1978 .................. . 1979 Carburetor numbers 8185, 8187. 8195 Carburetor numbers 8 I 86, 8 I 88 Carburetor number 8229 1980 Carburetor numbers 8256. 8257. 8253 Carburetor number 8254 .................. . Carburetor number 8255 ............. . Carburetor number 8277 ..
0.25 in 0.040 in 0.035 in 0.128 in 0.140 in 0 .150 in 0.128 in 0.128 0.120 0 . 140 O. 116
in in in in
4
4-2
Chapter 4 Fuel and exhaust systems
Carter BBD carburetor (In-fine six-cylinder engine) (continued I 19B1 through 1986 Carburetor numbers 8302, 8303, 8306, 8307, 8338,
8383,8384 .
. ....... .
Carburetor number 8311
Carburetor number 835' . Carburetor number 8349 ...
Fast idle cam sening
. ........... . ... . •. .•... . ..... .
............••.. • . . .... • •.•..
Choke cover I.tting 1977 and 1978 . 1979 1980 Carburetor numbers 8253, 8254, 8255, 8256. 8257 Carburetor number 8277
1981 1982 and 1986
0.140 in
0 .120 in 0.130 in 0.128 in 0.095 in 2 notches rich 112 to 1- 112 notches rich
2 notches rich 112 to 1· 112 notches rich 1 notch rich
Carburetor numbers 8338, 8339, 8360, 8362, 8364,
8367,8383,8384 . . . .. ..... . .... . Carburetor number 8349 ......... . Carburetor number 8351 .... . Choke unloader . . .. . ...•.. Accelerator pump setting
1978 .......... . 1979 and 1980 Carburetor numbers 8185. 8187, 8195. 8253, 8255. 8256 .... . . . . . . . . . . . . . . . . . ........ . . . Carburetor numbers 8186, 8188. 8229, 8254, 8257, 8277 ...... , ....... , .......... . 1981 through 1986 .... , .......... , ........ . Fast Idle speed seltlng 1977 lind 1978 1979 Cllrburetor numbers 8185, 8187. 8195 (automaticl Carburetor numbers 8186,8188,8195,8229 (manuan .. 1980 Carburetor numbers 8253. 8255, 8256 (au tomatic) Carburetor numbers 8254. 8255, 8257, 8277 (manual) •. 1981 through 1986 Carburetor numbers 8302, 8338, 8349, 8360. 8362. 8383 (automatic) .....•.•..••. . .•.••. ,. CarburetOl' numbers 8303, 8311, 8339, 8349. 8351. 8364.8367. 8384 (manuaO .•..•.••.•..
1 notch rich 2 notches rich - 1/2 to + 1· 1/2 notChes rich 0.280 in 0.440 in 0.470 in 0.520 in 0.520 in 1700 rpm 1600 rpm 1500 rpm 1850 rpm 1700 rpm 1850 rpm 1700 rpm
Rochester 2SE carburetor Floet tevel
1980 1981 Carburetor number 17081790 ......... . Carburetor number 17081791 ........... • , .•... 1982 . . . . . . . . . . . ,. . . . . . . . . . . . . . . . •..•. . 1983 . . . . . . . . . . . . .. ....... ... . .... . . Pump stem height 1980 . .. .. ....... ... ..•...... .•. . •...• . 1981 through 1983 . . . . . .. . ........... . Fast Idle cam adjustment 1980 1981 1982 and 1983 Air valve link Primary vacuum break 1980 1981 . 1982 and 1983 Unloader 1980 and 1981 1982 and 1983 Secondary lockout 1980 . . . 1981 through 1983 Carburetor number 17081791 Carburetor numbers 1708190, 17082380, 17082381 Choke coil lever plug gauge Carburetor numbers 17080685. 17081791 . ...... . . Carburetor numbels 17081790, 17082380. 17082381
0.216 in 0.208 0.256 0.169 0.216
in in in in
0.500 in 0.128 in
10" 25" 10"
2" 20" 19"
"" 3." ""
0.004 to 0.012 in 0.85 in 0.050 to 0.080 in 0.85 in 0.050 to 0.080 In
4-3
Chapter 4 Fuel and exhaust systems Fllsi idle speed 1980 . 1981 Carburetor number 17081790 ...... . Carburetor numbar 17081791 1982 and 1983 ...... . .. _ .. . . ...... .
2400 rpm 2400 rpm 2600 rpm 2400 rpm
Rochester E2SE carburetor Floet !evel 1980 and 1981
7 /32 In 0 . 1691n 0 .138 in
1982 1983 Pump lIem haight 1980 and 1981 1982 lind 1983 Fast idle cam adjustment Air valve link .. .. . ... Primary vacuum break 1980 and 1981 1982 lind 1983 Unloader 1980 and 1981 19B2 end 1983 Secondarv lockout 1980 and 1981 .. . ... . 1982 and 1983 . . . ... . Choke coil lever plug glluge 1980 lind 1981 1982 . . . . .. .. 1983 Fast idle speed setting 19BO through 1982 .. 19B3 . . . . . . . . .
0 .500 in 0 .128 in
10' 2' 20' 19'
32' 34' 0.004 to 0 .012 in 0 .050 to 0 .080 in 0.085 in 0.050 to 0.080 in 0.085 in
2400 rpm 2500 rpm
Carter YFA carburetor Float level .... . ........ . Float drop . . . . . . . . .. .. Initial c hoke plate clearance ... Choke unloader ... Fast idle cam setting index ... Fasl idle speed ....... .
0.570 to 1.250 to 0.225 to 0.370 In 0.160 to
Torque specifications
Ft· lb
V6 ........... . 150 cu in four-cylinder and
in~ine
six-cylinder
. . . . .. . .
151 cu in four-cylinder . .. . . .. . .. . ..... . . . Fuel pump bolts F- and l-head four-cylinder . . ............ . ..... . .. . .. . .
R
.. ............... . .. . .. .. .. . . . .
150 cu in four-cylinder and in-line SIX-CylInder ..... . ..... .
W .............. . .. . ................ . ..... . ... . .. . lSI cu in four-cylinder . . ............... . . . ... .. ...... . Exhausl pipe-to-manifold nuts F- and L-head four-cylinder .. . .. . .. . . . . . . . .. . . .. ..... .
V6 ... ....
. ........ .
150 cu In lour·cylinder and in-line six-cylinder
VB ............ ....
O.I90io
200 """
Carburetor-to-intake manifold nuts F- and l-head four-cylinder
VB ..•........
0.630 in 1.50 in 0.255 in
. ...... .
151 cu In lour-cylinder
10 10 12 12 10
Nm
to to to to to
16 15 19 15 16
14 to 22 14 to 21 16 to 25 16 to 21 14 to 22
13 to 10 to 13 to 13 to 12 to
17 15
16 to 23 14 to 2 1 17 10 25 18 to 25 16 to 24
29 15 18 15
to to to to 34 to
19 19 18 35
20 28 25
40
39 to 21 to 24 to 21 to 47 to
47 .5
27 3B 34
54
Fig. 4 .1 Typical early model fuel systsm components
, FUlIIIiM-to-carouf.tof 2 Carouf.tof 3 Choke cable 4 Throttle pedal 5 FUlII tank 6 FUlII pump
\
-
--,/
I
4
4-4
Chapter 4 Fuel and exhaust systems
Fig. 4 .2
TypIc:M Nrty mod. throttle IInb". component layout Is.e 21
The fuel .v.tem con,i,ts of the fuel tank, I fu el pump which drewl
fuel to the carburetor, end "soci.ted ho ••• , lines and 'litera. Thee.hBOlt system il composed of pipes, heet shields end mufflers for carrying 8xhaust gl.8. from the angina 10 the rear of tha vehicle. Later model, incorporate catalytic COfMIIrtera inlo the system to reduce axhaust emission •. Catalytic cOflVertet-equipped vehicles mult usa unleaded fuel only_
2
Thronl. linkage - cn.ck and adjustment
Periodically check the full length of the throttle linkage for wear,
IooI.ne.a and damage. 2 With the angine off. observe tha linkage IS an assiSlant push•• tha throttle pedal down completely and rele"81 it. Watch tha action of the linkage to determine If there af, any worn joints or bent link• . Make sure the return aprlngs are securely sea ted and not Itretched. Replace any worn or damaged component. with new ones. 3 Adjust the linkage If the thronle does not open completely. 4 Lubricate the linkage joints with a few dropi of engine oil or spray lubricant••uch graphite or .ilicone.
Fig. 4 .3 F-head four-cylinder engine fuel pump compOfients - eaploded view (Sec 3)
.s
3
Fuel pump - gen....1 Information
All models are equipped with mechanic al fuel pumps which Ife ac· tuated by an eccentric on the camshaft. latar model pomp. are sealed .nd mu.t be replaced as a unit if • fault develops. early model pump. can be di•••• embled . although it ia alway. a good Idea to replace a faulty unit with a new one. The fuel sediment bowl or fitter screen on early model fuel pumps ahould be removed and claaned periodically. early model F- .nd l -head engines are equipped with fuel pumps which incorporate a v.cuum pump to actuate t he windshield wipers.
4
I Retlline' 2 Bowl 3 Spring 4 Filter 5 Gasket 6 Pump body 7 Gasket 8 Valve essembly 9 SCfftWS
F~
pump - check
c.utlon: GIJ!J()linlJ is extremtlly fllJmmlJblfl and axtrJI plfJclJutions must ba taken whan working on any pIJrr of the fual system. 00 not smoka er allow open flamtls or ba", light bulbs naar the work a"'IJ. Also. do not work in a garega If a na turel gas·type appliance with a pilot light ;s plfJsent.
IU
11 12 13 14 15 16 17 18
"lIlve nouslfIll Valve assembly Sc,ews Di8ph,agm lind oil sllill Pump body Cam leve, spring Cam lever GIJsket Cem lever pin and plug
Inspect the fuel pump for signs 0 1 leakll\j& If the pump hilI! is leaking. replace it with a new one (Section 5 ). If the inlet or outlet connection. are leaking. tighten or replace them as nece.sary. 2 To check the fuel pump operation. disconnect the outlet hOle end foute it into 8 . ultable container .. 3 Disconnect and ground the ignition coil wire and turn the engine over with the . tarter while observing the fuel pump outlet hose. The pump should produce definite spurts 01 luel. If it does not or if very linle fuel is saen. replace the pump With a new nn'l.
5
Fuel pump -
r.movel and Installation
Caution: GIJsolinlJ Is exttemely flammeblfland extra pfftcautlons must
C hapter 4 Fu el and exhaust systems be teken when working on sny pert of the fuel system. Do not smoke or ellow open flames or bara light bulbs near tho work area. Also. do not work in a garage if a natural gas-type appliance with a pilot light is present.
4-5
porates an altitude compensation device. 6 The 151 cubic-inch four·cylinder engine is equipped with tha Rochaster 2SE on 49-stata modals and the electronic E2SE version in California .
Place clean rags 01 wadded-up newspapers undel the fuel pump
to catch any gasoline which may·be spilled duling removal. 2 To remove tha pump. detach tha fuel inlet and outlet (as well as ell othel) lines. Use two wlenches to plevent damage to the pump and flale-type finings. 3 Remove the mounting botts, pump and gasket. 4 Remove all lIaces of gasket material flom the pump and engine mating surfaces. 5 Coat both sides of a new gasket with RTV-type gasket sealant and place the gasket in position on the pump. 6 Placa tha pump in position. making sure the actuating lever seats securelv against the camshaft eccenllic. Install tha mounting bolts. 7 Connact tha luel and other hoses or lines to the fuel pump. S Stan the engine and check carefully lor leaks.
S Fuel lines end hoses -
check and replacement
Caution: Gasoline is extremely flammable and extra precautions must be taken when working on any part of the fuel system. Do not smoke or allow opan flames or bare light bulbs nesr the work sres. Also, do not work in a gaflJge if a natuflJl gas-type applillnce with s pilot light is present. All fuel lines, hoses and connections should be inspected periodical' Iy for damage. leaks and deterioration. 2 Check all rubber hoses for cracks. splits and signs of hardening. Partially kink or squeeze the hoses to see if cracks appear. Grasp each flose at the points of conn ection to maka sure !,pey aren't brittle or hardaned and move them back-and-forth to check for cracks. 3 Look for areas where oil or grease have accumulated, wipe the hose clean and inspect for damage. Petroleum products break down the rubber and make it soft. 4 Measure the length of each hose to be replaced and cut off a short (no more than 1/2-inch) piece from the and. With the length measurement information and sample pieces, go to an automotiva parts store to obtain replacement hose. The sample piace will make the selection 01 the proper inside diameter hose easier. It is a good idea to obtain replacement screw-typa hosa clamps to replace any original equipment clamps which are bent or damagad. 5 Inspect the metal fuel lines to maka sure they aren'l bent, dented, cracked or leaking. Chack the flalJl nut connactions for tightness. using twO wrenches to avoid damaga to Ihe line and component. Be careful not to overtighten them. Replacemant luelline and finings are also available at automotive parts stores. A tube-flering tool will be necessary lor installing the fittings. Use only steel tubing for the luel lines, as copper or aluminum tubing does not have enough durability to withstand norma! operating conditions. 6 If only one section of a metal fuel line is damaged, it can be cut out and replaced with a piece of rubber hose. The rubber hose should be cut four inches longar than the section it is replacing so there will be about two inches of ovarlap between the rubber and metal tubing at either end of tha section. Screw-type hose clamps ahould be usad to sacure both ends of the repaired section. 7 If a section 01 matalline longer than six inches is being removed , use a combination of metal tubing and rubber hose 50 the rubber hose lengths will not be longer than ten inches. Caution: NeVf!r use rubber hose within four (4) inches of any part of the exhaust system.
7
Carburetors - appHcatlon
The models covered in this manual were equipped with a variety of carburators over their long production life. 2 The Cartar YF carburetor was used on the F- and L-head fourcylinder and some models of the in-line six-cylinder engine. 3 Later models of the six-cylinder engine were equipped with the Cartar BBD carburetor. 4 The V6 engine was equipped with the Rochester 2G carburetor. 5 V8 engines use the Autolite/Motorcratt 2100 and the very similar 2150 carburetor. The 2150 differs from the 2100 in that it incor-
8
Carburetor - eervlclng
Caution: Gasoline is extremely flammable and extra precautions must be teken when working on any part of the fuel system. Do not smoke Of allow open flames or bare light bulbs neer the work eres. Also. do not work in e garage if a natural ges-type lJpplience with a pilot light is present. A thorough roed test and check ot carburetor adjustments should be done before any major carburetor service. Specifications for some adjustments are listed on tha vehicle Emissions Control Information label found in the engine compartmant. 2 Some performance complaints directed at the carburetor are actuallya result of loose. misadjusted or malfunctioning engine or electrical components. Others develop when vacuum hoses leak, are disconnected or ara incorrectly routed. The proper approach to analyzing carburetor problams should include a routine check of the following areas: 3 Inspect all vacuum hoses and actuators for leaks and proper instelletion (see Chapter 6. Emissions control systef7l$l. 4 TIghten the intake manifokLnuts and carburetor mounting nuts evenly and sacurely. 5 Perform a cylinder compression test ,Chapter 1). 6 Clean or replaca tha spark plugs as necessary IChapter 1). 7 Check the condition of the spark plug wires ,Chapter 1). B Inspect the ignition primary wires and check the vacuum advance operation. Replace any defective parts. 9 Check the ignition timing with the vacuum advanca line disconnected and plugged . 10 Adjust the carbutetor idle mixture as described in the appropriata Section. 11 Check the fuel pump operation as described in Section 4 . 12 Inspect tha heat cont rol valve in tha air cleaner for propar opara· tion (reler to Chapter 1). 13 Remove the carburetor air tiltar element and blowout any dirt with compressed air. II the filter is ax tremely dirty, replace it with a new one. 14 Inspect the crankcase vantilation systam (see Chapter 81. 15 Carburetor problems usually show up as flooding , hard starting, stalling. severa backfiring, poor acceleretion and leck of response to idle mixture screw adjustments. A carburetor that is leaking fuelandfor coverad with we t- looking deposits definitely needs attention. 16 Diagnosing carburetor problems may require that the engine be started and run with the air cleaner removed. While running the engine without the air claener, it is possible that it could backfire. A beckliring situation is likely to occur if the carburator is malfunctioning. but removal of the air cleane r alone can lean the air/fual mixture enough to produce an engine backfire. 17 Once it is determined that the carburetor is indeed at fault, it should be disassembled. cleaned and reassembled using new parts where necassary. Before dismantling the carburetor. make sure you have a carburetor rebuild kit, which will includa all necassary gaskets and internal parts, carburetor cleaning solvent and soma means of blowing out all the internal pass ages of the carburetor. To do the job properly. you will also need a clean place to work and plenty 01 time aM patience. 18 It should be noted that it is often easier end more conveniant to replace the ca rburetor with a rebuilt unit insteed of overheuling the original carburetor. If a rebuilt carburetor is purchased. be sure to deal with a repu table auto parts store.
9
Carburetor - removi l end Instillatio n
Caution: Gasoline is ex tremely flammable and extra praceutions must be taken when working on any part of the fuel system. Do not smoka or ellow open f/en'/fJs or bare light bulbs near the work area. Also. do not work, in a garage If a natura' gas-type eppliance with a pilot lighr is present. 1 Remove the air cleane r assembly. 2 Mark or tag ati hoses and lines connected to the carburetor to simplify rainstatiation.
4
4-6
Chapter 4 Fuel and exhaust system s
3 Disconnect the throttle linkage, vacuum hOS6S, choke linkage snd other hoses and wires from the carburetor. 4 Remove the retaining nuts and lift the carburetor from the manifold. 5 Carefully clean the gasket surfaces of the carburetor. spacer or gasket and intake manifold. Inspect them lor nicks and damage which could affect carburetor-Io-manifold sealing. Replace the gasket or spacer with 8 new one if it is bent, damaged Of distorted. 6 Place the carburetor and spacer or gasket In position and install the retaining nuts. Tighten the nuts evenly lind securely in II crisscross
pattern. 7 Connect the throttle linkage,. vacuum hoses, fuel lines and other hoses and wires to the carburetor. S Install the air cleaner assembly.
10 Carter YF carburetor IF- and l-head four-cylinder enginea) - overhaul and adjustment Remove tne fast idle connector rod by prying tne pin spring and
Fig. 4.4
clevIs CliP Tree . 2 Remove the air hom and bowl cover reteining screws and tne choke tube clamp assembly . 3 Remove ,ne air nom and gasket. 4 Remove tne ball cneck valve retainer ring. turn the air hom assembly over and tap it lightly to dislodge tne ball cneck valve and retainer. 5 Loosen the throttle shah erm-to·shaft locking screw end remove the erm end pump connector link. 6 Remove the retaining screws and lift the diaphragm assembly from tne carburetor body. 7 On eerly modela, remove the pump intake strainer housing with tne tip of a knife blade. 8 Witn the air horn inverted. remove the pin and float . Turn the air horn over and catch the neadle pin and seet. 9 Remove the metering rod jet end low speed jet. Do not attempt to remove any of the pressed·in components sucn es tne nozzle. pump jet or air bleed. 10 Remove the mounting screws and separate tne flange assembly from the body.
Carter YF ca rburetor IF- and L-haad four-cylinder anginas) - exploded vlaw (Sac 10)
1 Choke shaft end lever
2 Screw 3 Choke spring lever 4 Screw end washer
5 Choke plete screw
.
•
Choke pl8te 7 Screw IJnd washer 8 Air horn Needle selJt gasket 10 Needle spring and seat 11 Needle pin 12 Float pin 13 Float 14 Gaskat 15 Pump spring Metering Ipd pin 17 Pump link 18 Pump spring retainer Vacuum diaphragm spring 20 Screw and washer 21 Diaphragm housing 22 Diaphragm 23 Body 24 G8Sket 25 Idle port plug Throttle body laver and shaft assembly 27 Pump link connector 28 Throttle shaft arm Screw and washer 30 Throttle valve 31 Throttle valve screw 32 F8st idle arm 33 Adjusting screw 34 Body flange plug 35 Clevis clip Idle adjusting screw 37 Idle screw spring 38 Fest idle connector rod Pin spring 40 8ell check lIalve 41 8all check lIalve retainer 42 Metering rod jet 43 Low speed jet 44 Metering rod 45 Metering rod spring Inner pump spring 47 Pump spring retainer 48 Choke and throttle bracket and clamp assembly
•
"
,.
2' 2.
3. 3.
4'
..
Chapter 4 Fuel and exhaust systems 11 Remove the idle adjustment acrew, spring, Idle port rivet, throttle lever assemblv, washer. last idle arm, throttle plale end shah assembly. 12 Pry out the seal retainer and remove the throttle shah seal. Do not remova the vacuum passage orifice, which Is prassed into place. 13 Remove the choke valve screws, unhook the choke spring and slide the Ihaft out of the housing 14 The carburetor is now completelv disessembled and should be cleaned and Inspected for wear. After the carburetor components have been loa ked in lolvenllo remove dirt. gum and carbon deposils, IheV should be rinsed In kerosene and dried, preferablv wilh compressed air. Do not use a wire brush to clean the carburelor and clean all passagel with compressed air rather than wire or drill bits, which could enlarge Ihem. Inspect the throttle and choka . h.fts for grooves, wear end eltcessive looseness. Check the throttle and choke plates for nicks and smoOlhness of operation. Inspect the carburetor body end com· ponents for cracks. Check the floats for leakl bV submerging them in water which has been heated to just below Ihe boiling point. Leaks will be indicated bV the appearance of bubblel. Check the float arm needle contact surface for grooves. If the grooves ara light. polish the needle contact surface with crocus cloth or steel wool. Replace the floats il the shafts are badlv worn. Inspect the gasket mating surfaces for burfl and nicks. Replace anV distorted springl and all screws and bolts with stripped heads. 15 Install the throttle shaft seal and retainer in the flange casting. 16 Inltell the fast idle arm, weIher and lever auemblv on the throttle Ihaft. Slide the Ihalt Into position and inllall Ihe throttle valve. 17 Inslall Ihe idle port rivet plug and the idle adjusting screw and spring. 18 Attach tha Ilange assemblv to the body casling. using a new geskat. 19 Inllall the low speed jet alsemblv . 20 On earlv models. install Ihe pump inlake strainer in the pump diaphragm housing and press it carefullv inlO th&recess. Replace Ihe slfainer with a new one if it is aven slightlv damaged. 21 Install the pump diaphragm assemblv in the housing and then in· Iiall Ihe lower diaphragm spring and relainer. 22 Inltall the pump lifter link, metering rod arm. upper pump spring and relainer , followed bv the metering rod iel.
4-7
23 Insen the screws Into the housing while making sure the edgel of the diaphragm are not wrinkled. Lower Ihe assemblv into place and tighlen the screWI evenlv, following a crillcross pattern. until they ere lecure. 24 Inl18lllhe throttle shaft seal, dUlt seal washer and Ihaft leallpring on tha st]aft. 25 Inltelilhe pump conneClor link In the throttle arm alsemblv and then inltall the shaft arm assemblV on Ihe throttle sheh. Guide lhe connector link into the pump lifter Hnk hole. Make sure the linkage does nOI bind in anv position . If Ihere II binding, loosen the clamp Icrew in Ihe throttle arm. adjult il sllghtlV Ind retighlen the screw. 26 Inltall Ihe pump check disc, retainer and lock ring . 27 Initailihe metering rod end pin . pring and connect the metering rod Ipring. 28 Make lure Ihe flat on the metering rod arm il parallel to the flat on the pump liher link. Seat Ihe throttle and preis down on the uwer end 01 the diaphragm shaft until the diaphragm bottoms In the vecuum chamber. Push down on the melering rod to make sure it Jeats pro· perlv in the calting. If it does not seat properlv or seats before the rod arm makes contaci with the lifter link flat. adjust it bv bending the lip on Ihe metering rod arm. 29 Inltall the needle seat and gasket assemblv, needle I10at and pin. The stop shoulder on the flost pin must be facing away from the cerburetor bore. 30 Wilh the float bowl inverted, allow Ihe weight of the floal to rell on the needle and spring. Mellure the diltance between the float and cerburetor body as shown in Ihe accompanying ~Iultration to deter·
t i
;/ Fig . 4 .5
Earty modal YF carburetor IF·.mt L-nead four.c.,llnder engl""1 'Sec 10)
, Main noule 2 Merering rod
Fig. 4.6 YF carbUletOl' [F- and L·hMd four.c.,linder engine., hlgh·speed clrcult and metering rod essembly
[See 101 , Nozzle 2 Metering rod 3 Pump lifter link 4 Metering rod arm essembly 5 Oiephragm shaft 6 Upper pump spring
., MJrnp diaphragm spring
8 Diaphragm IIssemb/y 9 Chllmber
10 Metering rod jet " Cllrbvretor cesting 12 Cerburator bore
Fig. 4 .7 YF clrburetor IF· and L·heed four.cyllnder englnesl float level meuurement [Sac 101
4
4-8
Chapter 4 Fuel and exhaust systems
mine the float level. Compere this measurement to the Specifications and adjult as necessary by bending the float arm lip. 31 Instalilhe air horn and choke tube assembly. TIghten the retaining screws in a crisscross pattern. sterting with the center screws. 32 Slide the fast idle connector rod into position with the offset portion on the top and the pin on the outside. Instsll the fest idle connecting rod spring.
33 Install the carburetor. 34 With the engine at normal operating temperature adjust the idle
speed . 35 Turn the mixture screw in or out. as required, until the smoothest idle is obtained (you may have to readjust the idle speedl.
'1 Carter YF carburetor Un-line .rx-cyllnder englnel - overhaul and adjustment Remove the cerburetor as described in Section 9.
Overhaul 2 On models equipped with a choke pulldown motor, remove the retaining screws, disconnect the choke pulldown link and remove the motor assembly, disengaging the link from the choke shaft lever. 3 Ramove the choke retaining screws, housing retainars, spring housing assembly, gasket, baffla plate and fast Idle link. 4 Remove the screws securing the air hom assembly to the carburetor and remove the air horn, gasket and solenoid bracket assembly. 5 With the air hom assembly upside down, remove the float pin, float and lever assembly. Turn the air horn assembly over and catch the needle pin, spring and needle and remove the needle seat and gasket. 6 Remove tha air cleaner brackat. File the staked ands off the screws retaining the choke plate and remove the screws and plate. Remove the choke link lever and screw. 7 Turn the main body casting upside down and catch the accelerating pump check bell end weight and !if equipped) hot idle compensator. 8 Remove the mechanical bowl vent operating lever assembly from the throttle shaft. 9 Loosen the throttle shaft screw and remove tha arm and pump connector link. 10 Remove the fest idle cam and shoulder screw. 11 Remove the accelerating pump diaphragm housing screws snd lift the pump diaphragm assembly out as a unit. 12 Disengage the metering rod spring from the rod and remove the rod from the arm assembly. Sketch the location of eny washers which may be used in shimming the springs so they can be reinstalled in the same locstion. Compress the upper pump spring and remove the spring retainer, spring and pump diaphregm assembly from the housing. 13 Use the proper size jet tool or screwdriver to remove the main metering rod jet and low speed jet. 14 On models with a temperature-compensated accelerator pump, remove the bleed valve plug from the main body with a punch. Loosen the bleed valve screw and remove the valva. 15 Remove the retaining screws and separate the throttle body from the main body of the carburetor. 16 File the staked throttle plale retaining screws and remove the screws and plate. Slide the throttle shalt and lever assembly out of the carburetor. Be sure to note the location 01 the ends of the spring on the throttle shaft to simplify reinstallation. Also be sure to note Ihe position 01 the idle limiter cap tab to ensure propElf reassembly. After removing the cap, count the number of turns required 10 lightly seat the nee· die and make a note of it for reference during reassembly. 17 The carburetor is now comple lely disassembled and should be cleaned and inspected for wear. After the carb uretor components have been soaked in solvent to remove dirt, gum and carbon deposits, they should be rinsed In kerosene and dried, preferably with compressed air. Do not use a wire brush to clean the carburetor and clean all passages with compressed air rather Than wire Of drill bits, which could enlarge them. Inspect the throttle and choke shafts for grooves, wear and a)(cessive looseness. Check the throttle and choke plates for nicks and smoothness of operetion. Inspect the carburetor body and components for cracks. Check the floats lor leaks by submerging them in water which has been heated to Just below the boiling point. Leaks will be indicated by tha appearance of bubbles. Check the float arm needle contact surface lor grooves. If the grooves are light, polish the
Fig. 4.8 Early model F-head engine YF carburetor adjustment screw locations (Sac 10)
•
, Idle speed screw 2 Fuel/eir mixture screw
needle contact surface with crocus Cloth or steel wool. !'Ieplace the ftoals if the shafts are badly worn. Inspect the gasket mating surfacli for burrs and nicks. Replece any distoned springs and screws and botte which have stripped threads. 18 To begin reassembly, install the throttle shaft and lever assembly in the throttle body flange. Make sure the bushings and springs al1l in the positions noted during disassembly. Position the throttle plste on the throttle shaft with the notch aligned with the slotted idle port Install the throttle1:Jlete, using new screws. Tighten the screws so thev are snug and then move the throttle plate around to make sure that it doesn't bind in the bora. Make sure that the idle speed screw is backed off when checking the throttle plate fit. Reposition the plate II necessary, tighten the screws and stake or peen them in place. Instal the idla speed screw and turn it out the seme number of turns recorded during removal. 19 Attach the mein body to the throttle body flange and tighten the screws evenly and securely. 20 Install the low speed jet and main metering rod jet. 21 Install the pump diaphragm in the pump diaphragm housing. Place the pump diephragm spring on the diaphragm shalt end housing assembly. Install the spring shim weshers. spring retainer, pump liltar link metering rod erm end spring assembly and upper pump spring on the diephragm shaft. Depress the spring and install the upper pump end spring retainer. 22 Assemble the metering rod on the metering rOd arm so the rod hangs down. Place the looped end of the metering rod spring around the upper end of the rod . Align the diephragm pump with the housing, making sure the holes are lined up. Instell the mounting screws to main· tain allanment. 23 Insert tne screws into the housing while meking sure the edges 01 the diaphragm are not wrinkled. Lower the assembly inlo place and tighten the screws evenly, following a crisscross pattern, until they all secure. 24 Place the pump bleed valve and washer in position end install the retaining screw. Install a new welch plug, using a 1/4-inch lIat drift punch to seat it. . 25 Install the fast idle cam and shoulder screw, throttle shaft arm and pump connector link and tighten the lock screw. 26 Install the E-clip. spacer, wave wesher and bowl vent ectueting lIMIt and tighten the retaining screw. Instell the hot idle compenaetor valve end acceleretor pump check ball and weight. 27 Insert the choke sheft assembly through the choke housing. Slip the pulldown link lever into the air horn and tighten the retaining screw. 28 Place the choke plate in position on the choke shaft and install the retaining screws snugly, but not tight. Check the choke plete lor bin-
4-9
Fig. 4 .9
60
Lala model YF carburetor
61
~
1 Alf horn
2 Chokfl plste 3 Screw 4 Shaft 5 PIston
6 Pi" 7 Solenoid and braCKet
••
10 II
®:JW;
Coil housmg screw Coil housmg r&rainer Choke covel Coil housing gllsk81 Co;1 housing b(Jlfle pf(fte UPPfJ( pump spring retainer
12 13 14 Upper pump spring 15 Metering rod firm 16 Diaphragm lifter link
11 Washer Diaphragm spring Diaphragm housing screw 20 DlaphrtJgm housmg 21 Washer 22 Spacer
" "
23 24 25 26 27
2' 2.
30 31 32 33 34 35 36 37
Di8phfagm
Discharge ball weight Dischllrge ball Body flange sere w Fast ,dIll cam Fast idle cern screw Mllin body
Body gashr Idle screw "'ruler ctJp Idlt! mllt:tl/le screw
Spring Throttle body WlJsher
A'm
Screw Pump connector Imk • 39 Throttle shaft arm
3.
40 41 42 43 44 45 46 47 4. 49 50 51 52 53 54 55 56 57 58 59 60 61 62
[='.-.
Rel'mtlt Forked 'ever Metering lad iet
l:::a..2J
®
Jf ~® I C5f
..
::§, ®--6 ®-~~ ~ l
,)JD
\"®®
®-,",~8 ~ A 'iJ, 1 , -Je"'""
4
Low $P~ 161
Fiollt Float pm Needle pin Nlltldle spring Nl!JI!Jdle, needle sellt, gesket Chake cann6C tar rad Chake Cann6Ctar rad retainer Lever Metarlng rod A,r hom gesket Sprmg Lifter BeHcr.nk Ret.1n1N Spring Shart ." ham screw Lang IIlr horn screw A i, cleaner brack.et Scre w
,
1 ~
31
Chapter 4 Fuel and exhaust systems
4-10
ding, then tighten the screws and peen or Slake them in place. 29 In51alilhe needle s8at and gasket In the air horn. Turn the air horn over end install the needle, pin spring, needle pin, float end lever assembly and fl081 pin. Adjust the II08t ISV1l1 85 described below. 30 Align the bowl vent flapper valve with the vent rod, making sure that the spring is properly instilled on the vent rod shaft. Install Iha spring retainer. 31 Place 8 new air horn gasket in position and install the air horn, makIng sure that the mechanical fuel bowl vent IngBgBs the forked actuating lever. Install the solenoid bracket. 32 Install the choke coil hOUlIing (with the identification marks feeing oull. the g8sket and baffle plate. The thermostatic spring must engage the choke lever tang and not be stopped by the bellie plate retaining tab (if so equipped). Set the choke housing to the indell mark specified on the Emissions Control Information label and tighten the screws. 33 Install the air cleaner bracket and last idle link. 34 Engage the choke pulldown link with the choke laSllever and the pulldown diaphragm rod. Plilce the diaphragm bracket on the air horn and install the attaching screws. Connect the pulldown vacuum hose to the diaphragm housing. 35 Adjust the carburetor to the specifications listed on the Emissions Control Information label.
I-lOat level adjustment 36 Invert the air hom and measure the clearance from the top of th. float to the bOllom of the air horn with a suitable gauge.. Thelir hom should be held at eye level during this procedure and the float lever should be resting on the needle pin. 37 Bend the float arm as necessary to bring the float level within the specified range. Do not bend the tab at the end of the float arm as this prevents the float from striking the bottom of the fuel bowl when the bowl is empty.
Float drop adjustment 38 With the carburetor air horn held upright and the float hanging fret, measure the distance from the air horn gasket surface to the top of the end of the float . Compare this float drop measurement to the Specificetions. 39 To adjust, bend the tab at the end of the float arm.
Metering rod adjustment 40 With the air horn removed, back out the idle speed adjusting screw until the throttle plate is closed tightly in the bore. 41 Push down on the end of the pump diaphragm until it bottoms. 42 To edjust the metering rod. hold the diaphragm down and turn ths
• AOJUSTING SCREW
Flg.4.10 YF carburetor Un-line sill-cylinder engine' float leve l adjustment (Sec 11)
Fig . 4.11 YF carburetor lin-line sill-cylinder englnel float drop measurement and edjustment (Sec 111
PRESS OOW"
~
'""'> '"''
Fig.4.12 Metering rod adjustment IYF carbu rator) (Sec 11)
T
--..
,.,
FIg.4.13 Initial ckoke plate adjustment and gauge fabrication lYF carburetor) (Sec 11 1
lEvE~
IN
W
Fig. 4 .14
YF carburetor ckoke unloader adjustment (Sec 11) Fig . 4 .1 5 FIBt Idle urn linkage adjustment (YF carburetor! (Sec 11 I
Ch apter 4 Fuel and exhaust system s aDJustment screw until the metering rod just bonoms In the body casting e5 shown in the accompanying illustration. Tum thaadjustmant scraw clockwisa one additional turn for final adjustmant.
Initial choke plate-to-air horn clearance adjustment 43 Bend a 0.026-inch diamelar wire al a 90" Ingla approximataly 1I8·mch from tha end to labrielle a wire gauge IS shown in the ac· companying illustration. 44 Opan the throttle partially and close Ihe choka plate to position tha choka piston at tha top of its Dore. 45 Hold tha choke plata closed, relaase tha throttle and insert the wire gauge inlo the piston slot and against the outboard slda of the piston bore. Push down on tha piston with the gauge until the bant end entera tha piaton Dora sial. Keep Ihe gauge in place and push on the choke pillon lever 10 move the piston up and lock tha gauge in position. 46 Measure the choka plate lower edge-to·"r hom wan clearance with a gauge or dlill bit shank. 47 Use a naedle·nose pliers 10 carafully bend the choka piston lever and adjust tha clearanca. oecreasa the clearance by bending the lever toward tha piston and Increase it by bending tha lever away from the piaton. 48 Install tha choka baffle plate, gasket cover Ind retaining screws. On 1973 through 1977 models, adjust the cover to the specified setting and tightan the ratalning scraws. On 1978 models, turn the cover countarclockwlse toward tha IIch side and tighten one rataining screw. The linal edJustment is made aftar the last idle clm linkage is adjusted.
Fast idle cam linkage adjustment 49 Placa tha fast idla scraw on the sacond ~tep 01 tha last idla cam and again~t the shouldar of tha high step. 50 Check the clea ranca between the lower edge of the choke plate and tha air horn well using a gauge or drm bil shank. Compare this mlasurement 10 the Specifications. ~1 To adjust, band the choke plata conn8(:ting rod until the proper choke olata·to·air horn wall clearance is achieved.
Choke unloader adjustment 52 Hold the throttle complately open white pushing tha choke plate toward tha closed position. Measure the clearance between tha choka plate lower edge and the air horn wall with a drill bit shank. Campara this maasurement to tha Specifications. 53 To adjust, bend the unloader tang which contacts tha last idle cem. 54 After adjustment, operate the throttle to make sur. the linkage does oot bind. 55 Thera should be a 0.070·inch clearance between the unloader tang .nd carburetor body with the throttle completaly open after adjustment.
Bowl vent adjustment 56 Disconnect the emissions ceniSfer hose Irom the carburetor and Ittach a n.w piece of clean hose to the Dowl vent. 57 Place the throttle on Ihe high step 01 the fast idlll cam and blow
FIg . 4.16 Checking cholta unloed.,·to·body clearance ISec 11)
4-11
into the hose. There should be considarable reslsUlnce felt, indicating Ihe ... ent is closed. 58 Move tha laat idle cam until the throllie .crew drops to the third step of Ihe cam. 810w Into Ihe hose to v.rify that Ihe Dowl vent hIS opened and that pressure I. reli.ved . 59 Repeat the t.st procedura to verify that the Dowl vent ia properly adjusted. 60 II no pressure is fett with the thronle on the high step of the cam, the vent is not closing. If the pressure is not r.leas.d on the third step of tha cam, the vent la not opening. Adjuat by bending the forked .nd 01 the lavar.
Altitude compensator adjustment 61 Some model. are equipped with an attitude compensation device which faatures a compenlation cirCUit that prevents a too-rich mixture at altitudes above 4000 feet. The altitude compensalor is adjusted manually. 62 When operating the vehicle aDo1/8 4000 feet, use a screwdriver to turn the compen.eto. plug counterclockwise approximately 2-1/2 turns to the outer (high-attitude) seat position. 63 Balow 4000 feet, adjust the plug clockwiae to the inner seat position. 64 The plug has two positions; all the way in now altitude) or ell the WIJII out (above 4000 feet). 00 not adjust the plug to any other polition.
Idle speed and fuel/air mixture adjustment 65 Pnor to idle speed or mixture adjustment the follOWIng precautions must be taken and conditions exist:
Parking brake securely Sltt Transmission must be in D,ill8 (autOfTlllticl or Neutral (menuel) Engine at normal operating temperature Air cleaner instlllled Adjust idle spHd before IIdjusting the fuellllir mll(fure The engine must not be idled for more tfllln three minutes /if the adjustment tekes more than rhree minutes. run the engine lorane mmute at 2000 rpm in Neutral)
66 Attach a tachometar to tha engine, following the manufactur.r's instructions. 67 Turn the idle speed adjustment screw to obtain tha specified idle speed. 68 II the carburator is .quipped with a lolenoid, turn the nut on the plunger to obtain the specified idle speed and tighten the locknut IiI so equipped). Disconnect the solenoid wire and adjust the ce.bure l or kHa speed screw to achieve an idle of 500 rpm, ttl.n reconnect the wire. 69 On non·catalytlc convener·equlpped vehicles, the manulactur.r recommends that mixture edjustments be made using speciallnfrerad analyzer equipmant. Consequently, these modals should ba taken to your dealer or a properly .quipped shop lor mixture adjustment. Th. Idle drop proc.dure, described below, is used on catalytic con ....rter· aquipped modala. 70 Adjust tha idle mixlura screw to the luR rich stop tcoumer-
Fig. 4.1 8 Oa.npot adjlultment IYF carburatorllSec: 1 " Fig. 4. 17 YF c erburetor adjullment Icrew Iocltlons (Sec 11)
4
4-12
(HOlef HOUSING
THElMokAt COVII ~~~
All HOIN SCReW
Uf'l:,t--~~~~~~;"-tJ PlAtE
THEIMOn,,' covn GAS«U
,
COil COVEl InAIHn
flAIflD lUIE CONNECTOR
I'OWU
fUH INLET STUINEI ·
LEVEl
NHOIE SEAt G ... SUl
flO'"
,
VALVE cu,~ COUNHISHAFT
'UM'
'IN S,IING
flO'"
HINGE
I
"N~~
•
flO ... , VENTURI CLUSTER CENUI SCREW
I,
VENTURI CLusnR OUTER KREW
I CENHI self ...... GASKET
I
OUTU $ClEWS lOCkWASHEI
I
VENTURI CLUSTfI
DISC HUGE GUIDE
VENIUR. CLUSTU GASUT WHl
~a 'I OISCHARGE ~
INs!.T~ ~DISCH"'.GE
.ALl S'IING .A' (
I'OWU VAlVE,e
powu
VALVE GA5IC'ET _ ....
"""'IN MElfllNO JET
PU .... , RETUIN SPIING
~ I,...J ,"0" .00
-
fAST IDLE CAM
[
ATTACHING selfW
- . .JjJ--~
"LOAT 10Wl
THIOTTLE lOOT GASKET
~d
~
P\
'HlonlE 100'1'
IDLE STO' $ClEW
,
IDLE
T-IODY SCUWS lOCKWA$HU
Jt-
THIOrTle 100Y SCIEW
GA~'~ Fig.4.19 Roche'ter 2G carburetor (V6 engine' - exploded view ISec 121
4-13
Chapter 4 Fuel and exhaust systems
--
..........1 '0 ""IIII!
.001 Of .. OI
A._tDGI
QII~'O"
-~
-~
GASo:l1 ...... "
10 10"000 QII HQ.o,.
A FIg.4.2 1
, Fig. 4.20
,
B FIoII ad)uatment (2G c.-burltor) ls.t 12)
A Fiolt level
•
2G clrburltor IIr hom .crlW tlghtlnr.g sequence (Sec 12)
(counterclockwise). note Ihe position 01 the screw head slots and remove the pllstic limilar ClpS. This can be accomplished by threading • No. 10 sheel metal screw mto the cenlar of thl cep. 71 Connect a tachomeler Ind perform thl idle speed Idjustment procedure described abov.. 72 Beginning al !he full rich posiuon (Slip 701. tum the mixture screw clockwise in me leon direction untillhere is an rpm drop. Turn Ihe screw in a counlerclockwise direction unlil the highest rpm previously anained is obtained. This is the lean bast idle. 73 Turn the idle mixture screw unlil the specified Idle drop is reached . 74 If the final reading varias more than 30 rpm up or down from the idle speed specification. repeat the idle speed adjustment. 75 Install a new idle mil(ture screw ~miter cap wit. the eat of the cap against Ihe full rich stop. taking care not to alter the mixture setting.
D8shpot adjustment 76 Set the thtonle at the curb idle position. depress tha dashpot Slim completely and measure the stem-to-thronle lever clearance. Compare this measurement to Ihe Specifications. 77 To adjust. loosen the locknut Ind tum the dashpot untillhe specified clearance Is obtained.
Fast idle adjustment 78 Th. fast idle Idjustment IS made with the engine at normal operating temperature. the EGR valve and TCS solenoid disconnected and the last idle screw contactin 8 the second slip and against the shoulder of the high step of the last idle cam. Turn the fast idle adjustment screw to obtain the specified rpm setting. 12 Rochester 2G carburetor Ive .nginel - OYIrlIlullnd adjustmlnt
Overhaul Remove the fast idle cam retaining screw. then remove the cam from Ihe end of Ihe choke rod. The upper end of the rod cannot be removed until the air horn has been detached from the float bowl. 2 Remove the air horn attaching screws and lock washers. then lift oil Ihe air horn. 3 Remove the float hIOge pon and lift off the float. Th. float needle 8fId pull clip {where applicable) can now be removed from the floal arm. • Unscrew Ihe float needle seal and remove Ihe gasket. 5 Depress the power piston and release it to allow it to snap free. 6 Remove the pump plunger assembly and Inner pump lever from the .haft by loosening the set screws on the inner lever. 7 If the pump assembly is to be overhauled. break oil tha flattened • nd of the pump plunger st.m; the replacement pump uses a grooved pump plunger stem and retl ining clip. Aftlr removing th.lnner pump lever and pump assembly, remov. the outer lever and sh.h assembly from th. air horn. Remove the plastic washlr from the pump plunger .h.lt. 8 Ramov. th. gasket from the air horn. 9 Ramov. the fuel Inlet balli. lnelll to the nlldl. seat). 10 Taking care not to bend the choke shaft. remove the choke val ..... Th. ends of Ihe raleining screws may have to b. filed away to permit
8 Float drop
r.mova' of the screws. 11 Remove the chok. vllw shaft. Remove th. fast idle cam rod and lever from the shaft. 12 Remove tha pump plunger return spring from the float bowl pump well. then Invert the bowl and remove the aluminum ball. 13 R.move th. m.in melering jets, power vel .... and gasket from insid. the floal bowl. 14 R'move the thr.. scrlws which rellin the wnturi cluster; remow thl clusler and gasket. 15 Use a neldl.-nose plilrs to remove the pump disch.rge sPfing re tainer. then remev. the spring and check ball from the dischlrge passag" 16 Remove the three large throttle body-to·bowlanlching screWI Ind lockwashers. Remove th. throttle body and gasket. 17 Remove th. thermoJl.tlc chok. coil COVII (t!;lree screWI and re tainers) and gasket from th. choke housing. 00 not remove the cap b.lIl. from beneath the coil cover. 18 Remove the choke housing b.llle pleta. 19 From inside th. choke housing. remove thl two attaching scr.wI: remove the houllng and gasket. 20 Remove the screw from the end of the intlrm.diate chok. Ihlft. then remov. the choke lever from the sheft. R.move the inn., choke coIl lever and Ihlft essembty from the choke housing. followed by th. rubber dust se.l. 21 Funher disassembly is not recommended , p.niculany with rlgard to the thronl. v.lvel or shih. since it may b. impossible to reassembl. the valves correctly in rei Ilion to the Idl. discharge orifice.. If it i, necessary to ",move thl idle mixture neadl.., break off the pintle limitll caps (if so equipped) !hen count th. number of turnl requirld to bottom the needles and instill replacementlln e)(ICtly th. same poaIlion. New limiter capl should be Instlll.d Iftlt running adjullmentl have been made. 22 Clean all met.1 panl with solvent. 00 not immerse rubblt pert., plaslic pitts. diaphragm assemblies or pump plung.rs, because permanent damag. will result. 00 not probe th. jets with wire: instead. blow through them with clean, dry. compressed air. Examin •• 11 pertl for cracks. distortion. wear Ind other damage; repllce as nec.... ry. Discard all g.. k.ts .nd th. fuel inlet filter. 23 Assembly is eSSlntially the reverse of the diSlssembly procedurl. but the following points should be not.d: a) If new idl. mil(turl screws wire used. and the original letting was not noted. install the screws finger tight to seltlhem, then back off one (1) turn IS • prelimin.ry .djuSlm.nt. b) When instal~ng the rubber duat seal In the choke housing cavIty, the leal lip faces toward the carburelor aftlr the hOUling is instaliid. cl When Installing th. venturi cluller, make sure that. gask.t is instilled on the center SCrlW. d) Instell the choke valve with thel.tllrs RP or the pert number facing up. el Carry out floll level and floll drop chaco as specifi.d below. II Install and tight.n the lir hom screwl I I shown. gl After rlassembly, carry out th. adjuJlments listed below.
Float level me8surement and sdjustment 24 Hold the air horn assembly upaide down and meaaure Ihe distance from the air horn gasket surfaca to the top of thl float tOl. Compare this m.8Iurem.nt to the SpecificatIons and band the float arm as necessary to .dju...
4
Chapter 4 Fuel and exhaust systems
4-14 __ _
00
.. _ _ to_
~--
Fig . 4 .24 Dllhpot adjultment (2G carburetorl {Sec 121
- " ' y...... 1 Mn aOMO
Fig. 4 .23 20 carburetor ulamlll componantt {Sec 121
FIg . 4 .22 Accelerator pump edjustment {2G carburetorl {Sec 121
, 2 3 4 5
Fuel inlet Choke Choke cable breeker Idle speed adjusting screw Idle fuel mixtun screws
1 Throrrf(J fever
3 Dashpot
2 Plunger
4 Locknut
Float drop measurement and adjustment 25 Hold the air horn upright and mellure Ihe distance from the gasket surface to the bottom outer end of the float pontoon. Bend the fl081 lang to bring the measurement within the specified range.
Accelerator pump clearance measurement and adjustment 26 Un.craw the curb idle adjustment scraw lind completelv close Ihe throttle valves. Meesure from the top 01 the air horn ring to the top of the pump rod . Bend the pump rod to adjust Ihe clearance.
OIAPHRAGM ASSEMBLY
Curb idle and mixture adjustment 27 Connect I tachometer to Ihe engine. With the engine at normel temperature, the ail cleaner installed, the Ignition ti ming and dwell cor' rectly eet Ind ell emissions devices in working order, turn the adjust· ment screw until the idle is IS specified. 2a Adjust the idle miKture screws until I smooth iole is achieved. Re· ad}ust the idle speed as necessery.
•
SPRING
Dsshpot sdjustment 29 The dlmpot should be adjusted with the engine et normal operating tamperature and tha idle spaed Ind miKIUre correclly adjusled. With the engine at idle, loosen Ihe dashpol locknut and turn Iho dashpol assembly until thO plunger contacts the Ihrottle lever. Turn Ihe dash pot assembly 2-1/2 turns toward the throttle lever, depress the plunger and tighlen the Iocknul. Check the adjustment by opening Ihe throttle and allowing it 10 snap closed. There ehould be IpproKmetoly a two·second dalay before the throllie closes.
13 Autolltel Motorcreh 2100 and 2160 cerburel O... va englnel - overhaul Ind adjultment Fig . 4 .25
Overhsul , Bafole disassembly, cleln the eKterlor of the clrburetor with sol· vent end wipe it off using a lint-free rig . 2 Remove tha air cleaner anchor scraw and automatic choke con· trol rod retainer. 3 Remove Ihe air hom attaching screws, Iockweshers, carbu reior identification leg, lir horn and gasket. 4 Loosen the scraw securing the choke control rod to the choke shaft lever. Remove the choke control rod I ..d slide out the plastic dust seat. 5 Remove the choke pllte screws Ifter filing off the staked ends and remove the choke plate by sliding it out 0 1 the top ollhe air horn. Slide the choke sheft out of the sir horn. 6 Remove Ihe choke modulator assembly. 7 Fro m the automatic choke. remove the fast idle cem rote lnar. ther· mostetic choke spring housing. clemp end retainer. a Remove the choke housing assembly, gasket and fast idle cam end
Ch oke modulator assembly components (2 100f2 1S0 Clrburatorl lSec 131
rod from the last idle cam laver. 9 Use a screwdriver to pry the fl oat shaft retainer out of the fuel in· lat seat on Ihe main body. Remove the float. float 5hafl and fuallnlet neadla aS5embly. 10 Remove tha retainer end lIoat $hah Irom the float lever and remove the fuel liller bowl. 11 Remove the fuel inlel needle. seal filter screen and main jell. 12 Ramove t he booster venturi, metering rod assembly end gaskeL Tum the mllin body upside down Ind let the IccelerllOr pump, discharge weight and ball 1111 into your hand. 13 Disassemble thelih rod flam the bo05ter by removing the lilt rod spflng reta ining clip and spring and separaung the lilt rod assembly from the booster. Do not remove the metaring rod hanger from the lih rod .
4- 15
Fig. 4 .26 Autollte/M otorcraft 2100/2150 carburetor components - exploded view (Sec 131 I
2 3 4 5 6 7 8 9 10 II
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3I 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57
Compensator choke shaft Retainer Compensator choke valve Choke valve screw Compensatol choke rod Choke valve Choke shaft Air hom Air hom retaining screw (4) Air hom gasket Flollt shaft lelainer Flallt and lever assembly Floal shaft Needle leraining clip ClJfb idle adjusting screw CUlb idle adjusting screw spling ThloUle shafl and lever assembly Dashpot Oashpot locknut Dashpot bracket Dashpot bracket reteining sClew Adjusting screw Carliage Electric solenoid Mounting bracket Throttle velve retaining screw Throttle valve Needle end seat assembly Needle seat gesket Main jet Main body • Nylon valve Pump retum spring Pump diaphlagm Pump lever pin Pump cover Pump lod Pump lad reteiner Pump lever Pump cover retaining screw Fuel inlet fitting Powel valve gasket Powel valve Pawel valve cover gasket Power velve cover Pawar valve cover retaining screw ldla limitar cap Idle mixture screw Idle mixture screw spring Retllinel Retainer Fast idle lever retaining nut Fast idle lever pin Retainel Thelmostat choke shaft Fast idle cam rod Choke shield
4
58 59 60 6' 62 63 6. 65 66 67 68 69 70
"7273 7. 75 76
Choke shield letaining screw Piston passage plug Heat passage plug Choke cover retaining clamp Choke cover retaining screw Choke cover Choke co ver gasket Thermostat level letaining scre w Thermostat lever Choke housing retaining screw Choke housing Choke shaf t bushing Fast idle cam /ever adjusting screw Choke diaphragm Hose Link Screw Fest idle speed adjusting screw Fast idle lever
77 Fast idle cam
78 79 80 8' 82 83 8. 85 86 87 88 8. 90 9' 92 93 9' .5
Choke housing gasket Pump discharge check baD Pump discharge weight Boostff ventun' gasket Booster venturi assembly Air distribution plate Pump discharge screw Retainer Choke rod Gasket Compensation chamber Gasket Screw Aneroid Screw Choke lever retaining screw Choke plate lever Choke rod seal
4-16
Chapter 4 Fuel and exhaust systems
14 Remove the fol pin from Ihe accelerator pump cover, using 8
the idle screw limiter caps.
luilable punch. Retain the roU pin and remove the accelerator pump link and lod assembly, pump cover. diaphragm assembly and spring. '5 To remove the nylon Yalve from the accelerator pump assembly, grillSp it firmly and puH it out. Examine the ... alvI and, if the tip is broken oH, be sure to remove it from the fuel bowl. Discard the ... alve, 16 Turn the main body upside down and remove the enrichment valve cover and gasket. Using an eight -point socket, remove the enrichment valve and gasket. 17 Remove the idle fuel mixture adjusting Icrews and springs. Remove
18 Remove the fast idle adjusting lever assembly and then remove the idle screw and the spring f,om the leve,. 19 Before removing the throttle platel, lightly scribe along the Ihrottla shaft and mark aach plata fOI reinstallation in the proper bore. File off the staked ponion 01 Ihe thronla pleta screws before removing Ihem. Remove any burrs from the shaft after plata removal so that tha shaft can ba withdrawn without damage to the throttla shaft bores. Be raady to catc h tha mechanical high·speed cam located between the thrOttle plates when the shaft is removed.
F",. 4 .27 Removing the 2100(2150 carburetor float Ihaft rltaln., with I Icrewdriver (Sec 131
Fig. 4.30 A lockat wranch II ulad to ramova and Inl~. the enrichment vllve e ..embly 12100/2150 carburetor! ISec 131
Ag. 4 .33 Ellr/y model 2100/2150 Initial choke pilla clasllIoce adjustment (Sec 13)
FIg. 4 .28 2100/2150 carbu reto r float bowl compon.nt layout ISec 13) FIg .4 .29 Accelerator pump "nembly components 12100/2150 carburetor' [Sec' 3)
Fig. 4 .31
Meal urlng tha dry float laval 12100/2150 carburetorllSac 13)
FIg. 4 .34 Ltlrermodel2 100/21S0 inltiel choke platl cIN,.nce adjustment (Sec 13)
Fig. 4.32 Using a T-lcale to maasurl the 2100/2150 carburetor Wit flolt "v~ (Sec 1 3)
Fig . 4 .35
Initial choke plate .djustment on Iltltud. compenlator-equipped 2150 carbureto, ISec 131
Chapter 4 Fuel and exhaust systems 20 If an altitude compensator is instililed. remove the four screws at laching the assembly to the main body and remove the compensator assembly. Remove the three acrews holding the aneroid valve and separate the aneroid. gasket and valve. 21 Disassembly is no complete and all parts should be thoroughly cleaned in solvent. Remove any sediment from the fuel bowl and passages. taking care not to scratch any of the passages. Remove all tracas of gaskets with a scraper. 22 Reassembly is basically the reverse of disassembly. but note the following : al Check that all holes in new gaskets are properly punched and that they are free of foreign material. bl When installing a new nylon valve in the accelerator pump assembly. lubricate the tiP before inserting it into the accelerator pump cevity hole. Reech Into the fuel bowl with needle·nose pliers and pull the valve tip into the fuel bowl. Cut off the tip ahead of the retainer shoulder. cl Install the idle mixture adjusting screws by turning them with your fingers until they just contact the seat. then back them off two turns. Do not install the limiter caps at this time. The enrichment valve cover and gasket must be installed next as the limiter stops on the cover provide a positive stop for the limiter ceps. dl After installing the throttle plates in the main body. hold the assembly up to the light. Little of no light should be saen between the thronle plates and bores. Tighten and stake the throttle plate screws at this time. el Whefl checking the float setting. make sure that the nylon valve in the accelerator pump does not interfere with the float.
Dry float level measurement and adjustment 23 Press down on the float tab to raise tha float to a position where tha fuel inlet needle is lightly seated.
'
24 Use a scale of float level gauge to measure the distance between the fuel bowl machined surface and the flat surface of the float at the free end. Compare this measurement to the Specifications. 25 Bend the float tab to adjust. taking care to hold the fuel inlet nee die off the seat to prevent damage to the Viton-tipped needle.
Wet float level measurement and adjustment Clution: Because fuel vapOf"$ ere present during this procedure, make
sure a/l smoking materials are extinguished and that no ooen flemes present.
4-17
chined top surface to the surface of the fuel. This measurement should be made at least 1/4·inch away from any vertical surface to ensure accuracy. because the surface of the fuel is actually slightly higher at the edges. Compare the measurement to the Specifications. 30 To adjust the fuel level, bend the float tab up where it contacts the fuel if)let valve to raise the fuel level and down to lower it. 31 After adjustment. replace the air hom and gasket and run the engine for one minute before repeating the check and adjustment procedure. 32 Install the air horn lusing a new gasketl and air cleaner assembly.
Automatic choke adjustment 33 Loosen the choke cover screws and rotate the cover in the desired direction. The rich setting is to the right iclockwisel and the lean to the left (counterclockwise).
Initial choke plate clearance measurement and adjustment 34 On standard models, rotate the choke cover 1/4·turn counterclockwise toward the rich setting side. On altitude compensatorequipped models, open the throttle and rotate the choke cover until the choke plate is closed. On all models. tighten one choke cover retaining screw. 35 On standard models. disconnect the choke heat inlet tube and align the fast idle speed adjusting screw with the indeM (second) step of the fast idle cam. On altitude compensator models, close the throttle with the fast idle speed screw on the top step of the cam and apply vacuum to the choke diaphragm to hold it against the set screw. 36 On standard models. start the engine (without moving the accelerator linkagel and turn the fast idle adjusting screw counterclock · wise three 131 full turns. 37 On all models. measure the clearance between the choke plate lower edge and the air horn wall with a gauge or drill bit shank. Compare this measurement to the Specifications. 38 After setting the choke to the specified position. tighten the choke cover screws. 39 On early models. adjust by bending the modulator arm as shown in the accompanying illustration. On later models, the clearance is adjusted by turning the set screw located at the bottom of the modulator. On altitude compensator-equipped models. turn the adjustment screw on the back of the diaphragm to attain the specified clearance. 40 Shut off the engine and connect the choke heal tube. Reset the choke cover only after adjusting the fast idle cam linkage.
a(8
26 With the vehicle parked on a level surface and the engine at nor· mal operating temperature, remove the air cleaner assembly and anchor screw from the carburetor.27 Remove the air horn retaining screws tlnd the carburetor identification tag. Start the engine with the air horn and gasket in place and allow it to idle for one minute. 28 Turn off the engine and remove the air horn and gasket. 29 Use a scale to measure the distance hom the carburetor ma-
Fast idle cam adjustment 41 Push down on the fast idle cam lever until the fast idle adjusting screw is in contact with the index (secondl step and against the shoulder of the high step. 42 Measure the choke plate lower edge-to-air horn wall clea rance and check it against the Specifications. 43 Turn the fast idle cam lever screw to adjust the linkage. 44 Adiust the automatic choke and tighten the retaining screws.
FIg. 4.37 210012150 c arburetor chot. unload.r adju.tmant ISec 131 Fig. 4 .36 Fast Idla eam Iinkege adjustment 12100/2150 carburetorl 15 ec 131
Fig. 4 .38 Choke unloader fa.t Idle cam clea rance 12100/2150 carburetorl 15ec 131
4
4-18
Chapter 4 Fuel and exhaust systems
Choke un/oader adjustment 45 Hold Ihe thronle completelv open with pressure IIpplied on the c hoke plate toward the closed position.
46 Measur. the choke pIlle lower edge-Io·alf horn wall cleararn::e end
compare II to the Specificalions. 47 Adjust the clearance by bending the choke unloader lang. 48 Aher adjustment, open the throttle unullh, unlo8def tang is directly below the lest !dIe cam pivot and check the clearance against the Specificatlona. Adjust neeallary and heve en assistant push the thronle pedal down , Make lure the Ihfollie linkage opens completely and, if it does not. !KIlu" the throttle cable bracket or remove any 8X· cess pedding Irom under Ihe Iloor mal.
N~
UVEII
.s
Accelerator pump stroke adjustment 49 The accelerator pump OV8nr.vellever has lour adjustment holes and Ihe pump le.... r hal lwo. DUling normal operelion, Ihe pump rod should be in Ihe Ihlrd hole of Ihe ovet!ravellever and Ihe inboard hole of Ihe pump lever. 50 In eXlremelv hOI wealhellhe pump rod can be moved 10 Ihe second hole of Ihe overuavellever and. in very cold weather. to Ihe fourlh hole 10 provide ImoOlher acceleralion. 5' Remove Ihe operaling rod Irom Ihe retelning clip 10 move I he rod to a different politlon on the OI/'tIrtnrvellever. MOI/'tl the clip 10 the deSired position. insert tha rod end Inep the clip over the rod.
Fig. 4 .39
Dashpot adjustment
Accelerltor pump Itroke adjustment [2' 0012150 c arbu'lt o~ (Sec ' 3 )
52 With the Ihronle in Ihe idle position, depress Ihe dashpot stem and meaSlJre the Item-to -thrOllle cleeranca. Compare the measurement to the Speclflcltions. 53 To adjUst the clelrance, loosen the locknut Ind turn the dashpot.
Fast idle speed adjustment 54 Connect a tachometer to the engine and sel the laS! idle speed with the fest idle adjUsting acrew agiinsl the index mark llocated on the second step) 01 the fist Idle cam. The engine must be at normal operating temperlture Ind the EGR Ind TCS solenoids disconnected. Turn the IdjUltment screw to obtain the specified selting.
•
Idle speed adjustment 55 The idle speed mUlt be adjusted with the engine at normal operating temperlture, the Ilr cleaner essemblv Installed end the transmission in Dnve (Iulomltlc) or Neutrll (menuel). Caution: Since the automatic triJnsmission must be in Drive during adjustment. make sure the park· ing brake is firmly Sflt. 56 With a tachometer connected Ind the engine at idle, turn the ed justment Icrew to obtlln the specified idle speed. If the carburetor il equipped With I solenoid, turn the hex screw on Ihe solenoid to adJust t he idle speed. Disconnec t t he solenoid wire and then edjust the idle speed screw to obtain an Idle of 500 rpm. Reconnect the wire to the solenoid.
Mix ture adjustment
III!TAIHEII
."\ '''~ "'--
1
flOO
ACCfLE IIATOII
'~'r"
"\..
~ LOCXI
sellEM AHO
ACCE LEIIATOII f'IJMf' II H It
Fig. 4 .4 0 BBD car buretor accelerator pump and lever ellambl y (Sec 14)
57 The manufacturer recommends that mixture adjustment on these models be accomplished with speciallnlrared eqUIpment. Consequentlv. the vehicle Ihould be teken to a dealer or properlV eqUIpped shop for the edjustment.
14 C.nar BOO c8fbu~or IIn-ll". .Ix-cylind... engine) - OYem lt\lland adjustment
Overhaul With the carburator removed flom the vehicle. clean away all external dirt. 2 Where applicable, remove the throttle position solenoid. 3 Where applicable, remove the var.uum throttle positioner 4 Whflre applicable, remove the idle enrichment vacuum diaphragm, the vecuum nipple and diaphragm return spring (three screwsf. 5 Remove the retaining clip and take off the acceleratol pump arm link. 6 Where applicable, remove the step·up piston cover plete and gasket. 7 Remove the screws and locks, then slide Ihe accelerator pump arm level out of the air horn. Lift out the vacuum piston and step-up rods.
Flg . 4. 41 Piston and meterin g rod assemblv remova l tBBD ca rburetor \I Sec 14\
,------------------------------------------------------ 4-19
WITH AUTOMATIC TfilAHIMIISION
Fig. 4.42 BBD carburetor component' - e.pk)ded view (Sec 141
2 3
4
4 5 V/flve 6 Metering rod 7 S -link 8 Pump arm
•
Gasket
'0
RoNove! check vll/ve
"'3
Screw
Zoql,--®
12 Lock Rod lifter
'4 8r8cket 15
N",
'6 Solenoid
,. "
Screw
18 Ai, horn retaining
20
screw (short! A" hom ,.tsifling screw (fongl Pump lever
21 Venturi cluster screw 22 Idle fuel pick-up tube 23 Gesket
24 Venturi cluster 25 GIfSKe/
26
Check b811 (small}
27 FIo/f! 28 Fulcrum pin
2. Baffle 30 Clip
3' 32 33 34 35
Choke Ifnk
Screw F/Jst idle cam G/fsktu
Thermostatic choke shaft
36 Sprmg 37 Screw
38 3. 40 4' 42 43
Pump /ink Clip Gasket
Limite' cap
Screw
Thronle body 44 Choke housin~ 45 Baffle 46 Glfsket 47 Rert,iner 48 Choke coil
4' Lever 50 Choke rod
51 Clip
52
NeedltJ lJnd selH IJssembly Mein body
53 54 MlJin ~te'mg jet 55 Check bllN (llIrge) 56 Acc.J.ultor pump 57 58 5. 60 6'
plunger Fulcrum pin relainer G/fsket Spring Air hom Lever
4-20------------------------------------------------------"' H.OA.T FUU::III"IIiI riM IU,TAINtl!
FUEL IHUTlEAT
IHLIT NnOlE
Fig. 4.43
Floet ....mbly C:Ompooentl IBBD carburetor,
(Sec '41
Fig . 4 .44
BBD carburetor mil" mitering jets (Sec 14)
CHlCk .... LL
Fig. 4 .46
Checking the 8BO carburetor accelerator pump
'Vitam ISle 14) AOJU5TING
Fig . 4.45
SCREW
Check ball location. (BBD carburetor' (Sec 141
....., FIg.4.47
BBo cllfburltOf flO.lle ... ~ adjustment (Sec 14)
..
."
Fig . 4 .48
,~"'~ Vacuum pilton gap check (BBD c llfbutator)
(Sec '4)
Chapter 4 Fuel and exhaust systems
4-21
"'--AIIIM
"""
IClIIlW
Fig. 4 .50
Fig. 4 .4 9
Acc.llrillor pump IdJultmant (BBD clrburetorl ISec 14J
Vlcuum pl,ton adju,tment (880 carburltorl ISlc 141
8
Remove (he main body·(o-choke vlcuum hose. Remove the choke diaphragm. linkage and brackel. 10 Remove Ihe fasl idle cam and linkage. 11 Remove (he screws and take off the air horn. 12 Inll'lln the air horn. compress the accelerator pump drive spring and remove the S-link ao the pump can be removed. 13 Remove the fuel needle valve. seat and gasket. 14 Remove the retainer and baffle. than lilt out the)loats and fulcrum pin. 15 Remove the m .. in metering jets. 16 Remove the venturi cluster and gaskets, but don't remove the orifice tubes or main vent tubes. 17 Inven the carburetor and drop out the pump discharge and intake check balls 18 Note the poSitions of the limiter caps. men remove thorn and count the elltact number of turns required to just bonom the idle milltture acrews. Remove the screws and aprings. 19 Remove the screws and separate the throttle body from the main body. 20 Oon't dismantle the valve plates and shafts unless needed to raplace worn parts. 21 Clean and inspect all compone-nts. and replace any that are worn. 22 Reassembly ia the reverse of diaassembly, using the new gaskets and components from the rebuild kit. After installing the accelerator pump discharge and intake check balis, fili the cerburetor bowl about half-full with clean gasoline. Insert the pump piston into the cylinder Ind work it up-and-down to elltpel any air. Hold the discharge check ball down with a brass rod, raise and lower the accelerator pump piston and make sure no fuel is emined Irom the intake or discharge passages.. If there is leakage and the passages and ball seall are In good condition, replace the mein body, During reassembly, measure thelloat setting as described below and reset the idle mixture screws to their original positions {Step 181. 9
Float level adjustment
Fig. 4 .51
lnillel chob v.ve Mijustm.nt (BBD carburetorl {See 141
stalled, back off the curb idle screw to close the throttles. Note the number 0 1 turns I8Quired. 28 Depress the piston completely while applying moderate pl8ssure to the rod lifter tab end tighten the rod lifter screw, 29 Releasa the piston and rod lifter. Return the curb Idle screw to the original position,
4
Accelerator pump adjustment 30 Back off the curb Idle adjusting screw to completely close the throttle plate and open the choke plate so the fast idle cam will allow the throttle plates to seat in the borea. 31 Back off the cu rb Idle screw until it just contacts the stop, then back it off an additional two turna. 32 Meaaure the distence from the surface of the air horn to the top of the accalarator pump Ihaft and co mpara it to the Specifications. 33 To adjust, loosen the pump arm adjusting lock screw and rotate the slee.... to adjust the pump travel. Tighten the lock screw.
Initial choke valve clearance adjustment
23 With the fuel inlet valve and floets Instalied in the carburetor. loven the body so the weight 01 the floats is on the valve. 24 Place a straightedge across the 11011 bowl and measure the distance from the lurlace of the bowl edge to the crown of each float at its center. Check thll measurement againlt the Specifications. 25 II adjustment is needed. bend the float lever. Always release the floats from the needle before adjustlOg to avoid damage to the synthetic rubber t ip.
34 i.J)osen the cover Icrews and rotate the choke 1I4-turn in the rich direction. TIghten one screw. 35 Open the throttle plate lufficiently to placa the fast idle screw on the high Slap of the cam. 36 Apply 19 Inches 01 vacuum to the diaphragm to pul the plunger again" the ItOP. 37 Measure the choke plate-to-air hom wall clearance end check it against the Specification •. 38 Bend the diaphragm connector link to adjust.
Vacuum piston gap adjustment
Fast idle cam position adjus tment
26 Check the vacuum piston gap and compare it to the Specifications. Adjust as necessary by turning the adjusting screw 81 the top.
39 Perform the operations described in Steps 34 and 35. 40 Measure the choke plate·to-air horn walt clearance with a gauge or drill bit shank, There should be a slight drag when tha dritt or gauga is removed. if the adjustment Is correct. 41 To adjust, bend tha fast Idle connector rod as necessary.
Vacuum piston adjustment 27 With the vacuum oiston and metering rod assembly correctly in-
4-22
Chapter 4 Fuel and exhaust systems
AOM' ev elNOI~ Itilll
Fig. 4 .53 Fig. 4 .52
Fast idle cern adjustment (BBD carburetor) (Sec 14)
BBD carburetor choke unloader adjustment (Sec 14)
Choke un/08der adjustment 42 With the throttle held in the wide open position, apply light pressure 10 the choke plete and hold it in piece. 43 Measur. the choke DI8Ie-to-"r hom will clearance with 8 gauge or dull bit shenk. 44 AdIUS! bV bending the unloaderllng. making sure thet it operates smoothlv after adjustment.
Curb idle speed adjustment 4S The curb idle speed must be adjusted under the following conditions: Transmission in Neu'r.' (manullfJ Of Drive (automatic! Perking brske securely 5er Engine .t norma' opeflJting temptlflture Air cleaner installed
Fig. 4 .54
BBD Clfburetor Idle mldure adjusting screw , locations {Sec 141
Tachometer properly trtteched
46 Turn the adjustment screw to Inain the specified idle speed. 47 If the carburetor is equipped with 8 solenoid, turn tne nut on tne solenoid to adjust tne idle rpm, tnen tlgnten Ine locknul. 4B Disconnecl the solenoid wire and edJusllne cerburelor idle screw to obtain a 500 rpm idle speed. Reconnecl Ihe solenoid wire.
Mixture 8djustment 49 The ml)(ture adjustment preparations are the same as those for curb idle adjustment described in Step 45. Adjust the idle mixture screws to the full rich stop (counterclockwise). note tne position ot the screwhead ,lot5 end remove the plastic limiter caps. This can be accomplished by threading e no. 10 sheet metel screw Into the cenler 01 the cep. 50 Adjust the idle speed. Use tne procedures in Steps 47 and 4B for solenoid·equipped models. 51 Beginning et the tua rich poaition (Step 49). turn the miKtule Icrewl clockwise in the lean direction until there il an rpm drop. Turn the screwa In the counterclockwise direction until the higne,t rpm previously achieved is obtained. This Is celled the lean best idle. 52 Tum the idle mixture screws In small. ellen Increments until the specified Idle drop is reacned. 53 II the tinal reading varies more than 30 rpm from the curb idle specification, repeat the idle speed adjustment. followed by the mix· ture lean best Idle and idle drop adjustments (Steps 51 and 52). 54 In8lall new idle mixture screw limiter caps with the limiter cap ear agllnll the full rich stop. Be carefUl not to change the mixture settings.
16 Rochester 2SE end E2SE carburetors 1161 cu In four·cyNnder engine) - overheul and adjustment
Overh8ul Mount the carburetor on 8 holding !iKture 10 prevent damage to
15.1 A punch held in a vile can be used to suppon the carburetor if a stand is not available tl'M! throttle valves. If no holding liKture IS 8V8ilalJ!e. a sUltable-si~e punc:fl securely mounted in e vise is a good alternative (photo). 2 Remove the gesket from the air horn and the fuel inlet nut IfId fihttl assembly. 3 Remove the pump lever attaching screw, disconnect the pump rOd from the lever and remove the lever (photol. 4 Disconnect tne vacuum break diaphragm hose from the throttle body.
4-23
Chapter 4 Fuel and exhaust systems
Fig. 4.55 Rochest.r 2Se carbur.tor component. - exploded view (See 15) I
Gllsket
2 Intake IIdapter 3 Insulator 4 Throttle body
5 Main body
•7 8 9 10 If
12 13 I.
15 I' 17
18 19 20 21 22 23 2. 25 2. 27 28 29 30 31 32 33 3'
15.3 Removing the pump lever attaching screw
15.5 Removing the idle splffld solenoid/vacuum break diaphragm bra cket
Elilctric choke covllr and coil Needle seer assembly Spring Fuel filter Gasket Fuel inlet fitting Float assembly Filler block Akhom A;r vlllve Gasket Vent screen Choke plate Pump lever Vacuum break and brllcket Idle stop stolenoid Vacuum hose Vllcuum break lever Choke link Air valve rod Air valve lever Accelerator pump Metering rod Power piston Idle needle end spring Fast idle cam Intermediate choke rod Pump rod Throttle lever assembly
15.6 Lift off tne idle speed solenoidl vacuum break assemblv and disconnect the air valve rod from the outside vacuum break plunger
4
4-24
Chapter 4 Fuel and exhaust systems
5 Remove tha IcreWI Ihllt secure the Idle speed solenoid/vacuum break diaphragm brackel Ilf 10 equippedllphotol. 6 Lift off the Idle .pHd lolenoidlvacuum break diaphragm assembly end disconnect the air valve rod from the out.ide v.cuum bresk plunger HI 10 equippedl Ipholol. 7 Disconnect the vacuum bruk rod (if so equipped) from the Ineid. vacuum break diaphragm plunger. S Pry off the clip thlt secures the intermediate choke rod lever end
I.perate Ihe rod from the lever Iphotol. 9 Remo~ the IcreWI that secure the ventller•• n assembly to the air horn end lift off the .... mbly. 10 Remove the fetainlng .crews end lift the .olenok! from the air horn Iphoto). 11 Remove the eir hom retlining screWI. If the carburetor is equipped with II hot idle compensator. h must be remOV1ld to gain access to the shon air horn screw.
15.8 Use a screwdriver to pry off the chp securing the Intermediate choke rod to the choke lever and separate the rod from the lever
12 Rotete the fait idle cam up. lif! oflthe air horn and disconnect the fest idle cam rod from the fast Idle cam (photol. 13 Disengage the faat Idle cam rod Irom the choka lever and save the bushing lor later reassembly (photo). 14 If the pump plunger did not come out 01 the air horn during removal. remove the plunger from the pump well in the float bowl. 15 Compren the pump plunger spring and remove the spring retaine! clip and spring from the piston. 16 Remove the air horn gasket from the IIoat bowl. 17 Remove the pump return spring Irom the pump well. 18 Remove the plastic filler block that covers the float (photo!. 19 Pull up on t he retaining pin and remove the float valve and float assembly. 20 On E2SE carburetol'!l, remove the float valve seat and gasket and the extended metering jet (photo). 21 On 2SE carburetors. refer to the accompanying illustration fOf the
15.10 Altar removing the retaining screws. use a slight twilting motion while lifting the solenoid out
15.13 Removing the flit idle cam from the choke lever
15.18
Ufting out the filler block
15.22 When removing the discharge spring end check ball. do not pry on the white plastic retainer
15.23 Removing the choke housing·to·throttle body screws
15.12
Removing the eir horn
15.20 On E2SE carburetors, remove the float valve SOlIt and gasket (AI end the extended metering jet (8) from the float bowl
15.28 Use a punch to break out the throttle body casting. then drive out the idle mixture needla cover plug
Ch apter 4 Fuel and exhaust systems power piston removal operation. 22 Use needle-nose pliers to pullout the white plestic retainer and then remove the pump discherge spring and check ball (photo). 23 Remove the choke housing from the throttle body (photo). 24 Remove the four retaining sc rews and separete the throttle body from the float bowl. 25 Carefully fi le off the heads of the rivets securing thll choke covllr. Use a hammer and small punch to tap out the remainder of the rivet. 26 Remove the choke coil lever screw and lift out the lever. 27 Remove the intermediate shaft end lever assembly by sliding it out the lever side of the float bowl. 28 The plug covering the idle mi xture needle should not be removed unless the needle needs rllplacing or normal cillaning proclldurlls fail to cleen the idle mixtura passaglls. If removal is required. USII 8 punch end hammllr to drive the plug out (photo!. 29 Clean the air hom, float bowl. throttle body and related components with clean solvent and blow them out with compressed air. A can of compressed air such as is available in camera stores can be used if an air compressor is not available. Do neit use a piece of wire for clean ing the jets and passages. 30 The idle speed solenoid. mixture control solenoid. throttle position sensor. electric choke. pump plunger. diephragm, plastic filler block end other electrical. rubbllr and plastic parts should not be immersed in carburetor cleaner because they will harden, swell or distort. 31 Make sure all fuel passages. jets and other metering parts Bre free of burrs and dirt. 32 Inspect the upper and lower surfaces of the air horn, float bowl and throttle body for damage. Be sure all material has been removed. 33 Inspect all lever holes and plastic bushings for excessive wear and out-of-round conditions and replace if necessary. 34 Inspect the float valve and seet for dirt. deep wear grooves end scoring and replace if necessary.
4-25
35 Inspect the float valve pull clip for proper installation and adjust if necessary. 36 Inspect the float, float arms and hinge pin for distortion or binding end correct or replace as necessary. 37 Inspect the rubber cup on the pump plunger for excessive wear or cracking. 38 Check'the choke valve and linkage for excessive weer, binding or distortion and correct or replece as necessary. 39 Inspect the choke vacuum disphragm for leaks and replece if necessary. 40 Check the choke valve for freedom of movement. 41 Check the mixture control solenoid for binding or leaking in the following manner: a) Connect one end of a jumper wire to either end of the solenoid connector and the other end to the positive terminal of a bettery. b) Connect another jumper wire between the other terminel of the solenoid connector and either the negetive terminal of II bettery or e ground. c) Remove the rubber seel and retainer from the end of the solenoid stem and attach a hand vacuum pump to it (photo). d) With the solenoid fully energizad (laen position), apply at least 25 in-Hg of vacuum end time the leak-down rate from 20 inHg to 15 in-Hg. The leak-down rate should not exceed 5 in-Hg in five (5) seconds. If leakage exceeds that amount. replace the solenoid. e) To check if the solenoid is sticking in the down position, agein pump ebout 25 in-Hg of vacuum into it, then disconnect the jumper lead to the bettery and watch the pump gauge reading. It should fall to zero in less than one (1) second. 42 Prior to rellSsembling the carburetor. compare all old and new
•
4 Fig. 4.56
Float bowl component layout (2SEfE2SE carburetor) (Sec 15)
Fig. 4 .57 ....' " " 'O 'UTA,IP
;,.- "no, RETAINER
!'OWER PISTON
Fig. 4 .58 Remoye the metering rod from the 2SE cerburetor power piston by compressing t he spring on the top and aligning the g roove with the IIlot in the holder [Sec ' 5)
Fig. 4 .59
Removing the idle mi xture .crew (2 SE/E2SE ca rburetor ) (Sec 151
4-26
Chapter 4 Fuel and exhaust systems
gaskels beck·to-back to be sure tnoy malch perfectly. Check especially thai aU the necessary hoLs8 are present and in Iha proper position in Ihe new galkelS. 43 If the idle milnure needle end .pring heve been removed, reinstall by lightly seating the needle. then back it off dU1I1 131 turns. nils will
provide a preliminary idle mixture adjustment. Final idle miJ!ture adjustment mu,l be made after the carburetor is in.talled. 44 Install 8 new gasket on the bottom of Ihe flollt bowl. 45 Mount the throttle body on the flollt bowl so that it is properly eligoed over the locating dowel, on the bowl and reinstall the attaching screWI, tightening them evenly lind securely. Be sure that the steps on the fe5t idle am lace toward the last idle screw on the Inrottlelever when installed. 46 Inspact tha linkage to maka sure thst the lockout tsng property engegas In Ihe Ilot of tha secondsry lockout lavar snd thst the IInll:age moves freely without binding. 47 Altach the choke hauling to the throttle body, making sure the locating lug on the teer of the hauling sill in itl recess in the fIoal bowl. 48 Install the intermadiale choke Ihsft and lever assembly into the float bowl by pUlhing il Ihrough from the Ihrottle levar side. 49 Polition the Intermadiste choke laver in tha up position snd inltall Iha thermOltatlc coil lever onto the end sticking int o tha choke housIng. The call lever II properly Illgnad when the coil pick-up ling il in tha 12 o'clock polilion (photo). Inltll the Ittachlng Icrew in lhe end of the intermediete shift to lecure tha coil lever. 50 Three self-lipping screws supplied in the overhaul kit are used in place of Ihe original pop rivell to sacure the choke cover end coil Issembly to Ihe choke housing. Stert the three screws into the hous· lng, making lure that they start ealily and are properly aligned (photo), then remove them Igain. 51 Place the fill idle screw on the highest ellp of the fast idle cam, then instill the choke cover on Ihe housing, aligning the notch in the cover with the railed casting projection on the housing cover flange. Whan insteiling the cover. be sure the coil pick-up tang engages the Inside choke lever. 52 With the choke cover in place. inllsll the thtee .elf-tapping screws and tighten them securely.
53 Install the pump discharge check ball and spring in the passage next to the float chamber. then place a new plastic retainer in the hole so thaI its end engagelthe spring and tap it lightly into place until the retainer top is flush with the bowl surface. 54 InSlali the mein metering Jet in the bottom of the floet Chamber. 55 InSlali the float valve seat assembly and gasket. 56 To meke tloat leve!adjuSlments easier. bend the flOBt erm up slightly at the nOlch shown in the photo before Instslling the tloat. 57 Attech the floal valve to the float arm by sliding the lever under the pull clip. The correct inSlaliation of the pull clip is to hook the clip over Ihe edge of the float on the lloal arm facing the float pontoon (photo). InlteM the float teteining pin in the float srm, then install the lIoat a8lembly by aligning Ihe valve in ilB saat and the floal retaining pin in lIB locating channels in the floal bowl.
.. o.t .....
LIYI.~_"""
Fig . 4 .60
Floet needle pull cNp instaMatlon (2SE/E2SE carburetM) (Sec 16)
I '15.4 I lelling the mixture conlrol solenoid wilh a vacuum pump
15.56 Prior to inltallatlon, bend the float arm slightly at the point Indicated
15.49 Installing the thermostatIc coil lever with en Anan wrench
15.50 Reinstalling Ihe choke cover using the selt·tapping screws supplied with the overhaul kit
15.57 OWing installation the lIoat valve Should be positioned on the arm S9 shown
15.58
MeasurIng the float adjustment
4-27
Chapter 4 Fu el and exhaust systems Floar level adjustment 58 Adjust tha float lavel in the following mannar. Whila holding the float retaining pin lirmly in place, push down on the float arm at its outar and. against the top of the float valve. so the top o f the float Is the specified distance from the floet bowl surfaca IphotoL Bend the float arm as necessary to achieve the proper measurement by pushing down on the pontoon. See the Spacifications for the proper float measurement for your vahicla. Visually check tha float lavel after the adjustment. 59 On 2SE carbs. install tha power piston spring in the piston bore. I! the metering rod has been removed from the power piston essembly. reinstall the rod in the holder. making sure the spring Is on top of tha arm. Then install the assembly in the floet bowl. Use care when installing the metering rod into the main metering jet so as not to damage the metering rod tip. Press down firmly on the power piston's plastic retainer until it is firmly seated in its recess and the top is flush with the top of the bowl casting. Light tapping may be required . 60 Install the plastic filler block over the float valve so that it is flush with the float bowl surface. 61 If the carburetor is equipped with a throttle position sensor. install the TPS return spring in the bottom of the well in the float bowl. Then install the TPS and connector assembly by aligning the groove in the electrical connector with the slot in the Iloat bowl. When prop' erly installed, the assembly should sit below the float bowl surface. 62 Install a new air horn gasket on the flo&t bowl. 63 Install the pump return spring in the pump well (photo). 64 Reassemble the pump plunger assembly, lubricate the plunger cap with a thin coat of engine oil and install the pump plunger in the pump well (photo). 65 If used. remove the old plug plunger seal and retainer and the old seals and retainers in both locations and lightly stake both seal retainers in three places other than the original staking locations 66 Install the fast idle cam rod in the lower hol~ of the choke lever. 67 If so equipped. apply a light coat of silicone grease or engine oil to the TPS plunger and push it through the seel in the air horn. so
that about one·half of the plunger extends above the seal. 68 Prior to installing the air horn, apply a light coat of silicone greasa or engine oil to the pump plunger stem to help it slip through the air horn 9aal. 69 Rotate the fast idla cam to the "up" position so it can be engeged with the lower end of the fast idle cam rod and, while holding down on the pump plunger assembly. carefully lower the air horn onto the float bow!. guiding the pump plunger stem through its seal. 70 Install the six air horn mounting screws and lock washars and two air cleaner bolts, tightening them in the propar sequence as shown in the accompanying illustration. 71 If so equipped, install a new seal in the the racess of the float bowl and the hot idle compensator valve. 72 Install a new rubber seal on the end of the mixture control solenoid stem until it is up against the boss on the stem (photo). 73 Using a 3116·inch socket or other appropriate tool and a hammer (photol. drive the retainer over the mixtura control solenoid stem just far enough to retain the rubbar seel. while leaving a slight clearance between them for seal expansion. 74 Apply a light coat of engine oil on the rubber sea! and, using a new gasket. install the mixture control solenoid in the air horn, Use a alight twisting motion while installing tha solenoid to help the rubber seal slip into its recess. 75 Insta!1 the vent/screen assemblV onto the air horn. 76 Install a plastic bushing in the hole in the chokalever With the small end facing out. Then with the intermediate choke lever at the 12 o'clock position, install the intermediate choke rod in the bushing. Install a new retaining clip on the end of the rod. An effective way of doing this is to use a broad screwdriver and a 3116·inch regular socket as shown in the photo. Make sure the clip is not seated tightly against the bushing and that the linkage moves freely. 77 Engage the vacuum break rod with the inside vacuum break diaphragm plunger and the air valve rod with the outside plunger and mount the idle speed solenoid/vacuum break diaphragm assembly. 78 Engaga the pump rod with tha pump rod lover and mount the pump
' ~'-----' -----
l~tJ~~: t h.
lli
3
15.63 Inserting the pump return spring into the pump well
15.64 Inserting tha pump plunger into the pump well
15.72 Attaching a new rubber seal to the end of the mixture control solenoid stem
15.73 Tap the seal onto the mixtura control solenoid stem using a hammer and socket
Fig. 4 .81 Air hom .crew tightllning IIIquence t2SE/E2SE carburlltor) !Sec 15)
15.76 Using a small socket and screwdriver to install tha retaining clip onto the intermediate choke rod to secure it to the choke lever
4
4-28
15.78 Inserting the pump rod mounting screw through the pump rod prior to installation
8010 INTERMEOI"n
CHOK~
JUST CONTACT SIDE OF "~UG GAUGE
fig . 4 .64
Fig. 4 .62 2SE carburetor 8){temal component Iocationa (Sec 15)
Fig . 4.63
n,.o AOD
MEI;II"TE LEVER UNTil CHOKE VALVE ISClOSl:O
Choke coil lever adju.tment 12SEJE2SE carburetor) (Set: 15)
E2SE carburetor
adjullment locations (Sec 15)
TO ,0.011.15'
@REMOV!CAUCE
(])
~CE'''''TIOl(-;--1:~---l~~,,;;~..:t~
SCIt(W OH &leOND
IllP 0' C .... ACIoINST It~( 0' HIGH ITEP
Fig. 4.65
, .... , IDLE C .....
Fast Idle cam potilion adjustment (2SE{E2se carburetor) (Sac 15)
4-29
Chapter 4 Fuel and exhaust systems
LEVEl-ADJUSTMENT
GAUGE
SCREW NOTI. ON DIUT
"001~'
WITM " ,II IILUO. I'I.UO 11010 COYIII WITH ~IIC:I 0' , • • OU"III ...... 1111010 TAH:. IIIIIIOYI T "10( ""III "DJIJIT"INT
/
"
AIR VAlVE
,o0
TO "DoIUIT, 1111010 Y"C:UUM UIAIl 1100 UNTIL aulilf I. C(NTIIIEO
ADJUSTING WRENCH
Fig . 4 .66 Air valve rod edjustmant 12SE/E2SE cerburator) {Sec 1S)
Fig.4.67
Primary vacuum break adjuatmant {2SEfE2SE carburator) {Sac 1S)
CD HOLD CHOIII v.Lvl
WIOE OP[N 'Y 'UIHING COUNTER . C~OCIlWISE ON ' NTEII"£O'''Tl CHOU LIVIII
0,~
NICUI""Y TO AOJUlT . UNO LOCIlOUT LEVEll TANO CONTACT'NG ~"ST 'OLI C" ..
FP :fir::t-~-
Fe
~~~~t'j @GAUG ICLUII"NCI . 0' ''(''''0101 'HOUl O Sf •• " I C"'IO
FIg.4.68
Chokll unloeder edjustment {2SE/E2SE carburetorl {Sec 1S)
Fig . 4 .69
~~ O~IN
THIlOTTlE LIVIII UNTIL 11010 Of I(CONO"II' .CTUU,HO LIVIIIII o,.-olltl TOI O~ lOCUIOT LIV[1I
Sacondary lockout adjustment 12SE/E2SE carburetor) ISec: lS I
• lever on the air horn with the washer between the lever and the air horn (photo). 79 Reconnect the vacuum break diaphragm hose to the litting on the carburetor body. SO Install the luellilter so that the hole laces toward the inlet nut. Bl Place a new gasket on the inlet nut and install the nut. Be careful r.ot to over tighten the nut since this could damage the gaskets and cause a fuel leak. B2 Install a new gasket on the top of the air horn.
External linkage adjustments 83 Refer to the accompanying illustrations (Fig. 4.62 through 4.69) and adjust the linkages as shown.
Idle speed and mixture adjustment 84 Prior to adjusting the idle speed or mixture, the following precautions must be taken and conditions exist: Parking bt
4 The engine must not be operated at idle for more than three (3) minutes 85 Disconnect and plug the distributor vacuum hose and connect a timing light to the engine. 66 Adjust the ignition timing with the engine at or below the specified idle speed. 97 Connect the distributor vacuum hose and remove the timing light. 96 Disconnect the deceleration valve and ptJrge hose from the vapor canister and plug the hoses. Remove the air cleaner if necessary for access. 69 On air conditioned models, adjust the idle speed screw to achieve the specified idle speed. Tum the air conditioning switch on, open the throttle momentarily and make sure the solenoid armature is full y extended. Adjust the solenoid idle screw to achieve the specified idle and tum the air conditioning switch off. 90 On non-air conditioned models. obtain the specified idle speed by adjusting the solenoid idle screw with the solenoid energized . Disconnect the solenoid wire connector and adjust the idle speed screw to obtain the specified idle speed. Reconnect the solenoid wire. 91 Disconnect and plug the EGR valve hose. With the fast idle speed screw on the top step of the fast idle speed cam, adjust the fast idle speed to the specified rpm . 92 Turn off the engine, remove the tachometer and reinstall an y components or hoses removed during this procedure. 93 The fuel mixture adjustment on these models requires special tools and equipment and should be left to your dealer or a qualified shop.
Chapter 4 Fuel and exhaust systems
4-30
3
,
~
,
,
~
13
,
B
. ~ .--"
~ ~" -
' .":":- . -
"----'"
15---(1f).
,I
•
17
18
Fig. 4.70 YFA carburetor exploded view 1 2 3 4
5 6 7 8 9
Vacuum break diaphragm Airhom Choke plate Vacuum throttle positioner ChokeassembJy Accelerator pump assembly Idle mi.Kture screw and lamper proof plug
'0 I' 12 13
Accelerator pump check ball and wel9ht Main metering jet Floa t assembly Mixture conlro/ solenoid
14
Low speed Jl!1
15
Accelerator pump vent valve
16
Wide Open Throttle (WOT) SWitch
Throttle plate Main body
17 18
Throttle shaft and lever Throttle body
Chapter 4 Fuel and exhaust systems
4-31
"
Fig.4.71 Float (10) and float pin (11) remollal details
Fig. 4.72 After remolling the float and pin, invert the air horn and catch the needle pin (12), spring (13) and needle (14), then remove the needle seat and gasket (15)
Fig. 4.73 Tum the main body oller and catch the pump check ball and weight
16
Carter YFA carburetor (150 cu in four-cylinder engine)ollerhaul and adjustment
Overhaul
•
1 Remove the choke cover by drilling out the rivet heads and then using a tiS-inch punch, drive out the remainder 01 the rivets. Remove the choke retainer, thermostat spring assembly, housing gasket and Iockinglindexing plate (Fig 4.70). 2 Remove the lIacuum break diaphragm. 3 Use a screwdriver to disengage the lIacuum break connector link and then remove it from the choke shaft lever. Remolle the throttle positioner and bracket. 4 5 Remove the two screws and detach the mi)(!ure control solenoid from the air hom. 6 Remove the air hom attaching screws and the fast idle link and then detach Ihe air hom gasket from the carburetor main body. 7 Separate the floal from the air hom by holding the air hom bottom side up and then remove the Iloat and pin as shown in Fig. 4.71 . B Tum the air hom upside down and catch the needle pin, spring and needle (fig. 4.72). Remove the needle seat and gasket. Invert the main body casting and catch the pump check ball and 9 weight as shown in Fig. 4.73. 10 Remove the throttle shaft retaining boll and detach the wide open throttle switch actuator. 11 Loosen the throttle shaft arm screw with an Allen wrench and remove the arm and pump connector link as shown in Fig. 4.74. 12 Remove the screws and separate the throttle body from the main
body. 13 Remove Ihe wide open throttle switch and mounling bracket. 14 Remove the accelerator pump housing screws and lift out the pump assembly litter link and metering rod as shown In Fig. 4.75.
4
Fig. 4.74 Use an Allen wrench to loosen the throttle shaft ann screw (17)
Fig. 4.75 LIft the accelerator pump assembly lifter link and metering rod out as a unit
Chapter 4 Fuel and exhaust systems
4-32
l\ L
"
•
Fig. 4.17 Low speed jet IL) and main metering jet (M) locations
$--'
, " o
Fig. 4.16 Accelerator pump components
A B
C
o E F G H
J
Metering rod arm spring Metering rod Metering rod assembly upper pump spring Spring retainer and cup Pump lifter link Pump diaphragm shaft Pump diaphragm spring Pump diaphragm spring
,~ -~
G
retainer K
15
Pump diaphragm housing
Fig. 4.78 Use a punch to remove the plug (N) so the bleed valve (P) can be removed
Re/ernng to Fig. 4.76, disassemble the pump as tollows:
a) Disengage the metering rod arm spring from the metering rod and
remove the rod from the 8ssembly. b) Compress the upper pump spring and Ihen remove Ihe spring
retamer and cup. e) Remove the upper spring. metering rod arm assembly and the pump lifter link from the pump diaphragm shaft. d) Compress the pump diaphragm spring and remove the diaphragm spring retainer, spring and housing 'rom the Shaft. 16 Use a screwdriver to unscrew the low speed jet and remove the main metering jet (Fig. 4.77). 17 Use a sharp punch to remove the accelerator pump bleed valve plug from the outside of the main body casting. loosen the bleed valve screw and remove the valve (Fig. 4.78). 18 Drill a hole In the tamper-proof plug and lever it out of the bore, then count and record the number of turns required to lightly seat the idle mixture screw. Remove the idle millture screw, O-ring and spring (Fig.4.79). 19 The carburetor is now completely disassembled and should be cleaned and inspected for wear. After the carburetOf componen ts have been soaked in carburetor cleaner to remove dirt, gum and carbon deposits. they should be rinsed in solvent and dried, preferably with compressed air. Do not use a wire bl1Jsh to clean the carburetor and clean all passages with compressed air rather than wire or drill bits, which could enlarge them. Inspect the throttle and choke shafts for grooves, wear and excessive looseness. Check the throttle and choke plates for nicks and smoothness of operation. Inspect the carburetor body and components for cracks. Check the float arm needle contact surface for grooves. If the grooves are light. polish the needle contact
Fig. 4.79 Drill out the plug (a) for access to the idle mixture screw (R) surface with crocus cloth or steel wool. Replace the floats If the shafts are badly worn. Inspect the gasket mating surfaces lor burrs and niCKs. Replace any distorted springs and bolts which have striPped threads. 20 To begin reassembly, atlach the throttle body to the main body with the retaining screws. Use thread locking compound on the screw threads. 21 Install the low speed jet, main metering jet, pump bleed valve and plug, accelerator pump assembly and the pump passage tube. 22 Slide the throttle shaft arm onto the shaft and install the retainir.g screw and pump connector link. 23 Instal l the wide open throttle SWitch actuator, the throttle shaft retaining bolt and the switch and bracket.
Chapter 4 Fuel and exhaust syst em s
c
4-33
•
Fig.4.81 Adjust the float level by bending the float arm (A) Fig. 4.60 To adjus t the metering rod, push down on and hold the pump diaphragm (8) while turning the metering r od (e)
...
\:.
'.'
",.,., Fig. 4.83 Accele rator pump check ball and weight installation
Fig. 4.82 Adjust the float drop by bending the tab (0) at the end of the float arm
-
4
Metering rod adjustment 24
With the air horn removed, back out the idle speed adjusllng screw until the throttle plate is closed tightly In the bore, then push down on the pump diaphragm until it bottoms. 25 To adjust the metering rod, hold the diaphragm down and tum the adjustment screw counterdockwise until the metering rod lightly bottoms on the main metering jet as shown in Fig. 4.80. Tum the adjustment screw one tum clockwise for final adjustment. 26 Install the float assembly needle pin. spring seat and gasket, fl03t and pin.
Float level adjustment 27 Turn the air horn assembly over and measure the clearance belween the top 01 the float and the bottom of the air hom with a float level 93uge or a dial Of vernier caliper. The air hom should be held at eye level during this Pfocedure and the float lever should be resting on the needle pin. 28 Bend the float arm as necessary 10 bring the float level within the specified range (Fig. 4.81).
Fig. 4.84 The fast Idle adjustment screw to) should be on the second step (E) of the fast idle cam IF) before adjusting the fast idle cam link
Float drop adjustment
mlJcture control solenoid. 33 Install the choke cover locking and indel(ing plate, cover and housing assembly and retainer, using screws to replace the rivets
29
Fast idle cam index adjustment
W,th the carburetor air horn held upright and the float hanging free, measure the distance from the aIr hom gasket surface to the top of the float. Compare thiS floal drop measurement to lhe Specifica· tions. To adjust, bend the lab at the end of the float arm (Fig. 4.82). 30 Install the accelerator pump check ball and weight (Fig, 4,83). 31 Inslall the air horn and gaskel on the main body. 32 Install the fast idle cam link, throttle positioner and bracket and
Place the fast idle adjustment screw on the secood step of the fast idle cam and against the shoulder of the high step as shown in Fig. 4.84, 35 Check the clearance between the lower edge of the choke plate and the air horn wall using a drill bit as a gauge. Compare this mea· surement to the Specifications.
34
Chapter 4 Fuel and exhaust syst em s
4-34
Fig. 4.85 Adjust t he fas t idle ca m index by bending the link (G)
Fig. 4.86 With the vacuum break seated with a vacuum pump .. adjust the choke pl ate-to-air hom clearance by bending the conn ector link (6 )
Choke unloader adjustment
----H
J
Fig. 4.87 With t he throttle (HI held wide open, adjust the choke unloader by bending the unloader tang (J ) which contacts the fast idle cam (K)
38 Hold the throttle wide open while pushing the choke plate toward the closed posi tion. Measure the clearance between the choke lower edge and the air hom wall with a drill bit shank. Compare this measurement to the Specifications. 39 To adjus t, bend the unloader tang which contac ts the fast idle cam (Fig . 4.87). ~ 40 Install the idle miKture screw until lightly seated and back it out the number of turns recorded in Step 18.
Anti-diesel adjustment 41 Turn the anti-diesel adjustment screw counterclockwise until the throttle plate is closed, then turn it clockwise 3/4- turn as shown in Fi g_ 4.88. 42 Install the carburetor on the engine.
Fuel/air mixture adjustment
Fig. 4.68 Anti-d iesel adj ustm ent s crew (4)
36 To adjus t the fast idle cam, bel'ld the fast idle cam link as shown in Fig. 4.85 until the choke plate clea rance is as specified.
Initial choke plate-ta-air hom clearance adjustment 37 WIth the fast idle adjustment screw on the top step of the fast idle cam, connect a vacuum pump to the vacuum break, apply vacuum and measure the choke plate lower edge-Ie-air horn wa ll clearance with a drill bit shank as shown in Fig. 4.86. Bend the vacuum break link 10 adjuslthe clearance.
43 Because of the special equipment and techniques required, fuellair mixt ure adjustment should be left to a dealer service department or properly equipped shop. 44 Prior to setting the idle speed the following precautions must be ta ken: Parking brake securely set Transmission must be in Neutral Engine at normal operating temperature Air cleaner installed 45 Following the manufacturer's instructions. attach a tachometer to the ignition coil TACH connector. 46 Prior to idle speed adjustment. the vacuum actuator must be adjusted. 47 With the engine idling. connect a vacuum pump to the vacuum actuator, apply 10 to 15 in-Hg of vacuum and adjust the vacuum actuato r until an idle speed of approxima tely 1000 rpm is achieved as shown in Fig . 4.89. 48 Disconnect and plug the vacuum actuator hose and turn the hex head curb idle speed adjustment screw to obtain an idle speed of 500 rpm as shown in Fig. 4.90.
Fast idle adjustment 49 The fast idle adjustment is made With the engine at normal oper· ating temperature. the EGR valve hose disconnected and plugged at the valve and the last idle screw on the second step of the last idle cam. Turn the fast idle adjustment screw until a settin9 of approximately 1500 rpm is reached (Fig. 4.91)
4-35
Chapter 4 Fuel and exhaust systems
I/o> 3
Fig. 4.89 Wilh vacuum applied 10 the actuator, adjust the idle speed at the actuator adjustment screw (2)
Fig. 4.90 Use a small wrenCh to adjust the curb idle speed screw (3)
Fig. 4.91 Fast Idle adjustment screw loca ti on (1)
HICTIII C
"100111 UHIT UQUIO CHICII VAlVI TO CANISUIIHOU LIOI,IIO CHICIt
,~,
.,•
4
"'TU,CHIHO .1I"'C~lT
Fig. 4.92 Typical rater model fuel tank and components· eJlploded view (Sec 17)
17
Fuel tank - removal and installation
Caution: Gasolme is extremely flammable and extra precautions must be taken when wOrXing on any part of the fuel sys tem. Do not smoke or allow open flames or bare light bulbs near the work. area. Also, do not wori( in a garage if a natural gas-type appliance with a pilot light is presen!.
1 The fuel tank on early models is located under the driver's seat and is retained by straps. On later models. il is located under the rear of the vehicle and IS held In place by brackets and bolts :1 Disconnect the negative battery cable Irom tne battery. 3 Drain 01' siphon the loellrom the tank so It will be easier 10 handle 4 On early models, remove the driver's seal. 5 On laler models, raise the rear 01 the vehicle and support It securely. 6 On all models. mark the locations of all noses attached to the tank. then remove them. 7 On early models. remove the strap retaining nuls and separate Ille tank from the vehicle
8
On later models. suppo!1 the tank With a jack. using a board to protect the tank on models which aren't equipped with a shield . Remove the retaining bolts and brackets and lower the tank 'rom the vehicle. 9 To instali lhe fuel lank on early models, place the lank in position. install the straps and connect the hoses. Install!he driver's seat. 10 On later models, carefully raise the lank into position, install the brackets and tighten the bolts securely. 11 Connect the hoses and lower the vehicle. 12 Connect Ihe negative battery cable. 18
Fuel lank - cleaning and repair
1 Drain and remove the fuel tank. 2 Remove the fuel tan k gauge unit by removing tna retalnln9 screws. 3 Turn the tank over and empty out any remaining fuel. 4 H repa ir work must be done on the fuel tank that does not involve any heat or flames. Ina tank can be satisfactorily cleaned by running not water into it and l&ning it overflow out the top lor at least live (5)
Chapter 4 Fuel and exhaust systems
4-36
MV'F~lA
I.
Fig. 4.93 Typical exhaust system components - exploded view (Sec 18)
•
J
FlANGE
EXHAUST
PIPE
I MUFFLEA
Fig. 4.94 Late model four-cylinder exhaust system and catalytic co nverter (sec 18) minutes. This method, however, does not remove gasoline vapors. If repair work involving heat or flame is necessary, have it 5 done by an experienced professional. The following, more thorough procedures should be used to remove all fuel and vapors from the tank. 6 Filt the tank completely with tap water, agitate vigorously and drain 7 Add a gasoline emulsifying agent to the tank according to the manufacturer's instructions, refill with water, agitate approximately 10 minutes and drain. S Once again, flush with water to overflowing (for several minutes) and drain. 9 The tank is now ready for repair woo. 10 Under no circumstances should repair work involving heat or flame be performed without IIrst carrying out the above procedures.
19
Exhaust system - check and component replacement
Caution: Inspection and repair of exhaust system components should be done only after enough time has elapsed after driving the vehicle to allow the system components to cool completely. Also. when working under the vehicle, make sure it is securely supported on jackstands.
The exhaust system consists of the exhaust manifold, muffler, catalytic converter ~f equipped), tailpipe and connecting pipes, brackets, hangers and clamps. The entire exhaust system is attached to the body or frame with mounting brackets and rubber hangers. If anyone of the parts is Improperly installed, excessive noise and vibration will be transmitted to the body. 2 Regular inspection of the exhaust system should be made to keep it safe and quiet. Look for any damaged or bent parts, open seams, holes, loose connections, excessive corrosion and other defects. Deteriorated exhaust system components should not be repaired; they should be replaced with new parts. Refer to Chapter 6 for catalytic cooverler removal and installation procedures. If the components are extremely corroded or rusted together, ~ 3 may be a good idea to have the work perlormed by a reputable muffler shop, since welding equipment wMi Pfobably be required to remove the components.
5-1
Chapter 5
Engine electrical systems
Contents Alternator -
brush replacement . . . . . . . . . . . . . . • . •.
...
,.•
Electronic ignition pick-up coil - removal and installation ___ . 20 Elactronic ignition system - check _ . _ . _ ...... . . _ External voltage regulator - removal and instalilltion _ . Generator - brush replacement .. _ ...•. 10 Generator - removal and installation 9 General information 1 Ignition coil - removal and installation .•....•••. 17 Ignition timing - check end adjustment. Chapter 1 Spark plug replacement .. _ . Chapter Spark plug wire, distributor cap and rotor - Check and replacement .•.......... _ . Chapter 1 Starter motor - brush replacement. . _ . . . • . • . • •. 13 Starter motor - removal and instellation . . . • . . . . • • 12 Starter solenoid - removal and installation .. _ . • . • .. 14 Starting system - check •......•.• ...... . . . • _ . 11
8
Alternator - removal end installation .. . . . . • • . .. . .. .. 7 Banery - check and maintenance . Chapter 1 Baltery - emergency jump starting ... ....... . . 3 Battery - removal end installation ... . Battery cables - check and replacement Charging system - check
2 4
5
Contact points and condenser - replacemanl and adjustment (1953 through 1974 models) . Conventional distributor - chec k
Conventional ignition system - check ..... . Distributor - removal and installation .... . ... . Drivebelt check Bnd adjustment Electronic distributor - check ....... . Electronic ignition module - removal Bnd inSlaliation.
Chapter 1 21 15 18 Chapter 1
22 19
• Specifications
Charging system Alternator and gllnerator brush wear limit Generator brush spring tension ........ _ . Motorcraft alternator output voltage Temperature Ot050 50 to 100 10010150 150 to 200
1/4 in 40 oz.
Voltage fange 14 .1 to 14.8 13.7toI4. 5 13.4toI4.2 13. 1 to 13.8
Electronic ignition system Coil resistan ce 1974 through 1977 Primary. . ........ _ Secondary .••.•..•.•• ...•..•.•.. 1978 through 1986 150 cu in four-cylinder. in-line six-cylinder and Primary 75°F •. 200"F Secondary
75°F 200"F .•.. 1980 through 1983 lour-cylinder engine Primary . Secondary Coil-to-ground Cranking voltage test 1974 through 1977 SWitch-on voltage ....... _....... _ Cranking vollage ...... __ 1978 through 1986 150 cu in four-cylinder, inline six-cylinder and V8 engines . . __ . Distributor ignition pickup coil resistance t974 through 1977 ....... _ 1978 through 1986150 cu in four-cylinder, lnline six-cylinder and V8 engines . . _ . 1980 through 1983 four-cylinder engine Pickup connector. Connector-to-ground
5 1 to 2 ohms 8nnn to 17500 ohms VtI engines 1.13 to 1.23 ohms 1.50 ohms 7700 to 9300 ohms 12000 ohms Zero or near zero on the low scale Less than Infinity on the high scale Infinity
12 to 13 volts 9.6 volts 6 volts 1.6 to 2.4 ohms 400 to 800 ohms 500 to 800 ohms Infinity
5-2
Chapter 5 Engine electrical systems
Conventional ignition system Cranking voltage 6-volt system 12-\1 011 system Voltage drop test
4.5 lIolts 9 volts
Battery cable-to-staner ............... . Distributor primary terminal on the coil-la-the primary
0.2 or less
terminal on the distributor . . ... . Distributor coil terminal-la-distributor body.
0.05 or less 0,05 or less
Starting system 1953 through 1972 models -
Autolile 6-voll.
brush spring tension
. . . . . . . . . . . . . . . . . . . . . . , ...... .
Autolit8 12-\1011 . . . . . . . . . . . . . . .
Delco 6-volt .... . Delco 12-voll MOM-6005, MOU-7004 . .. ..
1107746.
. .....• .
......................
1107391 , 108366 and 1108375. . . . . . . . . . . . . . . . . .
42 to 53 oz 31t0470z 24 oz 31 to 47 350z
O~
32 to 40
Ol
Prestolite .. ...................... 32 to 40 oz 1973 through 1986 models (150 cu in four-cylillder, inline six-cylinder and V8 engines only) Brush spring tension .. ...•..•..•.. 40 oz Brush length . . . . . . . . . . ••. . •. . •. . •. . 112 in Brush wear limit
.. ... ... ...•..•..
1/4 in
Torque Specifications
Ft·lb
Nm
Alternator bracket·to·engine Alternator pivot bolt . Starter motor·to-bellhousing
231030 23 to 30 15t020
31 t041 31 to 41 21 to 28
1 Gana,,1 information The engine electrical systems consist of the starting, charging and Ignition systems. The sterting system is made up of the battery, starter relay switch. starter motor and solenoid and wiring. Some early models were not equipped with relays or solenoids for activating the starter drive and used Bendix spring or clutch devices to perform this function. Automatic transmission·equipped models feature a neutral start switch in tha system to prevent starting except when the transmission is In Neutral or Perk. The charging system consists of the generator or alternator. voltage regulator, battery and associated wires and cables. On leter models. the vohage regulator is an integral part of the alternator. The ignition system consists of the distributor, coil, sperk plugs, bat· tery, associated w iring and, on V6 models, a ballast resistor on the coil. Later models use transistorized ignition components to perform some of the mechanical functions of the distributor (such as contact points and spark advance) for improved performanca and emissions.
2
Battery -
removal end in.tallation
The battery is located in the engine compartment, usually to the right side of the engine. It is held in place by a hold-down frame and wing nuts or bolts and clamps at the base. 2 Caution: Since the battery produces hydrogen gas, keep open flames and lighted cigarefres away from it et a/l times. Avoid spilling any of the electrolyte (battery fluid) on the vehicle or yourself. Always keep the bafrery in an upright position. Any spilled electrolyte should be flushed immediately with large quantities of water. Wear aye pro· tection when working around the battery to prevent eye damage from splashed electrolyte. Alweys disconflflCt the negative f-) battery cable first, followed by the positive 1+) ceble. 3 After the cables are disconnected from the battery. remove the clamp bolts or wing nuts and hold·down frame. 4 Carefully lift the battery from the tray and move it out of the engine compartment. 5 Prior to installation, make aure the negative cable is properly ground· ed with a clean and secure connection. 6 Place the battary in position in the tray and apply a thin coet of light grease or petroleum jelly to the base of the posts. 7 Connect the positive cable first, followed by the negative cable.
•
8 Instell the retaining clamps and bolts or hold·down frame. Do not over tighten them or you may distort the battery.
3 Battery - emergency jump stertlng Refer to the 8006ter bartery (jump) starting procedure et the front of this manuel.
4
Battery cables - check and replacement
Periodically inspect the entire length of each battery cable for damage, cracked or burned insulation end corrosion. Poor battery cabla connections can cause starting problems and decreesed engine performance. 2 Check the cable·to·terminal connections at the ends of the cables for cracks. loose wire strandS and corrosion. The presence of white. fluffy deposits under the insulation at the cable terminal connection is e sign the ceble is corroded and should be raplaced. Check the ter· minals for distortion, missing mounting bolts or nuts and corrosion. 3 If only the positive cable is to be replaced. be sure to disconnect the negative cable from the battery first . 4 Disconnect and remove the cablets) from the vehicle. Make sure the replacement cablets) is the same length and diameter. S Cleen the threads of the staner or ground connection with a wire brush to remove rust and corrosion. Apply a light coat of petrOleum jelly to the threeds to ease installation and prevent future corrosion. Inspect the connections frequently to make sure they are clean and tight. 6 Attach the cable(s) to the staner or ground connection and tighten the mounting nuttsl securely. 7 Before connecting the new cablets) to the battery, make sure they reach the terminals without having to be stretched. 8 Connect the positive cable first, followed by the negative cable. Tighten the nuts and apply a thin coat of petroleum jelly to the ter· minal and cabla connection.
5
Charging sYltam - check
When a problem develops in the charging system. the first check should be for the obvious. Inspect ell wires for damege, corrosion and
5-3
Chapter 5 Engine electrical systems lOOSe connections. Check the dnvebelts to make sure they are in good condition and properly adjusted. 2 It the charging system is not working properly lindicated by the warning light staying on. ammeter showing discharge or a battery that II constantly discharged or overcharged). the altarnator or generatol output Ihould be checked.
e
Generator
Motorcraft alternator
3 Disconnect the armature (ARM) and blttery (BAT) leads from the /egulator and connect an ammeter between the two wires. Disconnect tIM lield (FLD) leld from the regulator end, W1th the engine at Idle, touch the laad to the regulator base. Increase the engine speed slowly and check the charging rate on the ammeter. 4 II the charging ISte does not increase. there is a fault in the wiring Mrnall or the generator is defective. 5 If an emmeter is not available,. connect e 6 or 12·volt test light 10 the ragulator terminel marked "Armeture." Start the engine and ground the other light leed. II the test light does not glow, the fault 18 either in the regulator 01 generator. 8 To locali~e the fault, disconnect the field and armature cables from the generator, connect a wire to the field terminal and ground the other end. Use a 60-watt, flO-volt test light to ground the ermature terminal. The test light will glow at apprOll.imately 1500 rpm if the generator is operating properly, indicating a fault In the voltage regulator. The l'IQulator should be replaced with a new one (Section 6) or checked IOd adjusted by an auto electric shop.
11 Connect a voltmeter to the battery with the voltmeter positive leld on the positive post and tha negallve lead on the negative post. 12 Apply a load to the system bV turmng on the headlights and tha heater or air conditioner blower motor. 13 Start the engine and slowly increasa the speed to appro)(lmately 2000 rpm. 14 Whan tha voltaga stabilizes, compare tha raading to the chart in tha Specifications. If the reeding II Within the specified range. tha alternator (and charging system! I' opelStlng properly. If the reading is high, the system is ollercharging and if it illow, it is undercharging. Procead with the appropriate checks to verily the conditions and locate the fault. Undercharging 15 II the system is undercharging, turn olf the engine and accessories and note the battery voltaga at the terminals using e voltmeter. 16 Start Ihe engine. turn on Ihe electrical accessories and slowly increese the engine speed to approll.imately 2000 rpm. 17 Note the voltage reading and cOrTlpare it to the one taken In Para graph 15. If the reading has increased at least 0 .5 volt, the charging system is operating properly. If the increase Is less than 0.5 volt. Ihe system is delinitely undercharging. 18 If the test indicatas undercharging, turn the ignition switch on and check lor battery voltaga at tha voltega regulator 5 terminal. If there is no voltage. or il it is less than that 01 the battery. check the yellow wire lor an open circuit and lor I!I faulty connection at the regulator or tha starter solenoid . 19 If no fault is found, disconnect the voltage regulator wires and con· nect onalaad of an ohmmeter to the F terminal and the other to a good ground as shown in the accompanying illustration. The ohmmatar should indicata lour (4 ) to 250 ohms. Less than four ohms indicates a shOrt, while more than 250 ohms indicates an open, dirty brushes, or dirty slip rings. If the reading il not Within tha specifica tions, the alternator should be raplaced or overhauled. 20 If the reading is within the specifications. connect the ohmme ter between the land F terminals of tha VOltage regulator. No resistance should be indicated. If the reading i, apprOll.imately ten (10) ohms. tha regulator i, damaged and should be replaced with a new one. 21 To lurther check the voltage reguletor, connect a jumper wire between the A and F terminels of the plug es shown in the accompanying Illustration, then repeat tha tests In Steps 15 through 17. II undarcharging is Indicated, replece the voltage regulator. 22 If the output is within the specifications, disconnect the jumper wire, lealling the voltage regulator connector unplugged. Disconnect
If the output is more than 13 volts but lass than 15 volts, the alternator is operating property. 9 II the voltage rises to 15 or 16 Wits, the regulator is faulty and should be replaced with a new one (Section 6). 10 If there is no current output, the alternator should be replaced With a new 01 rebuilt unit.
Motorola alternator 7 Unplug the field connector and connect a jumper wire between tha eUl(iliary and lield terminals. Connect a voltmeter to the aUl(iliery terminal, start the engine and allow it to idle.
•
DISCONNECTED
~r:J
~LPtd
REO
BLACK
o T
DC ¥OL T5
Fig . 5 .1
•
B~TTERY
Motorole altarnator output tut datalls (Sac 5)
~ETER Sl-tOULO INDICATE
"M""~' I'l!) c .0 v av"
• AND 250 ~~
SET OHIoIIoIETER
,
"IoIULTI~L
I(NOe AT "'"
••
,
.~ USE JIJfoII~ER WIRE TO CONNECT A AND AT REQU~ATOR ~~ua
fig. 5.2
Checking tha Motorcreft .ltamlltor cherglng syltem for an open circuit (Sec 5)
,
n""'N"'~$
Fig. 5.3 Using. jumper wire on the voltage regulator plug (Motorcraft altemator) (Sec 5)
fig . 5.4
Motorcraft alternlltor Jumper wlr. connections (Sec 5)
5
5-4
Chapter 5 Engine electrical systems
the wiring harness from the silemator lield IFlO) terminal lind connect II jumper wire between the battery !BAT) lind FLO terminals liS shown In the IIccompenying Illustrations. 23 Repeat the tests in Step. 15 through 17. If the output is within the specificatIOns, there I, a fault in the wiring harness and it should be replaced. If the output i.low, there il (I defect in the alternator and il should be replaced or overhauled.
MO.' TlRMI"'Al
...." f .. "
~''''V~''' "
Tl""""'L
Ov.rcharging 24 Connect. voltmeter positive lead to Iha battery positive post and the negatlVII lead to the oegativII POlt. With all electricel accessories turned olf, note Ihe voltmeter reading.
.
-,
,
'
25 Start the engine end slowly Increase the speed to epprOllimetely 1500 rpm. The voltage should Increase no more than twO (2) volta over the battel)' vollage noted in the previous Step. If it doe. increese more than two (2) volts, the overcharging condition is verified. 26 Disconnect the voltage regulelor conneclor and repeat Ihe teS!. If Ihe vollage il wllhin Ihe Ipecified range, Ihe regulalor is laully and muSI be replaced wllh a new one. II the vollage reading is Slill high, the allernalor wiring harness has a shorl and should be replaced.
Delco 81tern8tor 27 These altarnators laalure an Inlegral voltage regulalor and most lasting 01 Ihe charging syslam requires special equipment. However, simple checks 01 undercharging and overcharging conditions can be made with e voltmeter. Undercharging 28 With the Ignhion swilCh on, check between the alternator No. 1, No. 2 and battery (BAT) terminals and a good ground wilh a voltmeter. A zero reading Indlcatal an open circuit between the lead connection end the batteI)'. Tha vehicle should be taken to a repair shop lor further testing because of the Special equipment and techniques required. Overcharging 29 Connect the voltmeter between the No. 2 tarminal and a good ground If the reading II zero. the No. 2 circuit is open. If the No. 2 Circuit II not open and an obvious overcharge condition still e,,· iSIl, Ihere is a fault in the alternator.
6
Typical Delco aklrnator termlnll locations (Sec 5)
External wltag. regulator - r.moval and Inltallation
Unplug the connector. remove the attaching screws and lilt the voltage regulalor from Ihe engine compartment. 2 Place the new regulator in pOlition, InltaU the screws and plug 10 the connector.
7
Fig. 5.5
Fig. 5.8
Ullng a toothpick to retract thl brushes on the MOlorcraft alternator (Sec 8)
Alternator - removal and Inllallatlon
Belore removing the a!tarnetor, make sure the Ignition switch is oft and the negative csble II dilconnected Irom the batteI)'. 2 Disconnect the electrical leadl from the alternator. 3 Loosen the adjusting bolt and pivot bolt nut. then remove the drive belt from the pulley. 4 Remove the mounting bolts and lilt the alternator from the engine compartment. 5 To Install tha alternator. hold it in pOSition, align the holes and in· stall Iha bolts 6 Place Ihe drivebelt on tha pulley. adjult Ihe tension and tightan the 00111.
7 S
Connecl the eleclricalleadl to the alternator. Connect the negative cable to the batteI)'.
INSULATING
SCAf.W
Flg . 5.7
Delco ahlmetor brUlh holdar Inlpectlon (S.c 81
Worn or damaged brushes can reduce the alternator output. The brushes genereUy do not reQulle replacemenl until the vehicle has reached very high mileage (generaUy over 75000 miles).
3 Disconnect lhe field lead from the altern8tOr. 4 Remove the two self-lapping screws and Iha brush assembly COYer. 5 Pun Ihe brush assembly back carefully until it just clears the locating pins. tiP it eway from the housing and remove il. Do flOl pull the assembly Slralght back as Ihe brushes can break off and lell into tht allernator. 6 Installallon i, the reverse of "mova!.
Motorol8 81tern8tor
Motorcr8ft altern8tor
2 On Ihese model. the antire brush assembly can be repl8ced with the alternalor in place in the vehicle. Before proceeding, disconnect the negative bettel)' cable from Ihe battery.
7 Remove the alternator ISection and scribe aline across Ihe houting components to en.ure correct reassembly. Ramove the Ihrea hOuting Ihrough·bolts and Ihe nuts and insulators from the rear housing.
8
Ahernetor -
brulh replacement
7.
5-5
Chapter 5 Engine electrical systems
9
Generetor -
removal and lostallatlon
1 Disconnect the negatiV1l cable from the battery. 2 Disconnect the electrical leeds from the generator, marking them to ensure reinstallation in their original locations. 3 Loosen the adjustment bOlt. push the generator toward the engine and remove the drlvebelt. 4 Remove the mounting balta and lift the generator from the angine compartment. 5 To install the generator. place it in position and install the botts finger tight. Place the drivebeh in the pulley groove and install the adjustment
beh. 6
Adjust the drivebelt tension and tighten the adjustment boh se· cutelv. followed by the mounting bolt. 7 Connect Ihe electrical leads to the generator. Connect Ihe negatiV1l cable to the batterv.
a
10
Fig. 5.8
, 2 3 4
Ground cllbfe Betttlry PrJsitive clible Aftemetor wire
Early model Itartlng Iyltam circuit componentl ISee 111
5 AfttlmlJtor 6 fgmtion switch
w'm 7 Ignition SWitCh
B 9 10 11
Solenoid wire StlJrte, Solenoid Connector strap
Carefully note the insulator locations. B Withdraw the rear housing section from the alternator. 9 Remove the brushes and springs from the brush holder assembly, which Is located inside the rear housing. 10 Install the springs and new brushes in the holder assembly and Iwlld them In place by inserting a toothpick through the rear housing IS shown In the accompanying illustration. Make SUfe enough of the toothpick protrudes through the rear of the housing that it can be withdrawn later. 11 Attach the atator to the rear housing, rOtor and front housing assembly. making sure the scribed marks hne up. 12 Install the three housing through·bolts and rear end insulators and nuts, but do not tighten them. 13 CarefullY extract the toothpick from the rear housing and tighten the through·boll$ and rear housirv:J nuts. 14 Install the alternator.
Delco alternator 15 Remove the alternator. 16 Scribe marks on the alternator ca$8 components to make sure they Ire correctly aligned during reassembly. 17 Remove the four through·bolts retaining the rear housing. 18 Use a screwdriver to carefully pry between the stator assembly and front housing and separate the alte-rnator component$. 19 AI the rotor and drive 80d assemblies ara separaled from the slip ring nousing assembly. the brushes Will spring out onto the rotor $hah and can become contaminated with grease. If the same brushes are reinstalled, they must be cleaned thoroughly. 20 Remove the brush holder assembly retaining screws and lift the .asembly away. Note the order in which the parts are removed to simplify raassemblv. 21 II the same brushes and holder assembly ara to be rein$taUed. in· spect the brushea for wear and contamination and the brush springs lor damage and corrosion. Check the insulating screws for cracked and worn insulation. 22 InataU the springs and brushes in the brush holder. The brushes must slide in and out freely aher Installation, with no binding. 23 Retaln the brushes in position in the holder by inserting a toothpick "to the hole al the bottom of the frame. 24 Install the brush holder with the toothpick protruding through the hole in tha alternator end frame. 25 Make sure the rotor shalt bearing surfaces ele clean and position the housings with the scribe marks aligned. Install the through· bolts and nuts. Remove the toothpick from Ihe holder assembly.
Generator -
brush replacement
The generator brushes should ba replaced when they heve worn to less than the specified length or It thev have been damaged or can· taminated with oil. 2 Remove the band on the rear of the generator (if so eqUIPped). 3 Disengage the brushes from the holder arms and springs. remove the elecuicallead retaining screws and separate the brulhes from the generator. 4 Tha contact surface of the replacement brushes should already be radlused to conform to the commutator. It the brushes are not radio used, they must ba contoured with sandpaper prior to installation so thev Will be in full contact with the commutator. To do this, wrap a piece of emery cloth aroulld the commutator IroOgh side out, of course) and slip the brushes over it. Rotate the brushes or brush holder beck and lorth until the brushes match the contour of the commutator. 5 Connect the brush electrical leads end inltall the retaining screws.. 6 PIICe the brushes in position and engage them in the holders. The brushes must move freelv in the holders and be held against the com· mutator by the spring tension. Too high a Ipring pressura causes rspid brush and commutator waar and tOO little allows arcing and reduces generator output. Check the tension with a spring scale to make sure it is IS specified. 7 Inllal1 the band.
11
Starting system -
check
Note: In oldel for the starting system to opelete. the bllttery must be in II fulfy chluged condition lind the tnmsmission must bll in NlJUt$ or Pelk. If the bettery is not fuUy chIJrged, or if the neutnf stllrt switch is fIJufty. rechIJrge the tumery or meke .."y nece$$lIry repairs before trymg to ditJgnose the stllrting system.
It the starter does not turn, switch on the headlights and turn the key to Start or push down on the starting switch. tf the heedlights did not come on, or if they dim or go out when the starter is en· gaged Isee note above), the bsttery snd cable connections should be checked. If the headlights remain bright but the starter don not crank the engine. there Is an open circuit somewhere In the system llOme possible locations are the ignition switch and connections, the lIarter motor brushes, tha $01enoid or the starting switch on foot·operated early model startersl. If the solenoid clicks once when the kev il tum· ed to StaM. the battery and cable connectionl Ihould be checked. It should be noted thet a jammed Itarter drive. defective starter motor. engine mechanicel problems end extremelv low outside tempers lures can affect starting system operation, but the previously mentioned possible problems are tha molt common. 2 The mO$llikelv cause 01 starting svstem problems land one that is vary easy to fix) is loose. corroded or defective bettery csbles and cabla connections. Inspect the cables and check and clean the can· nectlons as described in Chapter 1. 3 AIBo, check the wiring and connections between the solenoid (if BO equippedl and the ignition swi tch. look for broken wires. burned insulation and loose or dirty connectionl.
5
5-6
Chapter 5 Engine electrical systems
4 On IOOI~oper8tea stanen;, check the starling switch for proper operation. This is done by shorling across the terminals, taking care to make a good solid connection to prevent arcing. On early models, remove the Sl8rter motor Bnd take off the outboard housing. Inspect the drive engagement mechanism to see if It is jammed, wipe it clean with a kerosene-darnptlned cloth and relubricate it with 8 thin film of light engine oil. The drive mechanism must be replaced with a new one if it is damaged. 5 II 8 voltmeter is al/ailable, it can be used very effectively to check voltage drops through the circuil wiring lind connections. The first check should be II cranking voltage test (il the starter will operate at all). Hook the voltmeter positive (red) lead to the positive post of the battery and the negative (black) lead to the negative post, Crank the engine and note the voltmeter reading. If it is less than 4-1/2 volts on six 16) voh systems and nine (9) volts on a 12-volt system. the battery is not lully charged. 6 Next. attach the meter leads to the battery positive post and the solenoid or starter switch battery terminal. Turn the ignition switch on and nOle the voltmeter reading. It should be extremely low (approximately 0.2 volts or less). II not, there is excessive resistance (such as a dirty or loose connection) in that pert of the circuit. 7 Repeat the test with the voltmeter leads attached to the negative post and the starter motor housing and the leads attached to the solenoid and starter switch battery and motor terminals. Remember. a high voltage reading means excessive resistance in that part of the Circuit. Each wire and connector cen be checked in this way. B If the voltage drop tests do not produce conclusive results end il you know the battery is good, then it is very likely Ihat the starter motor is defective. It should be replaced with a new or rebuilt unit Irefer to the appropriate Section in this Chapter lor removal, installation and brush replacement procedures).
12
... ery high mileage (approximately 75000 miles) . Brushes which 8,. worn. damaged or operating w ith low spring pressure will reduce the starter speed. 2 Remove the starter motor ISection 121 .
Early model Prestolite starter (F- and L-head four-cylinder and V6 engines) 3 4
Remove the band from the rear of the starter motor. Remove the brushes from the holders and use a soldering iron to
Fig. 6.9 ,
2 Switch button
3 Actuation lever
4 Bendix drive spring
Starter motor - removal and Installation
1 Disconnect the negative cable from the bettery. 2 Disconnect the leads Irom the solenoid or starter switch. merking them as necessary to ensure reinstellation in their original positions. On some models it will be necessary to raise the front of the vehicle and support it securely on jackstands to gain access to the starter. 3 Unscrew and remove the starter motor mounting bolts and withdraw the motor from the engine bellhousing. On 151 cu in. fourcylinder engines, be sure to remove the spacer shims along with the starter motor end reinstall them in their original locations. 4 Installation is the reverse of removal .
1J
Foot-operated starter components 15ec 111
ConteCf plate nut
Starter motor - brush replacement
~AONT
Fig. 5 .10
151 cu In four-cylinder engine starter moto r and shim Installation ISec 12)
The starter brushes should be replaced alter the vehicle has reached
Fig. 5 .11 va engine Delco atarter brush locetlon 1511c 13}
Fig. 5.12 Checking the starter brush spring tension (150 c u in four-cylind er, inline six-cylinder and va engines) (Sec 13)
Fig. 5.13 Typical remote-mounted, 150 cu In four-cylinder, inline six-cylinder and va starter solenoid installation (Sec 14)
Chapter 5 Engine electrical systems untolder the lesds wher" they are 8uached to the tleld COIL 5 Open the loop in the lield coillesd snd insert the new brush pigtail • 11 the wsy into the loop. Clinch the new brush leed tightly in the ter· minel end solder it in piece. Install the brushes In the holders and use e spring scele to meke .ure Ihe brush spring lenslon is within the specified renge. Hook Ihe Kele under Ihe spring near the brush and pull on a line perallel with the .lde of the brush and note the reading just as the spring leaves the brush . Adjust the tension as necessary by twisting the spring at the holdar with needla·nose pliers.
a
Delco starter (V6 engine) 7
Disconnect the staner motor field coil connector. from the solenoid termlnsl • • Unscrew and remove the through·boIts snd remove the commutelor end frame , the lield Irame assembly end the armature from the starter motor housing. 8 Pun Ihe pivot pin out and remove the brush assemblies and spring. Remove the retsining scrsws and sepsrste the brushes from the holders. 9 In$lslislion is the reverse of removs!.
Presto/ite starter (150 OJ in foor-cyfinder, irrline six-cyfinder and VB engines) 10 Aemove the brush cover bsnd and !ne staner motor drive yoke cover. I. Withdraw the brushes from the holders, using a hooked piace of wire to retract tha springs. Aemove the retaining screws Irom the leads and lilt the brushes from the starter. On some models it will be necessary to remove the through·bolts snd disassemble the starter motor for sccess to the insulated brush leads if the brushes are suffi· ciently worn to require replacement. Cut all the brush leads as close IS possible to the field coil connection. 12 With the brushes removed , check the brusn apring tension with • spring scale to make sure it is within the specified limit. Adjust the tanlron by bending the spring with needle· nose pliers. 13 Solder the insulated brush leads to the lield COil using rosin core lolder. 14 Pull beck the springs with Ihe hooked piece 01 wire end install the brushes. Connect the electricsl leed screws. 15 Aeassemble the Slaner motor and install the brush cover band and drive yoke cover.
Delco 5MT starter (151 cu in, four·cylinder engine) 16 Disconnect the field wind'ng connection from the solenoid terminal, then remove the sterter motor thrAugh·bolts, followed by the end frame. n Aemove the retaining screw end lift out the brush . 18 Inspect the brush holder for distortion end discoloration (indicating overheating, which could raduce the tension placed on the brusl'tes). Aeplece the brush holder with a new one i f it Is defective. 19 Clean the brush assembly ctlre fully and install the new brush. Check the movement of the brulh rn the holder to make sure there il no bind· rrg and that the brush contacts the commutator completely. 20 Install the retaining screw snd reassemble the starter motor.
14
Staner Ialenold - removal and installation
5-7
7 InSlsllation Is the reverse of removal. Al'Connect the negative bat· tery cable .
Prestolite starter motor (150 OJ in four",,__• il>-Une six-cylinder ard \18 engines) 8
The solenoid on these models is mounted separately from the starter motor and is located on the inner lender panel. 9 Disconnect the negetive battery cabfe. 10 Disconnect the cables and wires from the solenoid. 1 1 Remove the mounting bolts and separate the solenoid Irom the fender . 12 InSlalistion is the reverse of removal . Aeconnect the negative bat· tery cable.
Delco 5MT starter motor (151 cu in four-cyfinder engine) 13 Disconnect the negative battery CaOle, followea by the lolenold field strap. 14 Aemave the soleoold mounting bolts end motor terminal boit. GralP the solenoid and twllt It to separate it from the slsrter motor. 15 InSlaliation Is the reverse of removal. Aeconnect the negative bst· lery cable.
15 Convention.! ignition Iystem - check Check the ,gnition switch, wifing herness, Ipark plug wues and all ignition system connectors for damags. corrosion and loose con· nections. Inspect the distr ibutor componentllSection 21). Check and adjust the ignilion timing as described In Chapter 1. 2 Measure the voltege at the coil terminels with a voltmeter while cranking the engine over with the stsrter. If the voltage is below Ihat specified, there is a laull in the primary cucuit or the coil. If there ,s 1'10 voltage at all, the coil should be replaced w ith a new one. 3 Aemove the dlltnbutor cap and rotate the engrne until the contact points are closed . Install the cap and turn the ignition on. 4 Connect one leed of the voltmeter to the primary terminsl on the coil and the other lead to the distributor coil lead. If the voltege drop exceeds the Specifications, check for a corroded or loose connection. 5 Connect 0llII voltmeter lead to the distributor coil wire terminal and the other to s good ground on the distributor body. If the voltage reading exceeds the Specifications, the points are misaligned or the point can· nections are loose. 6 Aemow the distributor cap and open the points. The reading sholJld rise to close to battery voltsge. If the voltege il low, there is a short circuit in the distributor. 7 Disconnect the condenser lead, open the points and cheCk the voltmeter reading. If the reading jumps to full battery Voltage, there il a fault in the condenler and it should be replaced with s new one. If the voltage does not lump, replace the dislributor with a new or rebuilt unit. 6 Connect the voltmeter to the battery negative pOlt and a good ground on the distributor body. With the points closed thers should be virtually no drop in voltage Ivery little deflection of the voltmeter needle). If there Is e significant voltage drop, clean and tighten the bat tery cables. 9 Chack for a similar voltege drop between the distributor body and a good ground on the engine block. If there is a voltage drop, remove the distributor end cleen the mounting surfeces of the distributor body and block.
Autolite and Prestolite starter motors (F· and L·head four·cylinder and V6 engines) 1 D'iconnect the negalive battery cable from the battery. 2 Aemove the nut, and washers securing thelolenoid strap to the starter post and the ignition wire to the solenoid post. 3 Aemove the mounting bolts and separate the solenoid from the sterter motor. 4 Installation is the reverIe of removal. Reconnect the negative bat· tery cable.
Delco starter motor (V6 engine) 5 Dilconnect the negative battery cable and remove the two scrsws fltarning the solenoid to the sterter motor housing. 6 lift the solenoid from the housing and disconnect the wires Irom the S terminal and battery terminal. Aemove the solenoid.
Fig. 5.14 Wh.n checkIng for volt.g. drop, ma"- l ur. tn. voltmeter leads touch the circuit terminals rath.r then the cablel to get an accurate reading ,Sec 15)
5
5-8
Chapter 5 Engine electrical systems 1978 through 1986 150 cu in four-cylinder,
18
Electronic Ignition system -
check
in-line six-cylinder and va models 6
Check the igni tion switch. wiring harneu. sprark plug wires and ali ignition system connectors for damage, corrosion and loose connections. Check the ignition timing as described in Chapter 1 and ad just as necessary. Inspect the distributor components for wear, damage and corrosion (Section 22).
Ignition coil test
With the engine 8t normal operating temperature, grasp the con-
nector 8t the top and remove it by pulling it directly away from the coil. Make sure the ignition switch is off. 7 Connect an ohmmeter (set at the low scale and calibrated to zero) to the positive and negative terminals of the coil and compa re the readings to the Specifications (primary resistance) . To check the secondary resistance, connect the ohmmeter leeds
a
to the center tower and either the positive or negative terminal.
1974 through 1977 model. 2 With the engine at normal operating temperature and the ignition switch off. disconnect the coil positive and negative w ire term inals. 3 Connect an ohmmeter [set on the low scale and calibrated to zero) to the positive and negative terminals and compare the reading to the Specifications (primary circuit resistance). Connect the ohmmeter to the positive terminal and coil tower to 4 check the secondary coil resistance. Compare the reading to the Specifications. 5 If the primery end secondary resistances are not as specified. the igni tion coil should be replaced with a new one.
9 If either of the rasistance checks is not within the specified range. replace the coil w ith 8 new one. 1980 through 1983 1St cu in four-cylinder models 10 With the ignition otf. tag and disconnect the wires from the ignition coil. 11 Connect an ohmmeter (set at the high resistance scale I Detwe&n the positive terminal and the groundltd frame of the coil. The reading should be infinite resistance (no continuity). 12 Connect the ohmmeter between the positive and negative terminals using the low resistance scale of the ohmmeter to check the primary resistance. 13 To check the secondary resistance, connect the ohmmeter between
•
oo 0 •
CJ o
0
IGNITION SWITCH II.NO
olSTRlaUToR
".0
DI5TRleUTOR I_I URMINII.L
~"MM"'"""",
T~RMINII.L (+1
Fig. 5.15 Checking Iha coil primary IAI and u<:ondary (BI reslalance (Sac 161
Fig. 5.16 1980 through 1S83151 cu in four-cylinder engine ignition coil terminals (Sec 16)
Fig. 5.17 Checking the pick-up assembly Wllh an ohmmeter (Sec 161
CONN£CT OHMMET£R
T08lll.ND III
MQOULE
Fig. 5.19 1980 throu9h 1963 151 cu in four-cylinder distributor pick-up coil test (Sec 16)
Checking pick-up-roground fflsisttlnce 2 Checking reshsrtlnce lit the connector
~CKUP COIL CONNECTOR
DISCONNECTED FROM MODULE
INFINITE RESISTII.NCE
Fig. 5.16 Pick-up coil test lead connections (1976 through 1986150 cu in four-cylinder, in-line silt-cylinder and va models) (Sec 16)
5-9
Chapter 5 Engine electrical systems the negetlve terminal and the high voltage terminel, u510g the high re,iatance scalI!. 14 Compere all of the readings to the Specifications. Replace the ignition coil with a new one if any of the readings are out of the specified range.
Cranking voltage test 15 The cranking vohage test checks whether the system IS developing sufficient voltage to operate properly and reQuires a 0 to 16·volt voltmeter. 1974 through 1977 model _ 16 Connect the voltmetel positive lead to the coil positive terminal Ind the negative lead to the coil negative terminal. 17 Turn the ignition sWitch to the On position and record the voltage reading. 16 Crank the engine over and record Ihe VOltage reading. 19 If the voltage readingS are lower than sp8(:lfutd, check the battery, battery cabl8s, ignition SWitch and the wiring between the battery and coil for damage, corrOSion and loose connections. 1918 through 1986 150 cu in four-cylinder, In-line six -cylind er and V8 model s 20 Connect the VOltmeter positive lead to the ignition coil positive terminal and the voltmeter negative lead to a good engine ground. 21 Crank the engine over With the ignition SWitch and observa the voltmeter leading. 22 If the reading is below that specified, check the banerv, ballery cables, ignition SWitch and the wiring for damage. corrosion and loose connections. 1960 through 19831 51 cu in four-cylinder models 23 The vehicle should be taken to a dea!er or properly eQuipped shop for this test because olthe special eQuipment and techniQues required
Trigger whee! and pick-Up coil test 1974 through 1977 model, 24 With the ignition SWitch oil, disconnect the pick-Up connector and in,ert Ihe ohmmeter leads as shown in the accompanying illustration. The ohmmeter should be set at the low scale. 25 Wiggle the wires to ma.ntaln contact and note the reading. The reeding should remein constant despite the wire movement. 26 If the ohmmeter reading IS not within the specified range, replace the pick·up assembly with e new one. 1978 through 1986 150 cu in fou,-cylinder, In-line six-cylinder and V8 models 27 With the engine at normal operating temperature and the ignition off. disconnect the pick·up connectol leading Irom the distributor. 28 With the ohmmeter set on th ll mid-range Icale. insert the leads in· to the 82 and 83 terminals of the connector as shown in the accompanying illustration. 29 If the ohmmeter reading is not within the specified range, replace the pick-up coil assembly with a new one.
1980 through 1983151 c u in four-cylinde, models 30 Remove the distllbutor cap and disconnect the pick·up coil from the module. Connect a vacuum pump or source to the advance con Irol unit and applv 20 inches of vacuum. 31 With the ohmmeter I8t at mid-range. connect one lead to the connector I'ld the other to a good ground such as the distllbutor body as shown in the IccompanYlng illustration. The ohmmeter reading should not changa when vacuum is epplied to the advance control unlL 32 Connect both leads to the connector and check the resistance. 33 II either reading Is not within the Specifications, replace the pick· up With a new one.
Centrifugal advance check 34 Wilh a timing light installed and the engine running at idle speed, disconnect the vacuum hose from the vacuum advlnce control unit on the distributor. 35 Observe the timing marks on the front of the engine and ,lowlV accelerate Ihe ellgine. The timing mark on the crank.shaft pulley should appear to move smoothlv in a direction away from the stationery mark on the timing tab. When the engine is slowed down, the mark should return to its original position. 36 If the abo.... conditions ere not met, the advance mechanism inside the distributor should be checked for broken governor spllngs Ind other problems.
Vacuum advance check 37 With iii timing light installed and the allgIOe running at approximatelv 2500 rpm, remove the vacuum hose from the vacuum advance control unit on the distributor. When the hOSH is removed, the timing mark on the crankshaft pullev should appear to move closer to the stationary marl!. on the timing teg. lNhen the hOSH il reconnected, the mark should move away aglin. 38 If reconnecting the vacuum hOSH produces an abrupt increase In advance, or none at all, the vacuum advance control Unit is prob· ably faultV.
17
Ignition coil - removal Ind Instl!lltlon
Disconnect all wires from the coil. On 1976 through 1986 150 cu in four-cylinder, In·line six -cylinder and V6 models, this is accomplished by grasping the white plastic connector, SQueezing it and pulling it away from the COIL On all models, remove the secondary coil wire by grasping the boot, twlsling it one·half tum and pulling it out of the coil. It IS a good idea to mark all wires and connections With tags so they will be reinstalled in their original positions. This is very Important on later model electronic ignition systems, which can be damaged by Incorrectly installed wiring.
IONITION
O"R
Fig. 5.20 The coil connector on 1978 through 1986 150 cu In four-cylinder, inline six-cylinder and V8 models is disconnected by grasping it and pulling it off (Sec 17)
Fig. 5.21 Alway, ch.ck the ,erial numbe .. and marking l errow) to make l ure the repla cement coil i, correct ISec 17)
Fig. 5.22 The 1960 through 1983 151 cu in fou,-cylinder engine coli is located on the engine bl ock (Sec 17)
5
5-10
Chapter 5 Engine electrical systems
2 Remove the mounting acrews or bolts and lift the coil from the engine compartment. 3 If a new coil is to be installed, great care must be taken to obtain the proper replacement unit. Problems associated with installation of the incorrect coil can range from hard starting to, on later models, damage to the ignition system. 4 Place the coil in position and install the mounting screws or bolts. The coil must be securely mounted. 5 Reconnect tha wiring to the coil. After installation, check sll wires to make aure they arB correctly and securely installed before turning on the ignition.
18
Dlltrlbutor -
Note: On 150 cu in four-cylmder and m-Ime six-cylinder engines it is crucial to make surf) the number one cylinder is on rhe compression s/roke because the crankshaft pulley mark also aligns with the TDC mark when the number four or six cylinder is on the exhaust stroke. 5 Scribe a line on the distributor body and make a corresponding malk
removal and In.laU.tion
Disconnect the negative battery cable from the battery. Unplug or disconnect any wires from the distributor body and remove the distributor cap. 2 Disconnect the vacuum hose from the vacuum advance control unit on the distributor. 3 Pull the spark plug wires off the sperk plugs. Pull only on the ru bber boot, otherwise damsge to the sperk plug wire could result. It is a good idea to number each wire using a piece of tape. 4 Remove the spark plugs, then place your thumb over the number one spark plug hole and tum the crankshaft in a clockwise direction until you can feel the compression pressure in the number one cylinder. Continue to slowly turn the crankshaft until the notch in the crankshaft pulley lines up with the 0 or TDC on the timing mark tab. At this point the number one piston is at TOC on the compression stroke.
on the engine block. Mark the position of the rotor in relationship to the distributor body. 6 Remove the bolt end clamp and carefully withdraw the distributor from the engine. 7 Caution: Do not allow the engine to be cranked over until the distributor has been reinstalled.
8
To install the distributor. line up the mating marks on the distributor
IiInd the engine. Slide the distributor Into placa. It may be necessary to move the distributor back·and-fonh slightly to engage the gear. After the distributor is securely seated, the rotor must be pointing at the mark on the distributor. 9 Install the clamp and bolt finger tight. 10 Replace the spark plugs and install the plug wires. 11 Install the distributor cap and connect the wires and vacuum hOSEL 12 Connect the negative battery cable to the battery and check the ignition timing as described in Chapter 1. Don't forget to tighten the distributor clamp bolt when finished. 19
Electronic Ignition module -
removal and Installation
150 cu in four-cyfinder, in-fine six-cylinder and VB models 1
On these models the module is located on the firewall Or inner fender panel. 2 Unplug the wires from the module.
FIRING ORDER ' · 3-4-2 SCRIBE MARK
•
Fig . 5.24 Early model 11953 through 1911) cylinder numbering and distributor rotation (Sec 181 Fig. 5.23 Scribe a mark on the dl.trlbutor haUling oppollte the rotor tip before removal !Sac 18)
Eight-Cylinder Engine Four-Cylinder Engine
Six·Cylinder Engine LEFT BANK
0)
~. , ",
Fig. 5.25
CD
0)
0)
RIGHT BANK
CD CD CD
0)
Later model ,1911 through 1983) englna cylinder numbering and distributor rotation (Sec 181
FRONT!)
5-11
Chapter 5 Engine electrical systems 3 Remove the mounting screws end lift the module from the engine compartment. 4 Make sure the replacement module is exactly the silme type as the original. Modules of similar appearance can have diffemnt elec;:tricel properties which could lead to damage of the ignition system. S Place the module in poSition and install the screws. S Apply dielectric silicone grease to the cavities and blades of the coonectors to assure good elecuicill contact and plug them securely Into the module.
Fig . 5.26
151 cu in four-cylinder models 7
On these models the ignition module is part of the distributor assembly. Ramove the distributor cap. 9 Remove the two screws and lift the module out. 10 Noting the color of the wires to ens.u,e Installation in thei, original locations, unplug the pick-up coif wira connector and remove the module. 11 Installation is tha reverse of removal . Do not remove the speCial
a
Typlcelletar model electronic Ignition module Installation 191
,Sec
5
~,
SPACER
I
-"""-, A1~INN£RSI-1AFT ,..,
00 "0,,"'"
Fig. 5.27 1974 through 1977 .lectronlc dlatributor component layout lalx·cylioder aod vel (Sec 20 and 221
PULLER JAWS MUST GIU' SI-1OULO£1I
Fig. 5.28
Using a amall ga.r pullar to remove the triggar whaal (Sac 20)
1 Distributor cap 2 Rotor 3 Dust shiftkl 4 TriggeF whllel 5 ~t wick 6 Pick-up coil e$$embly 7 Distributor housing
8 Vitcuum control SCrIIW
9 Vitcuum fHI'4nce contrr:N unit 10 Shim /I Drive gell' 12 PI,
5-12
Chapter 5 Engine electrical systems U.o.OI "(KIlI O PIIINO
'OIUTIOfI
AIIOUND .. VOT I'IN
O"UO~
AII"'NSTHAT IIID~ Of VOU
b
L"rJ
FJg. 5.31 Checking the trigger whHito-plck-up bile clearance 11974 through 1977) (Sec 20)
Fig. 5.29 1974 through 1977 electronic ignitlc:Jn pick-up coil In.talliltion detaits [Sec 20)
Fig. 5.30
•
Using I gauge to position the pick-up [Sec 20)
dielectric silicone groase from the module or distributor base. II a replacement module is installed, it will have II package of the grease wilh it. Spread 8 layer of the grease on Ihe metal face of the module
"nd on the diSlriblllor surfece before instatlation.
20
..
,
Electronic Ignition plck· up coil - removal and Installation
I
1974 through 1977 in-fine six-cylinder and V8 models 1 Remove the distributor cap and lift off the rotor and dust cap. 2 Using iii small gear pulter, remove the trigger wheel. Make sure the jaws of tha puller grip the inner shoulder of the trigger wheel securely lind use II washer 8S 8 spacer on the top of Ihe distributor shafl as shown in the accompanying illustration. 3 Loosen Ihe ignition pick-up coil assembly screw 8pproximately three (3) turns using a sulteble driver bit tool or small needle·nose pliers. 4 Lilt out the pick-up lead grommet and pull the leads out of the slot around the spring pivot pin. lift the pick-up spring end release iI, making sure it clears the lelld as it is removed from the bracket. S To install the pick-up coil, place it on tha bracket, m8king sure the locating pin fits properly inlo the summing bar. Place the spring into position and route the leads around the spring pivot pin. Install the lead grommet in the distributor and make sure the leads are positioned so they will not cont8ct the trigger wheel. 6 It will be necesS8ry to obt8in or fabri cate a g8uge so th e pick-up can be accurately positioned. Instaillhe gauge end tighten the mounting screw. Position the pick-up and remove Ihe gauge. Repe811he operation until the geuge can be removed and replaced without 8ny side movement of the pick-up. 7 Tighten the mounting screw securely efter the pick-up hes been positioned lind remove the g8Uge. Set the trigger wheel in position lind meke sure that the pick-up core is positioned in the center of the trigger wheel teeth so the teeth cannot touch it. B Use a deep sockel to push the trigger wheel into pl8ce 8nd t8P II into position wilh e hammer. Bend a O.OSCHnch wire (usually included with the new p8rt) ,end check the trigg er wheeHo-p1ck·up base clearance as shown in the 8ccompenying illustration. The trigger wheel should JUSt louch Ihe gauge in the installed position. 9 Add five drops of light engine oil to Ihe felt wick at the top of the yoke and install the dust shield. rotor and C8P.
1978 through 1986 750 cu in (our-cylinder, in·line six·cylinder and V8 models 10 Remove the distributor cep and rOlor. 11 Remove the trigger wheeL This can be done with 8 small gear puller
Q'r,
I~O""
DISTIIIBUTOII
'00' WASHell
PIN
flllGGEII WHUL
...
""
GEAII
~@
Fig. 5.32 1978 through 1986150 cu in four-cylinder, in-line six-cylinder and V8 distributo r co mponents (sec 20 and 22)
lusing a washer IS a sp8cer on the lOP of the distributor shalt) or with two screwdrivers lused to lever the wheel off!. Remove the pin from the wheel. . 12 On four-cylinder and Six-cylinder engines, remove the pick-up coil retainer and washers from the base plale pivot pin. '3 On va engines. remove the snap-ring which retains the pick·upto the shaft. Remove the vacuum advance mechanism and move it out 01 the way. , 4 Remove the harness tab ground screw and separate the pick-up assembly from the distributor. 'S To install the pick-up assembly, place it in position. On four-cyli~ der and six-cylmder engines, insert the pick-up coil pin into the hole;'
Chapter 5 Engine electrical systems
the vacuum advance mechanism link. On VB engines, attach the vacuum advance mechanism lever and retainer to the pick-up coil pin. 16 On four-cylinder and six- cylinder engines, install the washers and retainers on the pivot pin so the pick-up coil is secured to the base plate_ On VB engines, install the snap-ring. n Place (he wiring harness In tha oistfiDutor nousing slot and install the ground screw through the tab. 18 Position the triggar whael on the distributor shaft with tha long portion 01 the teeth fecing up. Aher aligning the trigger wheel with the slot in tha shaft, insen tha retaining pin into the locating groove and tap it into place with a small drift punch and hammer. 19 Install the rotor and cap.
CAP _ _ ' -
CENTRIFUGAL _ _ _ I ADVANCE MECHANISM
151 cu in four-cylinder models " _ _ _ _ _ TRIGGER ... WHEEL
MAIN _ _ _ _--oj SHAFT
SNAP RING
20 Remove tha distributor. 21 Mark the relativa location of the distributor gear on the shaft, drive out tha roll pin and ramove the gear. 22 Remove the distributor shaft, complete with the rotor and advance weights_ 23 Ramove the snap-ring on tha top of the pick-Up coil, disconnect the wire from the module and remove the pick-up coil and plate assemblv_ The three screws should not be removed. 24 Installation is the reverse of ramovel. Be sure to align the distributor gear with tha mark made during removal.
21
VACUUM AOVANCE MECHANISM
•
ELECTRONIC MOOULE-TOIGNITION COIL CONNECTOR
IGNITION COIL CONNECTOR
•
1980 through 1983 four-cyHndat distributor componant layout ISec 20 and 22)
Conventlona] distributor - check
1 Remove the distributor cap and rotor. 2 Rotate the crankshaft until the point rubbing block is on ana of the high points of the cam. Grasp tha distributor sheft firmly and move it back-and-forth while obsarving the points. If there is enough play in the shaft bushing to allow the points to open, the distributor Is bad IV worn and should be raplaced with a new or rebuilt unit. 3 As a furthar test, connect a dwell metar as dascribad in Chapter I. Start the engine and observe the dwell mater raading , then rev up the angine. If the dwell varies more than two or threa degrees as engine spe&d increases, the distributor is worn and should be replac&d with a new or rebuilt unit.
22
Fig_ 5.33
5-13
Electronic distributor - check
1 Remova tha distributor cap and rotor . 2 Grasp tha distributor shaft firmlv and move it back-and-forth. If there is perceptible movement, the bushings are worn and the distributOf should be replaced with e new or rebuilt unit.
5
6-0
Chapter 6
Emissions control systems
Content. Air Injection (AU system.
. .................. .
Catalytic convener .. Evaporative Contro~System lEeS) Exhaust Gas Recirculation (EGR) system Feedback carbure tOl .
6
•3
General information . . .. . .. Positive Crankcase Ventilation IPCV) syst em
Spark con trol system Thermo-controlled Air Cleaner (TA C)
7
1
2 5
,
9
Speclfic.tlons
T orqu8 specific ations Air injection pump mounting bolts F-head four-cylinder
V6 In-line six-cylinder V8 Air inJection pump adjusting bolt (ell) Air rO!flction manifold screws F·helld fouf-cylinder
V'
Ft-Ib.
Nm
30 to 40 30 to 40
40 to 54 40 to 54
20 20 20
27 27 51
29 to 35 25 to 30
•
40 to 47 34 to 40
In-line sill-cylinder
1972 through 1974 . 1975 through 1983 V8
15 20 38
20 52
13 13
17 17
27
EuR valve ISO cu In foul-cylinder and In-line six-cylinder ...
VB
. . . . . . . . . . .•.••.••...
151 cu In four-cylinder Ollygen sensor 150 cu In four-cylinder and in-line sill-cylinder ..... 151 cu in lour cylinder .•.. , ..•
1
•
9
31
'2
20 to 25
27 to 34
General Information
To prevent pollution of the atmosphere, a number of emissions con· trol systems Ille installed on these models . The combination of sYltems used depends on the year in which the vehicle was manufactured, the locale to which it was originally delivered and the engine type. The svstems end enpine combi nations Include: Positive Crank~se Ventilation (PCV) system - all engines except pre-1960 models Fuel Evaporattve Control System (ECS) - all engines except pre-1960 models Exhaust Gas RecIrCulation (EGR) system - all engines except pre-l960 models AIr l"Iection (AJ) system - all engines except early models Spark control system - all later in-line six-cylinder, VB and lour-cylinder engines Thermo-controlJed Air Cleaner (rAC) - eillarer model engines Calalytic converter - most engines efter 1974 Feedback carburetor and oxygen sensor - 1980 through 1986 Callfomia mOdels
The Sections In this Chap ter Include general descriptions, checking procedures (where possibleland component replacement pr ocedures (where applicable) for each 01 the sySiems listed above. Before assuming that an emiSSions control system is malfunctioning, r..' .;:lk The fuel and Ignition systems carefully. In some casel, speciII tools and equipment, as welln specialized training, afe required to accurately diagnose the causes of a rough-running or dillicult·to·ltaft engina. II checking and servicing bacoma too difficult, or if a procedure is beyond tha scope o f the homa mechanic, consul t your dealer or a properly equipped shop. This does nOt necessarily mean, however. mit the emissions control systems are all particularly difficult to maintain and rapair. You can quickly and a,sily perform many checks and do most IiI not ail) of the regular maintenance at home with common tuneup and hand tools. Note: The most frequent clIUse o f emissIOns problems is simply a loose or broken vacuum hose or w iring connec tion. Therefore, e/ways check rhe hose and wiring connections first. Pay close anentian to the special preceUlJons outlined In this Chapt" Iparticularly those concerning the catalytiC converter, feedba ck ewburetor and oxygen sensorf. It should be noted that the illustrlltion. ot the various systems may nOt ellaetly match the system Installed on your particular vehicle Idue to changes made by the manufecturer during production or from year-to·yearL
6-1
Chapter 6 Emissions control systems 2 PositivI Crinkclsi Ventilation (PCV] system
General description 1 This system is designed to reduce hydrocarbon (He] emissions by routing blow-by gases (fuellair miXUJre that escapes from the combustion chamber past the piston rings into the crankcase) from the crankcase to the intake manifold and combustion chamber where they ere burned during engine operation. 2 The system is very simple and consists of rubber hoses and a small replaceable metering valve (pCV velve). Refer to Chapter 1 for illustrations of the PCV valve location.
Checking and component replacement 3 Rough idling is the most common symptom of a defective PCV valve. 4 Remove the valve and inspect it for a build-up of oil sludge.. Shake the valve to see if it rattles, which is an indication that it is not sludged up (photoL If there is a sludge build-up. clean the valve with solvent and blowout the hose with compressed air. 5 With the valve installed and the engine running, pinch off the hose and see if the idle speed drops about 50 rpm. If it does not. replace the valve with a new one. 6 Replacement of the PCV valve is described in Chapter 1.
3 Evaporative Control Sy8tem IECS)
General description 1 This system is designed to trap and store fuel that evaporates from the carbu retor and fuel tank which would normally enter the atmosphere and contribute to hydrocarbon (HCI emissions. ., 2 The system is quite simple and consists of a charcoal-filled canister and (depending on the model and yearl a purge valve. a manifold vacuum purge line, a carburetor vacuum line. a liquid check valve in the fuel line and a relief valve In the fuel tank filler cep. 3 On the earlier versions of this system there are only two hose connections to the canister; one connected to the fuel tank vapor line and tha other to the air cleaner. The fuel vapors are drawn from the canister to the air cleaner and into the engine by the vacuum developed by the air passing over the canister hose tube located in the snorkel. On later models, when the engine is off and a high-pressure condition begins to build in the fuel tank Icaused bv fuel evaporationL thll charcoal in
2.4
The PCV valve should rattle when shaken beck-and-fortrl
the canister absorbs the fuel vapor. On some models, the vapor from the carburetor also enters the canister. When the engine is started cold, the charcoal continues to absorb and store fuel vapors. As the engine warms up, the stored fuel vapors are routed to the intake manifold where they are inducted and burned during normal engine operation. As the engine vacuum increases, the secondary purge circuit opens so the vapors are purged at a higher rate. A liquid check valve incorporating a float and needle valve allows the free passage of vapors (but not liquid fuel) between the fuel tank and canister. The fuel tank filler cap features a calibrated two-way relief valve which allows outside air to enter the fuel tank and relieve the high vacuum.
Checking 4 Checking the canister, replacing the filter pad and inspecting the lines and hoses are routine maintenance procedures, Refer to Chapter 1 for details. 5 If liquid fuel is found in the canister, replace the check valve with a new one. 6 To check the filler cap and relief valve. remove the cap and inspect
CAIIBUIIETOII
8OW' ,,~
AIR CLEAIliER SIIIORKEL HOSE-TO·FUEL VAPOR STORAGE CAIliISfER
VACUUM
FlLTEII
SIGNAL
Fig. 6.2 Fig. 6,1
Early model ECS system component locetion end layout (Sec 3]
Typical later model ECS system component layout (SI(: 3)
6
6-2
Chapter 6 Emission control systems
the cap and filler neck for luel stains, indicating luel leakage. 7 lDok for 8 damaged Of deformed gasket and make SUfe the felief va lve Is nOI stuck. If tha gasket end valve are not In good condition, replace the cap with 8 new one.
4 Catalytic convener
General description 1 The catalytic COffl'8fter is designed to reduce hydrocarbon !HC'and carbon monoxide (CO) pollutants in the exhaust. The converter oxidize. Ihese components ,nd converts them to water end carbon dioxide. 2 The converter is located in Ihe ...haust system and closely resembles II muffler. Two types 01 converters are used; II conventional
Component replscement e Repl8'Cement Ind maintenence of the chercoel cenister, filter ped and lines Ire covered In Chapter 1. 9 Replacement of the ~quid check valve is very streight forward alnea II only Involves disconnecting the hoses and clemps from the fautty part, unbolting Jt and Installing the new ona. Mark the hose connec· tiona before removal to avoid milcing them up.
oxidizing catalyst (CDC) 80d 8 three-way ca talyst (TWCI. The coe converter controls the He end CO pollutants when the exhaust gas II forced over the trllated pellets and is sometimes celled B two-way cltaly81
TOC14 ... RCO ... L C.t.NISTlII
"
'ull OUTlET LI .. E TO
a"'UGE
LIOUIO CH(CIt V... LVE /
r-.J('~~~~'" l"~'
ROLLOVER CHECIt V ... LVE
FUEL T ..... 1t .~.
Vf"T LINts
Fig. 6.3
ECS system fuel vapot control component IIYOut (Sec 31
HANGER _ _ _ _ SUPPORT , ~ _ -
••
~
III ... CIt£T HANGEII
•
,•• u~ro.
~
\:i.t
IIIIACIt£T
,
CATALYTIC CONV(IITlII EXHAUST
""
o
~ Fig. 6 .4
MUfFLER
, CONVEIlTEII AIIIINJECTIOI
ru ..
l\'plCIII catelyUc converter Instillation [threl-wlY type) [Sec
4,
6-3
Chapter 6 Emission control systems because it controls two 01 the three exheust emissions. Three-way catalysts control HC and CO pollutants as well as ollidas of nitrogan (NOx). The three-way catalyst consists of two converters in one shell with a mixing chamber between them. The front chamber honeycomb catalyst is treated with rhodium and platinum lor controlling NOx, while the rear chamber is a two-way type. Air from the eir injection system is injected into the mixing chamber-to aid in the oxidation 01 pollutants. 3 Caution: If /iuge amounts of unburned geso/ine enter (he ctltafyst, it may OVBrhetlt tlnd cause a fire. A/ways obsarve the fol/owing precautions: Use only un/e/tded gasoline Avoid prolonged idling Do not prolong engine compression chacks Do not fun the engine with /t nearly empty fuel tank Avoid coasting with the ignition rurned off Do not dispose of /t used catalytic conVBrtar along with oily or gasoline soaked parts
it to soak in. Disconnect the air Injection tube from the converter fitting (if equipped). 9 Remove the nuts and clamps, then seperate the converter from the exhaust pipes. Remove the ol
5
Spark control syltam
General description
Checking 4 The catalytic converter requires little if /tny maintenance and servicing at regular intervals. However, the system should be inspected whenever the vehicle IS rais&d on a lift or il the exhaust system is check&d or serviced. 5 Check all connections in thl:! exhaust pipe assembly for looseness lind damage. Also check all the clamps for damege, cracks and missing fasteners. Check the rubber hangers for cracks. 6 The converter itself should be checked for damage and dents (mallimum 3/4-inch deep). which could affect its performance andlor be hazardous to your health. At the same time the converter is inspected, check the metal heat shield (if so equippedl lor damage and loose fasteners. 7 Refer to the air injection system Section for information on components which work in conjunction with the air i" jection system and catalytic converter.
Component replacement 8 00 not attempt to remove the catalytic converter until the complete ellhaust system Is cool. Raise the vehicle and support it securely on jackstands. Apply some penetrating oil to the clamp nuts and allow
1 The spark control system is designed to reduce hydrocarbon (HCI and ollides of nitrogen (NOxl emissions by controlling ignition timing advance when the engine is cold or dUling certain driving conditions. 2 The spark control systems and devices used on these models may include: Transmission control/ad spark (TCS) systam Coolant tamperatura OVBrrida (CTO) switch ~cuum advance control delay valVB Delay valve Non-linear vacuum regulator (NLVRJ system 3 The TeS system is used on 1973 through 1978 models and con trols NOx emissions by lowering the peak combustion temperature during the power stroke. This is accomplished by restricting the vacuum advance under certain condition5. System components Include a solenoid vacuum valve located in or near the intake manilold, a solenoid control switch located in the transmission case (manuall or spe&dometer cable (automatic) and a coolant temperature override switch (CTOI. The 1973 models are equipped with an ambient temperature switch instead of a CTO switch. It is located behind the left side of the radiator grille. This switch allows the system to operate at temperatures above 63"F. At low speeds on 1974 through 1978 models, with the engine temperature below normal operating temperature, full engine vacuum is supplied to the distributor advance mechanism. With the engine temperature above l60"F, the CTO blocks off the vacuum and the solenoid valve controls the ignition advance by releasing some or all of the vacuum to the atmosphere. At speeds over 38 mph (automatic)
SOL~NOIO
CONTROL
SWITCHOP~NAl
34 Mf'H IAUTOMATIC TRANSMISSIONI
•
;¢. /' <
I
,
~ /
SOLENOIO CONTROL SWITCH_OPEN IN HIGH GEAR (MANUAL TRANSMISSIONI
I
)
;;;'-'-;;-~~~;;;;~~~_'lY'I'" T '"
'0'"""'''0'
IGNITION fEED
~~~~~o _--if",)~ VALVE
SPARK
cro
PORT 2
PORT 0 ICENTERI TO
DlsTRlauToR Fig. 6_5
PORT 1 (OUTERI TOMANlfOlO VACUUM
Typical transmlllion controned spark [TCS] operation (Sac 5)
6
6-4
Chapter 6 Emission control systems
or in high gear !manuel), the solenoid is de-energi~ed by the control switch and normal vacuum advance Is used. 4 The CTQ i, used on most models in conjun.c:lion with 8 variely of emissions control devices. The CTO i, threaded inlo II coolant palllQ' and incorporllel 1'1 thermal unit which reacta to coolant temperature by moving. check ball up or down, which open, or closes the switch pons. The opening or closing 01 these ports foutes vacuum through Ihe switch In accordance with the operation of the emissions system involved. 5 A delay valve i, used in conjunction with the CTO to help control vacuum advance on 1980 through 1983 four-cylinder models. The valve reduces NO)! aminions while improving driv8ability. When the coolant temperature i, below 120"F end the vacuum Increases because of sudden deceleration, the delay valve routes the air through a check valve to equalize the pressure. The ero bypasses Iha delay valva when Ihe lemperalure is ebove 120"F. Some models are equipped wilh a oneway revef1le delay valve, which prevents sudden relarding of Ihe ignition timing when Ihe manifold vacuum drop' due to sudden accelera tion right after the engine is "aned.
6
The non-linear vacuum regulator
(NLVA~
valve system Is usad on
1979 through 1983 in-line, six-cylinder and V8 enginas. The vacuum regulator is calibrated to provide a c011stant vacuum and maintain the ignition advance within limits under all driving conditions to reduce hydrocarbon emissions. The regulator has Inlet ports for manifold and carburetor ported vacuum and an outlet pon for the ero valve switch. At low engine torque. the NLVA valve meters the proper smount of the high manifold vacuum present under these conditions. As the engine torque increases, the valve then uses the higher poned vecuum from the carburetor.
Checking 7 The fltst check of the spark control system should Ilways ba I careful inspection of all the rubbar hoses for cracks, kinks and proper installation. Trlnlmi ..lon-c ontrolled ,plrk (TCS) Iyltem 8 To tlst tha TeS systam, a vacuum gauge. test lamp and jumper wire are needed. 9 The leS cunent supply is the flfat test of this system. With the
4~"·~~~= "
SOUNOIO CONTROL
swncH
IGNITION HIO
CURRE~T
SU .... Ly TEST
Fig. 8 .8
TCS Iyllem coolant telTlpentture override ICTOI switch port locations ISec 5)
• -'UNE ... 111
"
~;:::=="''''- SOLENOIO
.::;
CO ~TR OL
,~
SWITCH
IIEOU~ATOIll
VALVl
OROUND CIRCUIT HIT
MAIrIIfOLD ,~
I
10NITlON OR ... NOi FUD
lIiOULATlD
OISTRIIUTOII
,~-
,~
~"
Fig. 6.8
Non"'nl" V!ICuum raguilitor INLVR I syatem layout (Sec 51
SOUNOIO CONTIIOL SWITCH TUT
Fig. 6 .7
Fig. 8.9 Non-linear vacuum ralluilltor INlVRI vllve vacuum port details (Sec 51
TCS Iyllfem te.t. ISlc 51
Chapter 6 Emission control systems ignition switch on, disconnect the wires lrom tha solenoid vacuum valve and connact one lead of the test lamp to a good ground. Touch the Olher lead of the lamp to each connector terminal. The lamp should light at one 01 these terminals Ion later models It will be the orange wire). II the lamp does not light, there is a laull in the ignition feed between the switch and the valve connector. 10 To check the ground circuit, shift the manual transmission in to Neutral. On automatic transmission-equipped vehicles, raise the rear of the vehicle and support it sacurely on iackstends so the rear wheels are free to tum. Connact one lead of the test lamp to the battery positive termineland touch the other lead to Ihe solenoid vacuum valve ground wire terminal. This will be the terminal opposite the one which caused the test lamp to light in the previous test (on most modals this will be Ihe tan wire). On manual transmission models, shift inlo every gear but high and verify that the lamp ramains IiI. Shifting into high should cause the lamp to go out. On automatic Iransmission models, start the angine and shift into Drive. Walch the test lamp and accelerate the angine, noting the speed at which the lamp goes out, which indicales when the solanoid switch is opening. Decelerat e the engine and note Ihe speed at which the lamp lights, indicating the switch is closing. It should be between 28 and 38 mph. II the switch operates outside of this indicated range, replace it with e new one. If the lamp did not ~ght at all during either of tile tests, check the solenoid switch. 11 To check Ihe solenoid switch, disconnect the wire from the switch 81 the transmission (manuall or speedometer cable (automatic). On laler models the wire will be tan. Connect a jumper wire between tha disconIl8cted wire and a good ground. The test lamp should light when canfl8(:ted balwaan the solenoid switch (tan) wire terminal and the battery positive terminal. II it doas not, the switch is faulty and should be replaced with a new one.. If the lamp does not light, the wire itsall is faultv. 12 To test Iha solanoid vacuum valve, place the transmission in Neutral (manual! or Park lautomatic). disconnect the vacuum advance line Irom !ha valve and connect a vacuum gauga. Start the engine. run it at be tween 1000 and 1500 rpm and verify that the gauge indicates no vacuum. With the engine still running , disconnecl Ihe wires from the valve. Tha gauge should now indicate vacuum. If it does not, tha valve is faultv and should be replaced with a new one. Coollnt temperature override (CTO) switch 13 The symptom 0 1 a faulty CTO switch is sluggish operation when the engine is cold (because vacuum is not reaching the distributor to actuate tha advance mechanism). With the engine cold, teg and remove the vacuum hoses from the eTC switch. Connect a hose to the center port ID! and either use a vecuum pump or suck on the hose to create I vacuum while holding your finger over the top and bottom ports. Vttcuum should be lelt only at the top INo. 1) port. Reconnect the hoses, .tart the eng ina and run it until normal operating temperature is reached. Repeat the test and verify that the vacuum i s felt only at the bottom (No. 21 port. If Ihe eTO switch fails either 01 these tests, replace it with a new one.
6-5
Delay valves 14 A failed delay valve can cause poor thronla response. Slnce special equipment is neaded to lest a delay valve. the home mechanic should (eave the checks to a dealer o' proper ly equipped shop. Non-linear vacuum regulator (NLVRI valve 15 Remove the vacuum hose from the distribulor port of the valve and connect a vacuum gauge. Start the engine and verify that the gauga reads approllimately 7 in-Hg at idle. Further testing requires special aquipment so the homa mechanic can either take the vehicle to a dealer or properly equipped shop or replace tha valve with one that is known to be good _
Component replacement TCS system 16 For all components, note the location of all wires or vacuum hoses Defore removal. Replacement of the components is a simple matter of removing the faulty one and replacing it with a new one. Make sure the hoses are correctly installed and tightan all mounting bolts and clamps securely. CTO switch 17 The CTa switch is threaded into a coolant passage. so removal should be done with the engine cold. The cooling system should be drained to below the level of the switch (see Chapter 1). Mark the hoses to simplify installation before disconnecting them. Apply thread sealant to the new switch before installing it and check for leaks when the job is done. Delay valves 18 Replacement of a delay valve is a simple manar of removing the vacuum hosas and installing a new valve. Be sura to nota the direction the valve is facing before removing it. The valves are cotor coded and the darker side has a crosshalCh pattern which faces toward the component being controlled (photol. NLVR valV1l 19 Tag the vacuum hosas before disconnecting them and replacing the valve. It is crucial that the hoses be connectad to the correct ports.
6
Air Injection (AI) systam
General description 1 This system supplies air to the ellhaust manifold to promote combuslion of unburned hydrocarbons and carbon monollide befOfe they are allowed to exit the exhaUst system. Some 1983 and later fourcylinder and in-line six-cylinder engines use a Pulse Air system which performs this function by using the positive and negative pulsations of the exhaust instead of an air pump to introduce the air. 2 The air iniection system is composed 01 an air pump, diverter valve. check valve. air injection manifold, a CTQ, on some six-cylinder modals, and connacting hoses. The air pump is driven by a belt from the crankShaft and supplies compressed air to I he exhaust manifold(s). The check valve prevents the reverse flow of exheust gases into tha system. The diverter valve directs the air from tha pump into the manifoldls) or vents it into the atmosphere. depending on the engina operating conditions. Some later models with th ree-way catalytic converters use a dual air input system to inject air downstream into the convartar mixing chamber. 3 The Pulsa Air system consists of an air injection reed chack valve, which opens and closes due to exhaust system pulsations, an air con trol valve, air switch solenoid, vacuum storage tenk and micro computer unit (MCU), which switches the air upstream or downstream, and associated hoses. This system Is part of the feedback carburetor system.
Checking
5.18 When replacing a vacuum delay valve (arrow I, note the Installed direction (the dark side has a crosshatch pattern facing the component being controlled!
4 Visually check the hoses, tubes and connections for cracks. loose fittings and separated parts. 5 Check the drivebelt tanaion and condition (refer to Chapter 1I. Pulse Air aystem 6 Checking of this system is confined to the above inspections because of Iha special aquipment necessary. Air pump 7 The air pump requires special tools lor checking and servicing, so have the job done by your dealer or a property equipped shop.
6
6-6
Fig . 6 .10 F-head fourcylinder, air-Injection . y.tem
componentl {Set: 8 1 1 Dlvener lIa/ve 2 All pump 3 Pump air filter
4 Air injection tube 5 AI' injection manifold 6 Check valve
'.;;. VIEW A
Fig . 6 .11 V6 engine I lr injection .y. tem componanll (Sec 6 ) View A Top rear of engme V,.w 8 Right side of engme
, 2
Air pump Air (ilte,
3 4 5
DlVerrer valve Check valve Air Injection mamfold assembly (le f t side}
6
Air injection tube
7
Air mjection manifold
8
Relief valve muffler
assembly 'right side}
\
VI EW B '
6-7
Chapter 6 Emission control systems Dlwrt.r valv. B Wltn tne engine Idling, cneck the diverter velve vents to make sure ittJe or no eir is felt. Accelerate the engine t o between 2000 and 3000 rpm end allow the thronle 10 snap shut. A burst of air should be felt It tne venta. If tnere IS no air, or if tnere IS a backfire. check tne vacuum line for reatrlctions and leaks. Accelerate tne engine slowly and verify that at between 2500 and 3500 q:lm, air Is felt flowing from the valva vonts. ChKk valv. 9 The air injection manifold tubes will be hot if the check vslve has f,iled . With the engine idling. disconnect the hose at the check valve. If exhaust glS is escaping past the check vslve. replace it with a new
00. AIr Injection CTO 10 With Ihe engine idling and the coolant below normal operating tamperature lap proximately 16O"F), disconnect the nose from the ero lit the sir control valve. Plsce your finger over the end of the hose to vorify thst vacuum is present. Reconnect tne nose snd warm up the engine to normal operating temperature. Disconnect the hose and verify that vacuum Is no longer present, indicating the valve is working prop· srly. 1/ the CTC faits these tests and the hoses are properly routed and not leaking, replace the valve with a new one.
Dual .Ir Injection syst.m 11 Tnis ayatem operates in conjunction witn the feedback carburltor and MCU and requires special equipment for testing. The diverter valve cen be lested using tne same procedures os for the conventional system.
Component replacement Air pump 12 The air pump must have all hoses and wires disconnected before it can be removed . Be sure to mark their locatloos to simplify instalia· tion. Loosen the pivot and adjusting bolts and then slip off the drivebelt. Ramove the bolts and lift the pump from the bracket. When adjusting tha drivebeh tension after instanation, do not pry on the aluminum pump body Itself as it could be distorted. Make sure the hoses are correctly inatalled before st arting the engine. Check vatva 13 Disconnect the hose from the valve, then use a large wrench to relTlO\le the valve from the injection manifold (same penetrating all may be required to loosen itl. When installing the new check valve, apply anti -seize compound to the threadl. Manifold 14 Tha air injection manifold on In·llne. six-cylinder engines csn be
""";;;~~:A'..~-~~
~
' -'
Fig. 6 .12 Typical In-line Ilx-cylinder Ingine Ilr-InJectlon component layout (Sec 61
, ,' C'i
~~~
, -~0-- -""""'" ~"'YI
,
6
~'"
~
~~ I
~ -Ag . 6.13 Dual lir-injectlon IV-11m components (Sec 6 )
Fig. 6.1 4 The Pul se Air system used on 1983 through 1986 six-cylin der engines and 1984 through 1986 four-cylinder engines (Sec 6)
6·8
Chapter 6 Emission control systems
removed only efter the exhaust manifold is removed . Refer to Chapter 2 for further Information. Use 8 flare nut wrench, if possible, on the eir injection manifold fitllngs. It may be necessary to apply heat to the joint while rotating Ihe injection tube with pliers to separate the connection. On VB engines, the air Injection manifold can be removed with the exhaust manifolds installed. Disconnect the air delivery hose and remove the injection manifold and tube assembly_ Carbon build-up on the tubes may make remoVI:I1 difficult. After removing the assembly, separate the lubes and gaskets from the manifold, Air Injection CTO 15 On models equipped with aCTO, Iha cooling system must be drained partially as the era is threaded into e coolant passage. To simplify installation, mark tha hoses before disconnecting them. Apply thread seelant to the new valve before installing it and be sure to hook up the hoses securaly and correctly. Divener velve 16 Tha diverter valw is atteche(! to a Dracket or suspended in Ihe hoses between the air pump and air Injaction manifolds. Mark tha hoses to simplify instellatlon. Remove the clamps andlor rataining bolts end lift the valve !rom the englna. Downltraam air Injection tuba 17 The dual air injection sySlem downstream tube should first be disconnected from tha air supply hose at the check valve. Remova the check valve if it is going to be rausad. Ramove tha retaining clamp and disengage the tube from the catalytic convertar. It may be necessary to heat the joint to aid in ramoval . Installation is the reverse of ramoval.
7
CAR BURETOR EGR P'OI'IT U'ORTED
~t ~t'AUUM SOURCE)
COOLANT
EGRVALVE
~
Y
~ r:~1 1./
------ ~
g ::.
-.
. ~ ." 'i<"'~ __
TEMPERATURE OVERRIOE SWITCH
GMKET /'
.- ~
TO INNER IS) PORT OF EGR eTO
~$o-z:._~
./[1
/'"I ~-".\"
/;..'
~~ FROM OI.ITER lEI PORT OF EOR eTO
Fig.6.15
Ty pical earty {non·back pressure sensorl EGR system (Sec
7,
Exhaust gas recirculation IEGR, system
General description 1 This system recirculates a portion of the exhaust gases into the intake manifold in order to reduce the combustion temperatures and decrease the amount of nitrogen oxides produced. 2 The main component in the system is the EGR valve. It operates in conjunction with a vacuum amplifier learly models), a coolant temperature overrida ICTO) switch, delay valve lIater models), thermal vacuum switch lTVS) lIatar models). vacuum dump valve lIater models) and a back prassure sensor lIater modelsl. 3 At low engine temperatures, the CTO, TVS (If so equippedl and EGA are closed and the exhaust gu is not being racirculated. At high temperatures, the eTa opens ilnd allows ported vacuum from the carburetor to actuate the EGA valve. The TVS is located in the air cleaner and, on models so equipped, it controls the vacuum to Ihe EGA valva, opening st higher ambient temperatures to improve cold engine drivaSbility. At low intake menifold vacuum levels, a vacuum dump valve is usad to interrupt vacuum to the EGR valve on some models. Also. some later models have a delay valve in Ihe vacuum line to apply the vacuum more graduallv and avoid sudden activation of the EGR velve. On Tour-cylinder lSI cu In engines. the EGA valve is located on a 4 spacer plate beneath the carburetor; on engines, at the rear of the intake manifold; on 150 cu in four-cylinder and in-line six-cylinder engines, on The side of the intake manifold. Two types of EGR valves are used on these models: back pressure sensor-equipped Oater 49state and all California models) and non-back pressure type (1970 through 1975 49-state models). On nonback pressure type valves, the flow of exhaust gas is controlled by the vacuum signal overcoming the spring inside the EGR diaphragm, which opens it and allows exhaust gas recirculation. Back pressure sensor-equipped EGA valves use a combination of ported carburetor vacuum and back pressure from the exhaust manifold to control exhausT gas recirculation. The exhaust gas enters the sensor and controls the EGR valve opening if the back pressure is great enough. On early models the sensor is remote from the EGR valve and connected by a tube. while on later models it is integral with it.
va
EGR VALVE laAcK·PRESSURE SENSOR INTEGRAl)
OUTER E·PORT
='" (7
,., "0
VALVE
FRONT
Fig. 6.16
later model six-cylinder EGR system with back pressure senlor and TVS (Sec 71
CAR8URETOR
EXHAUST CROSS FLOW
EOA VALVE
'1::"'(----- AOAPTER
__',f=";,r.~""-'G' VALVE
Checking 5
Check all vacuum lines and connections for demage and leaks. EGR valva 6 The most noticeable symptom whan the EGR velve is stuck in the open position is poor cold engine driveability. With the engine idling and et normal operating Temparature, check for proper opening of the valve by increasing engine spaed to about 1500 rpm and then allowing Ihe throttle to snep shut. Verify that there is definite movement of the valve diaphregt1l {photol. If there is no diaphragm movement.
INNER S·PORT
•
DELAY VALVE
Fig. 6.17
Typical 151 cu In four-cylinder engine EGR IYllem (Sec 7,
6-9
Chapter 6 Emission control systems
7.6 Checking Ihe EGA valve by reaching underneath 10 feel lor movement of the diaphragm
-
7.10 The black Of red side of the delay valve (arrow) must always fece the vacuum source and away from the EGA valve ...... ~ ... E
TO EGIII V"'~VE
TO EGR eTO VALVE
TO EGR VALVE
Fig. 6.18
Thermal vacuum Iwhch rTVSI pan layoU1 rSec 71
I)(HAUS'
"''' there may be a leak or break In a vacuum line. II the vacuum hosel and connectionlare all righl. Ihe EGR valve and/or back pressure sensor may be delective. 7 To check Ihe EGA valva for proper operation. depress the valve diaphragm with the engine at an idle (normal operating temperature). There should be an Immadiata drop in engine speed. which indicatas thallhe valve Is allowing the flow of exhaust gas. If the Idla is not chang ed by deprassing the diaphragm, tha gases are not reaching tha combustion chamber Iprobably dua to a plugged EGR passage in the in· Ulke manifold). If the engine idle IS rough and does not change greatly when the disphragm is depressed. the EGR valve is not closing due to a fauh In tha hoses or the valva itself. If the hose routing aod can· nections are all right . replace the valVfl with a new one. Al the specified intervals, the EGR valV8 should be removed. cleaned and Inspected. Use a wife brush to clean the dapoSits of carbon from the metering pintle. Check and clean the e)(haust gas passages in the valva using a small wire brush or drill bit. Coat the end of the drill with heavy grease and use pliers 10 rotate the bit in the passage. On non· back pressure·type valves, depress the diaphragm and place your finger securely over the vacuum inlet. Press on the diaphragm severa ltimas and verify that the pintle remains retracted. If It does not. the diaphragm Is leaking and the valve should be !Oplaced with a new one. On back pressure sensor· type EGR valves, apply vecuum to the inlet port with a hand pump to make sure it retracts the pintle and replace the valva if it does not.
a
ero 9 With the engine cold, disconnect Ihe vacuum hose reading from the ero at the EGA valve.. Connect a vlcuum gauge to the hose or pllce your finger over the end and ster! the engine. Accelerate the angine 10 appro)(imately 1500 rpm Ind verify that no vacuum is in· dicated. If there is vacuum. the ero Is faulty and should be replaced with I new one. Warm the engine up to normll operating temperature end repeat the test to make sure vacuum Is now present. If it is not. replaca the ero with a new one.
Fig . 6 .19
CONNECTING TUllE ....CK 'IIIESSVIIII _'C V... LVl
Ncn4nt.gral back p~..vr. EGA valv. (Set: 71
Delay v.lv. 10 The delay ... alve is located in the vacuum hOlle belween the erc and EGR valve. The only tast for a suspected f.ulty vatve ia reptace· ment with a unit known to be good. When Inspecting it for faults, check for cracks and make sure the vllve is installed facing in the proper direction. The black or red side alw.ys faces the vacuum source Iphotol.
TVS " With the air cleaner temperature below tha TVS operating temperature 140° to 500F/4 .4° to 10"CI. connect I ...acuum pump to one fitling and a vacuum gauge to th. other. Apply vacuum to the TVS .nd verify th.t no ...acuum passes through It. Warm up the engine to normal opereting temperature and repeat the v.cuum check to make sure the TVS will now allow vacuum to pass through. If the TVS f.il, either tesl. replace it with e new one. Vacuum dump .... Iv. 12 With the engine 81 norm.1 operating temperature. disconnect the vacuum dump va lve hose from the Intake menifold Iplug the manifold connection). Stan the engine, accelerate it to about 2000 rpm and verify th.t vacuum exits from the a)(hlult pons .t the bottom of the valva. Aeconnect the hose to the intlke m.nifold and repeat the test to make sure no ... acuum is coming from the ...alve e)(hauS! ports. If th. vel ... e lails either test. replace it with. new one.
Component replacement EGR ....t.... 13 The EGA ....IVfI is easily remo ... ed .fter dat.ching the ...acuum hose. Be aure to use a new gasket when Inat.lling the valve .nd chack for leaks when the job is done. Non·lnt.grat b.ck pressure ....r.... 14 The non·integral back prassure ... alve can be remo ... ed after mark·
8
6-10
Chapter 6
Emission control systems
ing and disconnecting the vacuum noses. The EGR valve and back pressure valve ere removed as an assembly. Cleen the msting surfaces of the inteke manifold before installation of the EGR and back pressure valve assembly. The CTO vacuum hose must be connected to the EGA valve fining with the restriction ss shown in the illustration.
em 15 Because the CTO Is threaded into a cooling system passage, the coolsnt must be drained to below the level of the valve before removal. Mark the hoses to simplify Installation before removing them. Apply thread sealant to the new valve before installing It and make certain the hoses are hooked up properly.
TVS 16 Tha TVS can be replaced after removing the air cleaner and ele· ment. Mark and disconnect the vacuum hoses. Remove the retaining clip and lift the TVS from the air cleaner housing. Installation is the reverse of removal. Be sure to install the vacuum hoses securely and correctiy. Delay valve 17 The delay valve is replaced by disengaging it from the vacuum hose and installing a new one. making sure tha hoses ara secure. The valves are color coded and the black or red side must be facing toward the vacuum source. Vacuum dump valve 18 Replacement Is a simple maner of disconnecting the vacuum hoses, removing the valve and installing a new one. Connect the vacuum hose leeding from the EGA valve to port 8, which is horizontal to the body valve. and the manifold vacuum hose to the vert ical port A as shown in the accompanying illustration.
Icing snd reduce hydrocarbon emissions on later models because 01 the leaner fuel mixtures. 2 The system is made up 01 8 heat shroud located on the exhaust manifold, a connecting hose and an air duct and valve assembly in the air cleaner snorkel. The air duCI and valve assembly incorporates an air valve which is activated by II thermostat or vacuum motor. later models heve a delay valve in the vacuum motor hose to prevenl the air valve trep door Irom closing when engine vacuum is low. 3 On thermastlll-equipped systems. the air valve is held closed by spring pressure when the engine is cold and air is drawn from the shroud mounted on the exhaust manifold. As the engine warms up to openning
tempersture, the thermostat starts to open snd air enters the air cleaner snorkle. When the thermostat is fully open. the air valve closes off thl heated air from the manifold and allows air to enter only through thl snorkel.
.. ... ~ TO MANIFOLO_
8
Thermo-contTolled Air Cleaner ITACI
\-----'--'IP -
"8"' TO EGR VALVE
General description 1
This system is designed to improve driveability. prevent carburetor
Fig. 6.20
EGA dump valve port layout (Sec 71
AO'
THERMAL
SI'fIING ENGINE COMP... RTMENT
."
MANIFOLD VACUUM
SNORKEL
THERMOSTAT UNIT tEXTENDEO)
",IR V"'LVE OI'I:N (HEAT OFF POSITIONI THEAMAl SENSOA
AIR VALVE CLOSED (HEAT ON POSITIONI
SPRING
THERMOSTAT
~"
(RETRACTED)
Fig. 6.21
HEATED AIR
Thermoltat type TAC IVltem Opef"etion (Sec 81
Fig. 6.22
Vacuum motor type lAC Ivstem operetlon ISec 81
6-11
Chapter 6 Emission control systems
4 On vacuum motor-type TAC systems, the manifold vacuum acting on the vacuum motor diephgram hold8 the air valve closed when the engine is cold. With the valve closed. heated eir from the exhaust manifold is directed into the er.gine. As the engine werms up, the thermal sensor in the eir cleaner housing bleeds off manifold vacuum and spring pressure in the vacuum motor opens the air valve, allowing air to be drawn through the air cleaner snorkel. II the engine iaaccelerated hard, the manifold vacuum drops, causing tha air velve to open and allows maximum air Ilow. Some leter models use an air cleaner with a spring loadad trap door which is closed whan the engine Is off. When the engine is st arted, the resulting manifold vacuum operates the door, opening it. A vacuum delay valve keeps the door from closing abruptly when the vacuum drops or the engine is shut off.
Checking
Fig . 6.23
V6 engine TA C component layout !Sec 8 )
Vacuum motor Air clellner assllmbly Thermal sensor Sensor spring 5 Air bleed valve 6 Hot air duct 7 Dilfphrtlgm spring
1 2 3 4
8 Diaphragm 9 Air valve 10 11 12 13
Linkage Aft inlet Vacuum chamber Snorkel tube
5 Refer to Chapter 1 for the general checking procedure. If the system is not operating properly, check the Individuel components as follows. 6 Check all vacuum hoses for cracks, kinks, proper routing and broken sections. Make sure the ahroud and duct are in good condition as well. 7 Remove the flexible duct and manually operate the air control valve and (i f equippedi tha trap door. "the valve or trap door sticks or hangs up, replace it with a new unit . S On thermostat-equipped TAC systems, if the air IIBlve does not opeo when the engine warms up to operating temperature. check the valve for binding and the spring lor proper connection. If the valve is in good condition mechanically, the thermostat is defective and the air cleaner housing must be replaced with a new one. 9 On vacuum motor-equipped TAC systems, if the air valve doas not open when the engine wa rms up, check for binding and vacuum leaks. If the mechanism is operating freely and there is no binding or vacuum leaks, remove the hose from the vacuum motor and connect a separate section of hose. Apply a vac uum with your mouth, a vacuum pump or manifold vacuum and see if the velve moves freely to the closed position, indiceting it is working properly. If the valve moves to the open position, the thermal sensor is faulty and must be repleced with a new one. If the valve remains in the heat off position, replace the vacuum motor assembly_ On some models this will require replacing the air cleaner housing.
AMa lf.HT ...... INDUCTION
Fig. 6 .24
"'SSf.M II ~ Y
161 cu In, In-Ilne four-cylinder engine TAC ' yltem (Sec 8)
6
6·12
Chapter 6 Emission control systems TH ERMAL VACUIJIjI ~ I T CH
TItA,!' DOOR
VACUUM MOTOII
IlIEVE RIE
DELAY VAlVf TilAI' 00011
TRAI' DOOR VACUUM MOTOR
Fig. 6 .25
Vacuum operated trap door air clean&r housing
ISee 8) 10 On tflilP door·equipped models, remove the hose from the manifold end connect a vacuum pump. The trap door should open w hen vacuum is applied. If it does not, remove the hose from the motor end apply vacuum directly to it. If the door does not open, check fo r binding. If it does open, check the vacuum hose between the mot or an d the manifold for obstructions and leeks. If the hose appears to be in good
condition, remove the delay valve. join the hOSBS and repeat t he test. Replace the delay valve with e new one if the valve now opens. Replace the vacuum motor with 8 new one if the door swings Ireely, unaffected by vacuum.
Componen t replacement 11 Replacement of the components is a simple matter of removing the faulty part and replacing it w ith a new one. Be sure to connect the hoses properly before checking the system operation.
9
Feedback carburetor
General description 1 The leedback carburetor controls elthaus! emissions while retaining driveability by maintaining a continuous interaction between the various emissions systems. The system is used on 1981 through 1986
in-line silt-cylinder and four-cylinder engines 2 The main components of the system are an elthaus t gas oltygen sensor, an electronic control module (ECM) clOd a controlled airlfuel ratio carburetor. 3 The exhaust gas oltygen sensor is mounted in the Blthaust pipe. upstream of the catalytic converter. It monitors the exhaust stream and sands information to the ECM concerning how much oxygen is present in the exhaust gases. The oxygen level is deter mined by how rich or lean the fual miltture in the carburetor is. 4 The electronic control module (EeM) is essentially a small onboard comput er located In the engine compartment on the left-hand inner fender panel on six-cylinder models and on the left-hand kick panel in the passenger compartment on lour-cylinder models. The ECM monitors up to 15 engine/vehicle functions and controls as many as nine dif· lerent operations. It is programmed with information specific to the model such as weight, linal drive. etc., and can't be used on another vehicle. The ECM receives continuous information from the leedback system and processes it in accordance with ils programming. It sends out electronic signals to the system component s, modifying thair performance. 5 The mixture control solenoid (four-cylinder engine) Of air meteling pins (six'cylinder engine) control the fuel flow in the carburetor, constantly adjusting the luellair mixture in accordance with the signals from the ECM.
MICROI' ROCESSO R
MICROI'ROCf.DOR
cf fig . 6 .26 151 Cf,I in four -cyHnder engine faedback c arburetor amiss Ion ••v-tem component layout (Sec 9)
Fig. 6.27
Six-c yllnder engine feedbec k Iyst em com ponent leyout (Sec 9)
Chapter 6 Emission control systems Checking 6 Since this system requires special tools and techniques for maintenance and repair. any work on it should be left to your dealer or 8 qualified technician, Checking is confined to inspecting the system for broken and damaged components and vacuum leaks. The oxygen sensor should be checked or replaced at the specified intervals and the emissions maintenance switch reset.
Component replacement (oxygen sensor) 7
With the engine cold. unplug the wire connector and unscrew the
6-13
sensOf with a wrench. 151 cu in four-cylinder engines require the use of a special tool (J -29533) for installation and removal. Clean the threads in the exhaust manifold. coat the threads of the sensor with anti-seize compound and install and tighten it to the specified torque, Install the wire connectOf. making sure the boot is not pushed closer than 1/2-inch from the sensor base. If equipped with an emissions system maintenance indicatOf light, the switch must be reset. The switch is located between the upper and lower speedometer cable on the left side of the dash in the engine compartment. Turn the reset screw coonterclockwise tl4-lum to the detent.
6
7A-O
Chapter 7 Part A
Manual transmission
Cont ents
EKlornal shlfl linkage
~
adjustment
n4A and T1 5A three-speed transmiSSion - disassembly,
5
General information 1 Oil level check ....... . Chapter 1 Planning major transmission work ........ . 6 Shift assembly - removal and insta llation ......... . 4 SR4 lour-speed transmission - disassembly. inspection and reassembly ........................ . 12 Transmission (1953 th rough 1971 models( - removal and installation .. . ............. . 2 Transmission (1972 through 1986 models)· removal and installation. . .. . ................... . 3 Transmission oil change ....... . Chapter 1 T4 four-spead transmission - disassembly, inspection and reassembly ............. . 13
inspection and reassembly. T5 five-speed transmission - disassembly, inspection and rea ssembly. T90C and TB6A A three-speed transmission - disassembly, inspection and reassembly. T98A/T1BA lour-speed transmission - disassembly. inspection and reassembly . T150 three-speed trsnsmission - disassembly, inspection and reassembly. T1 76 four'speed transmission - disassembly. inspection and reassembly.
Specificat ions
Column shift models Shifting clulch clearance. . . . . . . . . . . . . . . ...... . . Shift dog-Io-clutch slol cle arance ........ .
0.015 to 0.018 in 0.009 in
T90fT86AA three-speed transmission Interlock sleeve-to-shilt lever clearance Countershaft end play ....
0.001 to 0.007 in 0.012 to 0.018 in
T150 three-speed and T176 four-speed transmission Countershaft gear-to·case end play . .. ... .. .. .. ... Third·founh synch ron i ~ er hub-to·snap-ring end play. .. Reverse idler gear-to·case end play. ....... Mainshaft snap-ring-Io -second·lhird ~ynch ro ni~e r hub Mainshaft gear train end play .. . .. .....
0.004 0.004 0.004 0.004 0.004
to to to to to
0.018 0.014 0.0 18 0.014 0.0 18
in in in in in
0 .004 0 .004 0 .004 0 .030
to 0.0 18 in to 0.0 14 in to 0,0 14 in in
SR4 four-speed transmission Countershaft gear end play . . ...................... . Second gear end play Output shaft end play . ..... . ...........•.... Blocking rlng·to·cone saat clearance . . .. .. . ...
9 14 7
8 10
11
Chapter 7 Part A Manual transmission
7A-1
Torque specifications
T90fT9BA Filt end drein plugs . . ....... . Front beering cap bolt ...... . ..... . Shift control housing bolts .... '.' .. Trensfer cese drive gear locknut ...... . Transmission-to-transfer case bolts ........... .
Ft·lb 10 to 20 121018 10to15 145to155 25 to 35
Nm 14 to 27 17 to 25 17t020 197 to 210 34 to 48
15t020 10t020 121018 10t015 130 to 170 145 to 155 25 to 35 15 to 20
20 to 27 14 to 27 16 to 24 14 to 20 176 to 230 197t0210 34 to 47 20 to 27
15 to 20 10 to 20 30 to 36 145 to 155 25 to 35 15 to 20
20 to 27 14 to 27 41 to 48 197t0210 34 to 47 20 to 27
10 10 11 11
20 20 15 15
14 to 27 14 to 27 15t020 15t020
8 to 12 18 to 27 8 to 12 15 to 25 I I to 15 8 to 12 15 to 25 7 to 12 45 to 65
I I to 16 24 to 37 24 to 37 20 to 34 15t020 11 to 16 20 to 34 9 to 16 61 to 65
12 to 18 I I to 15 15 to 25 1 I to 15 15 to 25 15 to 25 5 to 9 45 to 65
16 to 24 15t020 20 to 34 15t020 20 to 34 10 to 34 7 to 12 61 to 88
T74A fT1 5A Backup light switch Drain end fill plug. Front bearing cap bolts . . Shift control housing·to-case bohs . . . . . .. . ... ...... . . Mainsheft rear beering nut ....... . Transfer case drive gear locknut ......... _ _ .. . Transmission·to -transfer case bolts ............. . TeS switch ...... . .... . . .... . . . .... . ........... _
T750 Backup light switch ..... _ . Drain and fill plugs ......... . Front bearing cap bolts ..... _ ........ _ ....... . Transfer case drive gear locknut ....... _ . Transmission-to-transfer case bolts. _ .. _ . _ . TeS switch ... _ . _ ........... _ .
T7 76 Backup light switch Drain and fill plugs Front bearing cap bolts. . ........... _ ...... . Shift housing-to-transmission bolts
to to to to
SR4 Backup light switch . _ . ... .... _ ....... _...... . Adapter housing bolt .. .. .. .. . Detant plug ................ . Fill plug . .... ...... ....... . _ .. _ ..... . . . _ . _ ... . Front bearing cap bait ...... . .. . ... . . Offset levar nut . ......... . .... _ . Reverse lever pivot bolt ...... . Shift control housing bolt .......... . Transmission-to·clutch housing bolt ............... .
T4fT5 Backup light switch . . . . . . . . . . . . . . . . . . . . . . . . . .. Adapter housing bolt Fill plug Front bearing cap bolt ............ . Reverse lever pivot bolt Shift control housing bolt . Transmission cover bolt ... Transmission-to·clutch housing bolts.
. ..
1 Generll informetion These models were equipped With a variety of transmissions over their long production life. The models from 1953 through 1971 were equipped with three and four-speed T90C, T86AA (V6) and T14A and T981T18A four-speed transmissions. The 1972 through 1986 models used T14A, T15A, T150, T1SA, T176, T4 and SR410ur-speed and T5 five-speed transmissions. Early models (through some models of the CJ6A) were equipped with column shifters while all others had floor shifters. 2 Trinamlilion !1953 through 1971 mode'li - removil end lnltlilitlon The transmission end transfer cese are removed and installed as unit. 2 Drain the transmission and transfer case oil into a suitable can-
(I
lair.e! end replece Ihe drain plugs. 3 Remova tha inspection plata from tha floor pan. 4 Ramove the shift lever and housing from the transmission. On column shift models, remove the remote shift rods. 5 Remove the set screw from the transfer case shift lever pin, followed by the pin, shift levers and lever springs. On column shift models, remove the pivot pin cotter pin. attaching nut and shift lever. 6 On power take off-equipped models, remove the retaining screws and lift out the shift lever. 7 After marking their relative positions. remove the driveshefts from the transfer case. Disconnect the power take off drives haft !if equipped) from the transfer case. 8 Disconnect tha speedometer cable from the transfer case. 9 Disconnect the hand brake cable and the clutch release cable. 10 Place two jacks directly under the transmission and englna, using a block of wood to protect the oil pan. '1 Remove the nuts retaining the rea r mount and transfer case rubber snubber to the cross member. 12 Remove the crossmember and bolts.
7A
7A- 2
Chapter 7 Part A Manual t ransmission
13 Remove the trensmission~lo·belihousing bolts and ca refully pry Ihe transmission to the right and disengage the clutch control lever tube ball joinl. 14 Slowly lower the jacks and slide the IflInsmission and mmster elise assembly to the rear until the input shaft is clear of the bellhousing. 15 Lower the transmission and trllnsfer case to the floor and remove them from thE! vehicle.
16 To separate the transmission from Ihe transfer case. remove the transfer case rOBr cover and boilS. On power take off-equipped models, remove the shift unit. 17 Remove the transfer case drive gear and nUl. If the drive gear cannot be removed, follow the procedure in Step 19. 18 Remove the attaching bolts and separate the transfer case from the transmission. If the transfer case drive gear is still in place, refer to the procedure in Step 19. 19 To keap Ihe transmission mainshall from pulling OUI of Ihe case, loop a piece of wire around the shaft directly behind the second speed gear. Partially install one right-hand and one left-hand shilt housing boll, twist the wire and attach Ihe endS to the bolts. Draw the wire up lightly to securely hold Ihe mainshaft in place. Support the transfer case and use a large plastic hammer or a brass drift and a hammer to tap lightly on the end of the mainshaft and loosen the gear. Separate the transmission and transler case. 20 InSlaliation is the reverse 01 removal except for the following points: al When installing the IranI adapter plate. install the bearing retainer in the plate before positioning the plate against the bellhousing. When the adapter plate bolts have been securely tightened, it should be possible to remove the bearing retainer. If thiS is not possible. loosen the bolts and reposition the adapter plale until the bearing retainer can be removed. bl Make sure the adapter plate bolt heads do not protrude beyond the lace 01 Ihe plate or prevent complete seating of the transfer case against il. cl When the transfer case gear is installed on the transmission rear spllned driveshaft, tighten Ihe gear nut securely and in· sert the cotter pin. The cotter pin ends must be benl well in to the nut slots to provide proper clearanc e for the power take off. d) Be sure to refill the transmission and transfer case wilh the specified lubricant (Chapter 1). 3
Fig. 7.1 I
Column shih control co mponents
Stop screw
2 Bi8s spring 3 Gearshift lever 4 5 6 7
Lever ball Steering wheel Horn button Column and bearing 8 End nuts 9 Shift rod ends
10 Shift rod II Shift rod 12 Cross-shift bracket 13 Control shaft 14 Lubrication fitting 15 Lever and clutch 16 Adjusting yoke 17 Aligning rod
Transmission (1972 through 1986 models) - removal and installation
The transmiSSion and transfer case are removed and Installed as an assembly. 2 Remove the floor shift lever knob, trim ring and boot, followad by the floor covering and the floorpan transmission access cover. 3 On n5 and n8A transmissions, remove the shih control assembly. On n76A, SR4, T4 and T5 transmissions, remove the shift lever and housing. 4 On modals where the transfer casa shiftar will interfere with removal, remove the shift lever and bracket assembly. 5 Raise the vehicle and support it securely on jackstands. 6 Mark their reletive positions to simplify installation and remove the front and rear driveshafts. 7 Suppo/t the engine by placing a jackstand under the dutch housing. S Remove the mounting nuts and bolts and detach the rear crossmember and support cushion. 9 Disconnect the speedometer cable and, depending on the model, the back up light switch, rcs, four-wheel drive indicator, pcuking brake cable and transfer case vent hose. On some VS models, it will be necessary to disconnect the exhaust pipes from the manifolds. 10 Support the transmission/transfar case assembly with a jack. 11 Remove the transmission-to·beHhousing bolts an d care.fully move the transmission/transfer case assembly to the rear until the input shah is clear of the bellhousing. Lowar the assembly to the floor and remove it from the vehicle. 12 Remove the retaining bolts ano sepaTata the transmission from the trans fer case. 13 Use needle-nose pliers to remove the pilot bushing lUbricating wick (if equipped). Soak the wick in engine oil. 14 Clean the mating surlaces of the transmission and transfer case to remove old gasket material. Attach the transmission to the transler case, using a new gasket.
15 Make sure Ihe th rowout bearing IS in position in the fork and is centered over the pressure pla te release lever. Install the lubricating wick ti f equipped! in the pilot bushing. 16 Raise the transmission/transfer case unit into position with a jack and move it lorward until the transmission is in place against tha bellhousing and the input shaft is engaged in the pressure plate. In· stall the transmission mounting bolt\! and tighten them securaly. 17 Install the crossmember and support cushion. 18 Remove the jack and jackstand supporting the engine. 19 Connect the exhaust pipes (VB models). 20 Connect the speedometer cable and any wires which were removed from the transmission or transfer cese. 21 Install the driveshafts, aligning the marks made during removal. 22 Lower the vehicle. 23 Install the transmission shift lever and housing or shift control assembly. 24 Install the trensfer case shifter and bracket assembly (if removedl. 25 Install the floor shift lever knob, trim ring and boot. followed by the accass cove r and floor cover.
4
Shih .ssemb!y - removaf
an~
Installation
T90 8nd T86AA remote control shift 8ssembly 1 Disconnect end remove tho shift rods from the transmission and clutch control, followed by the gearshift lever and fulcrum pin. 2 Ramove the plates from the toe boerd located at the steering col· umn. Remova the retaining screws and lift the remote control housing from the positioning pin on the steering column. Lower the assembly down and remove it through the floor pan. 3 Remove the lower clutch and shift lever, followed by the UPP6f
Chapter 7 Part A Manual transmission
7A-3
T18A and T150 floor shift assembly 11 To remove the shitt lever assembly, unscrew the shift control housing cap and remove the ret
SR4, T4 and T5 floor shift assembly 13 Remove the shift lever housing mounting bolts and separate the assembly from the tr
7176 floor shift assembly 14 Press down on the shift lever retainer, turn it counterclockwise and remove the lever, boot. spring and seat assembly. 15 To install the lever, pl
5 LEVER
'"
Fig. 7.2
Tvplcal Iranamls.lon shift conlrol 1T18A shown)
clutch and shift lever, by turning them counterclockwise. 4 Before re
T90 and T86AA floor shift assembly 8 Remove the mounting bolts and separate the shift housing and gasket from the top of the transmission. Installation is the reverse of remov
T14A and T15A floor shift assembly 9 With the transmission in Neulr
External shift linkaga -
adjustment
1 Only aarly models with column shift levers can ba adjusted. 2 Disconnect the shift rods from the remote control lever. i,md check for binding of the remote control shaft on Ihe sleering column. Lubricate
6
Planning major transmission work
Befora beginning transmission disassambly, read through the entire procedure to familiarize yourself with tha scope and requiremants of the job. 2 One of the biggast problems a beginner will face whan dismantling an assembly as complex as a transmission is trying to ramember exaclly whare each part came from. To help ei!eviate this problem, it ma,!, be helpful to draw your own simple diagrams or teke instant photos during the disassembly procedure. Laying each part out in the order in which it was removed and tagging parts will also be helpful. 3 Try to anticipate which parts may have to ba replaced and heva them aV
7A
.. ~,
•
Ii'
Fig. 7 .3
,
BeBring retainer bolt 2 SeBring retainer 3 Bearing reillin.r 011 selll 4 Bearing snap -ring ~
MtJin dn""fJ geaf snllp-,ing
6 Mam dril/fl geaf be/lfiflg
7 Front bearing washe, 8 MfJin drillfl geer 9 Pilot rollef beefing 10 Poppet bell Shift reil cap 12 Poppet spring 13 Lock wlJsher 14 Shift housing bolt 15 Control housing 16 Interlock plunger
"
T90CIT88AA Irenlmlulon component' - ... ploded view ISec 71
17 Shilt IINfJI spring 18 Shift to_, gllsket 19 High lind inte'm~illt.
shilt lork 20 Shift fOlk pin 2f High lind interm~ilJte shift ,.il
29 Filler plug 30 Blocking ring 3' Front countershefr thrust washer
43 Rear countershaft rhrost washer
32 Clutch hub s"ep-ring 33 Synchronizer spring 34 Synchronizer pItt'.
45 Countersh.'r bearing
23 Sliding gee'
35 Clu tch hub 36 Clutch s f _
24 Low and reve,s~ shift (ork 25 Low end reverse shift reil 26 Reer beering 27 MeinshlJ(t wesher 28 MeinshlJft nut
37 S~cond spHd geer 38 ReBr beering Bdapt er 39 BeBring splJcer 40 Lock plB t e 4' Countersheft 42 ROlJr countersheft thrust wlJsher
22 M"insh/ilfr
44 Countershe', belJring wllsher 46 Countershelt belJring splJcer
47 48 49 50
51 52
53 54
ReWJrsIJ ge., sh.ft Reverse idler g8ef Cou(I(ersheft gear set Shiff lever Oil collec tor Oil collsct or screw rrlJnsmission cese 8elJring f'fItlJiner gesket
Chapter 7 Part A 7 T90C .nd TS6AA thre.-.peed Ir.nlml"lon Inlpecllon .nd r," ••mbly
disassembly.
Dis8ssembly 1
Remo ... e the shih housing or co .... r plate and gesket.
2 Th. shlfl housing on floor shift models can be disessembled after remo ... el. teking care not to lose Ihe poppet balls and springs when the shift raill and forb are remo ...ed. On column shift models the mein dri ... e geer must be ,emo... ed before the shih forks can be remO\'ed. 3 Remo ... e the main dri ...e gear beering retainer (Ihree screws) and gllkel. 4 On .arly models. remove Ihe sock.t head screws from the front of the case. The screws support the 011 coll.ctor inside the case used on some .arly models. 5 loosen the countershaft lock plat. by tepping on the front end of the shaft. Remove the lock plate trom the slot. in Ihe countershett and reverse idler shaft. 6 Use a hemmer end a brass dritt to carefully drive the countershaft tow.rd the rear of the case and remove It. The countershaft gear set will drop Into the transmission case, which could dillodge the needle beaflng foll.rs. 7 Remo .... the mainshaft rear beering adepter, followed by the main· shaft assembly. The mainshaft assembly and gears are most easily ramoved through the rear bearing edepter opening. Be careful not to los. the pilot roller beering when the shafts are separated. 8 On .arly models equipped With oil collectors, drive the main dri .... gllr into the case sufficiently to provld. clearance and remove the collector. 9 Remove the main dri ... e gear from the case. 10 Remove the countersheft gear set and three thrust washers. Remo ... e the washars, needle bearing rollers afjd spacer from the assembly. 11 Use a hammer and a brass drift to dri ... e the r....erse idler shaft and geel into the case. then remo ... e them.
Inspection 12 On .arly models With column shifts. It IS Importent to inspect the poppat and interlock assembly which floelS betw.en the shift lev.r .... mblies. If it is 100 long, the assembly will make shifting impossible; if It Is too Ihort, it will not act as an interlock to prevent the shifting 01 two gears at one time. 13 With the intermedlete end high control arm in the second gear posi· tion, measure the cleerance between the ends 01 the interlock sleeve and each shih lever notched surfece. Check the clearances egeinst those in Ih. Specifications. If the clearances are beyond the specified limit, the transmiSSion should be taken to a deeler or properly equipped shop to he...e the Interlock sleeves replac.d with new ones. 14 Inspect the notched surlaces 01 the shihing lever lor roughness and nicks. Use e fine lile to smooth out the surface' as necessary end replac. any badly demaged lever With a n.w one. 15 Wash the inside and outside ot the tran.mission clSe thoroughly using sol....nt and a stiff brush. 16 Inspect the case for cracks and check the front and rear mating lurla-ces lor nicks .nd burrs. Minor imperf.ctions can be removed with I line 1I1e. Inspect the bearing bores lor scoring. cracks and nicks. II the bores are bedly damagod or worn or if cracks .re lound in the case, raplac. th. case With a new one. 17 Wash the gears thoroughly with sol ...ent and inspect tho teeth end bron18 blocking rings for chips. wear and craCks. Inspect tha bearings and bushings lor weer and demege. Check the first and re ... erse sliding gear lor smooth mo... ement on the melnshah. Make sure the clulch sleeve slides Ireely on the hub. Inspecl the beefing retainer oil see! for damage. Replace any worn or damaged components with new ones. 16 Prior 10 reassembly, make sure the new gas kits match the trensmis· sion case and particularly that drilled oil passages have corresponding openings in the gaskets.
Re8ssembly 19 Reassembly of the transmission is the re ....rse of disassembly. with attention paid to the following points; al In8lall the reverse idler geef into the case, followed by Ihe shaft. Make sure the slot at the end 01 the shah is properly eligned to allow instaltetion of the lock plete.
Manual transmission
7A-5
bl Use heavy greese to retail"! the main drive g881 bushings in place during installation. c) After installing the mainshafl. turn the !rensmission case o .... r and allow the gears 10 mesh to allow in.tellation of the counter· shah. Check Ihe counlersh.ft end play. The end play clearance is adjusted by installing the approprlele rllr thrust wesher. dl Attach the large bronze thrust washer to Ihe Iront olthe case with the lip of the wesher In the slot. Use heavy grease to re tain the wesh.r. Attach Ih. ste.1 thIVst washer to the r.ar 01 the case and insert the counterehaft sufficiently to hold the washer In place. Align the counter.h.ft slot with the reverl. idler geer shelt slot so the lock plate can be installed. Posilion the bronze washer against the rear end of the gear. place the countershaft in the running posilion and tap it inlo place with a h.mmer and brass dllit.
S T98AmSA four-.pHd tranlml.slon .nd r..... mbly
dl..... mbly, In.pectlon
Dis8ssembly 1 R.move the shift control housing from the transmission case. 2 Before removing the two blocking r1ngs.nd Ihe direct-to-third clutch steeve, mark them with e punch or last-drying peint so they can be assembled in their original politionl. Be sure to also mark the block· ing ring and low·.nd·s.cond speed gear. 3 Slide the Iow·.nd·second speed gear toward the reer 01 the transmission case and disengage the reverse shifting .rm and shoe from the re ...erse idler geer. Remove the .rm from Ihe pivot. 4 Move Ihe low-and-second speed gear Into the Neutr.1 position and remo ... e the bearing retainer and gas kit. followed by the snep-rings re · lainlng the main drive gear and the outer rece of the ball bearing. 5 Use e puller to remove Ihe m.in drive geer ball beering and then remove Ihe oil slinger. 6 Remove the snap-ring retaining the meinsheft ball bearing outer race and remove Ihe bearing with a pull.r. To gain sufficient clearanc. for the puller plates, it may be necessary to carefully tep Ihe malnshah 10 the r.ar. 7 Slid. the direct-and-third clutch sl8e118 10 Ihe rear or third gear posi • tion. Separll. the mainshah assembly lrom the drilffl gear, taking car. not to lose the pilot bearing roller •• 8 Remove the mainshaft by lifting it out of the lOP 01 the transmission CISe. 9 R.move the m.in dri .... gear from the case and then remove the beering rollers from the geer. 10 Prior to disassembly of the mainsh.h. mark the relationship of the synchronizer hubs end the splines. 11 Ramo ... e Ihe snap-ring retaining the direct and third synchronizer. followed by the front blocking ring from the Iront of the shaft. 12 Slide the direct-and-third synchronizer and gear assemblies off the mainshaft. 13 Remove the snap-ring from the rear of the mainshaft and slid. Ihe second synchroni3:er assembly and th. blocking ring off. 14 Remove the snap-rings end slide the thrusl washer. bearing rolle", second·speed gear and spacer off lhe mainshaft. 15 To disassemble the synchronizer eillmbl;as. Wfep a cloth around the second-speed synchronizer ass.mbly and push the clutch hub out 01 the low-and-second·speed gllr In the opposite direction of the shift fork groove. After removing the cloth. lift Ih. springs, balls and pletes Irom the hub. 16 Remove the lockplate retaining the countershaft end reverse idlef g88r Shaft end use a pry bar in the slot of the shaft 10 loosen It. Slip the Ih.'t out of the housing and gear .nd tift the reverse Idler gear ass.mbly from the case. 17 II the counte"heft is to be removed. use a brass drih to drilffl the shaft to the rear. Fabricate or obtain a dummy .haft mad. of steel rod measuring 1-1/S inch in diameter .nd ten inches in length. UII a Iii. to r.move any sharp edge •• With the countershaft even with the insid. 01 the case, use the dummy .h.ft to lorc. it the rest 01 the way out. The dummy shaft must be kept In contact with the countarsheft II .11 times to prevent the bearing rollers .nd thrust washers from f.lI · ing out. lS With the dummy shaft In place, position the transmission case on its side and roll the counlershafl gear cluster carefully out.
7A
7A-6
Fig. 7.4
nBIT98
tran.mlilion componantl exploded view (Sac 8)
2 3 4 5
Mainshl1fr pilot bean'ng rollBr spacer Thirc/lfourth blocking ring Third/fourth retaining ring Thirdlfourth synchronizer sflllp·ring ThirrJ!fourth shifting plate (3) ThirrJ/fourth clutch hub
6 7 Third/fourth retaining ring
8 Thifdlfourth clutch
• 10
5/"_ Thirdlfourth blocking
ring Thirdlfourth gesr
synchronizer lIssemb/y
11 Third ge8' 12 Mainshaft snap-ring 13 Second gSBf thNst washe, 14 Second gS8( 15 Mainsh8ft 16 Sacond ge81 blocking
ring 17 Mainsh8h snap+('ing
18 First/second clutch hub I. First/second shffting plat.
20
Poppet ball 21 Poppet spring
22 First/second insert spring
23 Mainsh"f, snap-ring 24 First/second clutch
s'-
25 Second gNr synchronizer assembly
26 Counfersh.fr geaf thrust wash.r (steel) (rB"r)
27 Countershtlft
988(
throst wl1sher (steel backed bronze) (reer)
28 Countershelt geer 2.
30 31 32 33 34 35 36 37 38 3.
beering wesher Countersheft gear beering rollers Countershaft geer beering spacer Countersheft gear Countersheft geer thrust washer "ront) Reverse shifting erm Reverse shifting erm shoe Filler plug Drein plug Lock wesher 80h (trensmission-toclutch housing) C-washer
40
Reverse idler geer snsp-ring 41 Reverse idler geer hrust washer 42 Reverse idler sheft
,"-
43 R8Verstl idler g8er 44
45 46 47 48 49
50 51
beering roffers Reverse idler .geer beering wesher Reverse idler gellr Lock washer Adapter plete bohs Drive gear locknut Washer Adapter plete Countershshlreverse idhlr shalt lockplste
52 53 54 55 56 57 58 5.
60 61 62
Reverse idler gear shaft Countershaft Adapter plete gesket Adapter plate S8el Sp8f1dometer gellr Splicer Reer bearing locllting snllp-ring Reer besring Reverse shifting arm pivot pin Reverse shilting erm pivot Reverse shilting erm pivot a-ring Wesher
63 64 65 66 67 68 59
70 71
72 73 74 75
Side cover bolt Side COlflBr Trensmission cese Mainshaft pilot beering rolfers Clutch sheft Front bearing retainer wllsher Front bearing Front bearing locating snep-ring Front bearing lock ring Front beering cap gasket Front beering cap Front beering cap bohs Lock washer
7A-7
Chapter 7 Part A Manual transmission
Fig. 1.5 I Blocking ring 2 Direct and third clutch ,,.~
3 Snap-ring 4 Spring 5 Shifting plete Direct and third clutch hub
•
T98 maln.haft component layout ISee 81
7 Third $plHJd gear assembly 8 Snap-ring ThruS t washer 10 Beering rollers /I Second spfHJd gea, 12 Spece,
•
19 Remove the dummy shaft, thrust washars, baaring rollers and ape cera. 20 To diaassemble the reverse Idler gear aBlembly, remove Iha snap ring, then tap out Ihe washers, bearing rollanl, center spacer sleeve lind remaining snap-ring. 21 To disassemble the shift con trol housing assembly, remove the lock wire and screws from the gearahift for1ls and rod ends. Remove the axpansion plugs from the lever base. 22 Remove the center gearshift rod first by driving it out of the rear 01 the gearshifl base wilh a punch and hammer. When withdrawing Ihe rod, remove Ihe Interlock pin hom Ihe crOBlova, hole in the rod . Before removing Ihe rod, place your finger over Ihe hole to prevenlloss 01 the ball and spring. Remove the rod. 23 Remove the gearshift rod lock balls and spring and use a piece of wire to push the intarlock plungers out 01 the pockets in the gearshift bue cenler seclion. 24 To remove the reverse lock-out plunge, from the rllVerse gearshift rocl end, remove the cotter pin while holding your linger over the hole to prllVent loss 01 the spring. Shake Ihe spring and ball out and comprell the spring and plunger sufficiently to expoae Ihe C-washer groove and remOlle the washer.
13 Mainshaft 14 Blocking ring 15 Shifting plate Poppet spring 17 8811 18 /..J)w and second sPfHld clutch hub
"
I. Rataining ring 20 /..J)w .nd stICond s{HHHJ ge.r 21 Second speed synchronizer 8s:sembfy 22 Direct and third :synchronizer assembly
of the geer clulter. 29 Place the assembly In the cese and Inllall Ihe countersheh from the rear, keeping contect with the dummy shelt so the bearing rollers don't drop out. Tap the shah lightly Into position without seating h until the rllVerse idler gear assembly and shaft have been instelled. 30 Install the reverse idler gear 5haft in the case until the lock plate slot is adjacent to the countershah slot. Inserl the tock plate into the slots with the plate ends square with the 'lots. Instell the lock plate screw and washer and elternately tap the shafts Into position. With the lock plate and shefts in the correct position, tighten the acrew. 31 To begin reassembly 01 the second-speed synchronizer assembly,
7A
Inspection 25 Clean the Iransmission case InSide and out with sollient and estill bru.h. 26 Inspect the case lor crack. and check Ihe fronl and rear mating aurffICel lor nicks and burrs. Minor imperfections can be removed with a file. Inspect Ihe bearing borea for scoring, cracks and nicks. If the bores are badly damaged or worn, or if cracka are lound in the case, replace It with a new one. 27 Wash the gears and shalts with solvent. Inspect the gear teeth for chips, cracks and wear. Check the shalts for scoring, wear and nicks. Repla ce eny worn or damaged components with new ones.
Re8ssembly 28 Assemble the countersheit components with the dummy shalt. The bronze front thrust wesher and the steel-becked bronze fear thruat washer should be coaled With heallY grease before installation. Inllell the washers wilh the lugs engaged in the notcha" in the end
Fig. 7 .8
A.sembllng the Mcond· sP"d synchronizer IT1SfT9811See S)
, 2 3 4
Low and second-splHld g_ BIJ" Low and second-sptHtd clutch hub ShiftlJr plIJt8S
7A-8
Flg.7.8 Second-spIed g88r assembly Inll.lIatlon on thl main gllar shaft
Fig. 7.7
Maln.haft snap-ring !2land thrult washer (11In"l1l1l1tlon (T98 onlyl (Sac 8)
(T98 only) ISec 8) ,
SpaClfJf
3 Rubber bend 4 Thrusr washer
2 Roller be/Iring:;
• ' ... Tf.IILOCK ~lU"'GERS
DIRfCT AND
~'" FORK
FIg. 7 .9
THIRD
StlllfT 1t"IL
TIS198 four-spa.d shift mlchanllcm components (Sac 81
Chapter 7 Part A
7A-9
Manual transmission
"AI'
LOW SYNCHRONIZER ASSEMaLY
Fig.7.10 Prop.r Inllallation of the ad.pter 011 leal (.rrow) 1T18/981 (Sec 8(
mtallthe clutch hub Into the low·lnd·second·speed gear. followed by Ihe retaining ring . 32 Slide the hub OUt of the gear in the oPPOSIte diflCllon of the shift fork groove until the hoi.. in the hub are clear of the gear. Install the shiher plltes and the springs. 33 Push the hub back into the gear until the springs touch the gear intern.1 taath and then push one 01 the shifter pletes toward the gear center while instelling the bel! to hold it in position es shown in the ICcomp.nying illustration. InStall the remaining two bills, following the stme procedure. Use care when rotating the assembly so the hub won't .Iip out of the gear. . 34 After the balls afl Inst.lled, push the hub into the gear until the bill••nlp into the Neutrll posItion. 35 Inltall the two springs in the high and intermedilte clutch hub so thlt the spring tension is opposed. 36 PI.ce the right !lipped) end of one spring in a slot of the hub and piece the spring in position in the hub. Turn the hub .round and, star· tlng at tha same slot, repeat Iha installation with the other spring. In· .taO the three synchronizer shiftIng plates in the hub slots with the smooth side out. With the plates held in position, slip the second·and· direct·speed clutch sleeve over the hub so the long beveled edge is toward the long pan of the clutch hub. Attach the two bla<:king rings to both sides of the hub and InstaN the complete as&embly on the main' shaft with the beveled edge of the clutch sleeve toward the front edge 01 the shalt. 37 The 118 second·speed gear·to·meinshelt Is a slide fit. while the T98 uses rolter bearings and requires the following procedure for assembly. Place the mainShlft securely in a vise. using wood bla<:k. to protect the shaft surf.ce. thre.ded end up. 38 Att.ch the snep'ring and thrust washer to the forw.rd end of the tecond·.peed position on the mainshaft a5 shown in the accompany' Ing illustration. The recessed SIde of the thrust walher should cover the snlp·ring. 39 Place. rubber band around the second·speed bearing surface and Install the 34 bearing roller •• uSing the rubber band to retain them. With Ihe rollers In place. install the sp.cer on the .h.ft IS shown in the Mlustrallon. 40 Install Ihe second· speed gear with the t.pered shoulder up .nd • lide It ontO the bearing rollers far enough to hold them in pl.ce .nd remove the rubber b.nd. Slide the gear completely over the be.tings Ind Instill the rear snep·ring and the bla<:king ring on the tapered lhoulder 01 the gear. 41 InstlUthe second·speed synchronizer assembly on the mainshaft, Iligning the marks made at the time of disassembly, and install the Stlapring. 42 With the tepered shoulder to the front. install the third·speed gear IISlembly on Ihe shaft .nd slide the diflct·and·third .ynchronizer on· to the mainshaft. Make sure the alignment marks made during disassembly .re lined up and install the snap·ring. 43 With the roller bearings in plica in Ihe front of the case. install the meinshaft assembly through the top of the case, taking care not to dislodge the bearings. 44 Install the main drive gaaf b.atlng retainar temporarily to provide
Fig . 7 .11
Removil or Inst.llition of Ihe flr.t ge.r .ynchronlzer hub .n.p·rlng 1T14Am6AIIS.e 9(
suppon, install the snap·ring on the main.hlft beering and prell th. be.ring into the c.se until the sn.p·ring seat.. 45 Remove the bearing t.tainer and inat.11 the o~ slingar onto the drive gear. Install the lnap·ring on the main drive geaf bearing and prell the bearing and sh.ft into the case. Instellthe thickest snap' ring Ihat will fit into the main drive gear groove. 46 Slide the drive gear bearing reteiner on, hold it lIecurely in place against the tran.mlllion and measufl the distlnce between Ihe re o tainer and the case with e feeler gauge. Inst.111 gasket which Is 0.003 to 0.005-inch thicker th.n the space between the retainer Ind CIISe. 47 The remainder of tt.nsmission .ssembly Is the reversal 01 disassembly. paying au.ntion to the lollowing points: al After reas.sembijng the shift housing. be sure to use safety wire on all the IIhlh fork and rod .nd lock screws. bl In5tell new exp.nsion plugs In the base of the shift housing. cl Inspect the transmission breather for demage and obstructions and replace It il necessary. d) The transmission .daptar plate oil 1111 must be correctly positioned with the lip of the seal toward the transler case.s shown in the illustration.
9 T14A.nd T16A thr••·.peed trlnaml.lIon Inapaellon .nd rll8 .. ambly
dl.....mbly.
Disassembly 1 Remove the tr.nsfer case gear Ia<:knut, followed by the drive ge.r, .dapter and sp.car. The aecond/third synchroniur sleeve mu.t be moved forward .nd the fillil/reverse sleeva t o the rear before the nut c.n be removed. 2 Usa a center punch to make alignment marks In the front be.rlng c.p and transmlllion c.se, then remove the cep and gasket. 3 Remove the front Ind rear baaring .nlp·rlngs, then use I puller to remove the beafings from the transmission case. 4 Remove the clutch .halt from the tr.nsmission case. 5 Move the secondlthird sychronizer sI_ Into the second gear po•. lion and remove the main.haft and gear train al8ambly. 6 Remove the lock plata retaining the idler .hah end countellihaft and t.p the shahs toward the rear to make removel e••ier. 7 Insen an arbor tool from the Iront of the tren.fer case Ind r.move the countershalt. 8 Remove the counterahaft gear thrust w.shera from the tr.nsml.sion case and the arbor tool. spacer w.sner., bearing rollers end center .pacer from the counterahaft ge.r. 9 Remove the reverse idler ge8r shaft, using 8 puller, followed by the gelr. thrust washers Ind roller bearings as .n assembly. 10 Remove the second/third .ynchronizer and .nlp·ting Illembly. 11 Remove the .econd gear and blocking ring, folowed by the t'IIViIfIe gear. 12 Remove the anap-fing retaining the fir.t gear clutch hub and remove the first gear synchroniur .ssembly as shown in Ihe accomp.nylng illustration. then remove the first gear end blocking ring.
7A
7A-10
Chapter 7 Part A
Manual transmi ssion
13 Remove the synchronizer springs from the second/third synchronizer assembly and mark the sleeve and hub for BBse of reassembly. Remove the sleeve and shifting plates from the hub.
on it. The letter is just under the shatt hole on the side opposite the pin. If the fork does not have the letter, it must be replaced with one whiCh does.
Inspection
Reassembly
14 Wash all of the transmission components with solvent. Use compressed air, if available. to dry ell parts 8Kcept the bearings. The needla and clutch shaft roller bearings can be cleaned by wrapping them in 8 clean cloth and submerging them in the solvent. Air dry the bearings only. Inspacl Ihe transmission case for cracks, stripped bolt hole threads. nicks, burrs and rough surfacas in the shaft bores and on the contact surfaces. Inspect all gears for broken, chipped and worn teeth. Check the blocking rings for wear and broken or worn teeth. Inspect the bearings, bores and shafts for wear, damage and galling. Check the thrust washers for wear and distort ion and the snap-rings for distortion and lack of tension. Replace anv damaged or worn com· ponents. When replacing a gear, t he gear with which It meshes must also be replaced. Also. if a synchronizer requires replacement, check the shift fork which opeflltes it to make sure it has the letter A stamped
15 Prior to installation, lubricate the components using the specified transmission lubricant (Chapter 11. 16 Install the reverse idlar gear, roller bearings and thrust washer, us· ing AMC tool J-25202 (TI4A) or J-25203 ITI5A) as shown in the flCcompanying ittustration. 17 Install the reverse idler shaft, which wililorce the tool out, and make sure the slotted end of the shalt is aligned correctly with the lock plate. 18 Install the cente r spacer and AMC arbor tool J·25199 (n4Al or J-25201 (TI5 A) into the countershaft gear bore. 19 Install the bearing washer at each end of the center spacer and slide the washers over the arbor tool until seated against the spacel. 20 Inst all the 22 roller bearings at each end of the countershaft gear, followed by the bearing wesher over the bearings. 21 Coat the countershaft gear thrust washer with petroleum jelly (not
..
..
~
2 3 4 5
•
7 8 9 10 11
12
Sacond/third synchronizer snap·ring Blocking rings Synchronizer springs Second/third synchronizer assambly Secondllhird clutch hub Secondllhird shifting plete Secondlrhi,d clutch sleeve Second gear Mainshaft pl10t baaring rollers Mainshaft First gear First geer synchronizer assembly
Fig. 7 .12
TI4Am5A thre e-speed transmission co mponants - u:ploded v iew (Sec 9 )
13 First/reverse clutch sleeve 14 Synchronizer spring 15 First gaar clutch hub
24 Countersheft goar 25 Countershaft/reverso idler
I. First gear shif ting plate 17 First gear snap-ting 18 Reverse gear bushing (included with reverse gear) 19 Reverse gee' 20 Coun tersha't gear thrust wesher (reer' 21 Coun tersha ft gear bearing wesher 22 Countersha ft gaar boaring ,ollers 23 Countersheft geer bearing spacer
2. Countarshaft 27 Countarshaft gaa( thrust
Shaft lockpleto
28 29 30
31 32 33 34 35
washer (front! Reverse idler gear thrust wesher Revelse idler gear Reverse idler gear bushing rollers Reverse idler gear shaft Mainshe ft locknut Mainsheft wesher Meinshaft bearing spacer Rear bearing adapter
3. 37 38 39 40
41 42 43 44 45 4. 47 48 49 50
Reat bearing lock nng Rear bearing Transmission case Fill plug Drain plug Clutch shaft Front beering reteiner Front beering Front bearing lock ring Front bearing snap-ring Front boaring cap gasket Front bearing cap oil seal Front beering cap Front beering cap bolt LocA washel
7A-11
Chapter 7 Part A Manual transmission ChlSlll greese) and install it at the flon! of the cale. Coat the small counterlhaft gear thrust washer with petroleum Jell.,. and Install it on the gear hub with the lip lacing the groove in the case. 22 PoSition the countershah gear as.emb!.,. in the case. align the gear boral with the casa borel and Inltall tha countarlhaft from the rear of the cesa. Meke sure the lock plate slot In the Ihaft aligns corTectl.,. with the Ilot in the reverse idler gear 5haft. Thi5 will force the arbor tool OUI. 23 In5tall the first gear and blocking ring onto the malnshaft. 24 Allemble the first gear I.,.nchronizer aSlambl.,. and align tha sleeve and hub using the markl made during disassembl.,.. Install the sleeve 'hifting plates, insart the spring and then install the aaaembl.,. onto the malnshall. 25 Inltall Ihe first gaar Clutch hub snap-ring. The,e are a select lit to eliminate end pia.,.. so be lure to usa the snap-ring which il of the proper thICkness. Use tha Ihickest snap-fing which will fit in the groove. 26 Inltall the second gear and the blocking ring onto the mainshalt. 27 A,sembla the secondfthird I.,.nchronizer allembl.,. and align the sleeve and hub using the merkl made during dilallembl.,.. Install the ahlhing platea and then insert the springs with the open ends opposite one another. 28 Install tha secondfthrrd ,.,.nchronllar assembl.,. onto the mainshaft. followed b.,. Ihe snap-ring and blocking ring. Again. tha snap-ring il a select fil to conlrol and pia.,.. so mike sura the correct one is used. 29 Installlhe rllYlrse gear onto Ihe malnshaft and Ihlll"l inltall the Ihaft Ind gear alsembl.,. in the transmIssion casa. 30 Inllall tha maIn shah pilot bearing rollers in the clulch shaft bore. using petrolaum jell.,. (not chassl' grease) to retain them in placa. Position tha clutch shaft In the casa with the cutawa.,. portion of tha gear facing down as shown in the accompan.,.ing Ulustration. Take care not to dISplace the bearing rollers and guide the clutch onto the mainshaft. Inltall the front bearing retainer on tha clutch shaft. 31 Inllalling Ihe fronl and rear bearings involves "the use 01 special tools. If thev are not available. the transmissIon should ba taken to a
properl.,. aquipped shop. If the tools are available. use the following procedures. 32 Install the thrull yoka 1001 by inserting tha 1001 yokes into tha second gear groove and belwean the clutch shaft teeth and blocking rmg and install the front and rear blocking rings. Tha front bearing can Ihen be installed as shown in the accompanYIng illultrl1ioo. 33 InSlalithe raar bearing as shown In Ihe accompanying illullratron and then install the front and rear bearing retaining snap-rings. The rear snsp-ring is the thicker of Ihe two. 34 Inspecllhe front bearing cap oil seal and replace it with a new ona If It II damagad, worn, loose or distorted. 35 Insllil the fronl bearing cap snd naw galkel with tha oil drain slOI aligned with tha hole In the transmission casa. Inslall the bolts and tighten them to the specified torqua. 36 Shih both synchronizers into gallr to prevent Ihe mainshall from lurning lind install the rear bearing adapter. spacer, transfar case gear. flal washer and driver gesr retaining nUl. TlIlhten the nut to the specified torqua. 37 Shift tha synchronizers into Neutral .. shown in Ihe accompanying illustration and chack the operation 01 the gears in sll positions. The gsars musr be in rhe Naurf81 posirion before insrafling rhe casa cove, and gasket. 38 This compleles Ihe reassembly of Iha trsnsmission. To disassemble tha shift conlrol housing, remove the TCS swilCh and backup lighl SWItch hi so equIpped). Remove the shift ra~ plugs from the resr 01 the housing by dliving tham sideways into tha bore and then pryIng tham out. 39 Move the first/reverse shift rail to the first gear poSItion and remove tha roll pin from Iha firellreversa shift fork and rail. 40 Slide Ihe first/reverse fork to the ralr. 8I(posing the roll pin hole In Ihe rail and insert a lapered punch inlo the hola. Rotate tha firsllreverse rsil loward the sacond and third rail. aligning the groove at the raar of the firslfreverse rail with tha interlock plunge!, Slida tha lirsllravars8 rail forward as far as it will go lind remove the interlock
CLutCH "~
Flg. 7.14 First gear synchronizer assembly IT14AmSAIISec 9) R.....,..ld ..' shaft Installation (T14ArnSA) (Sec 9)
Fig. 7.15 Fig. 7.13 Sacondfthlrd svnchronlzer allembly componants 1T14AmSAl (Sec 91
_.
an ........
,HOIIT GIIIV.II
.00 ;
TH!lun
,Oxl OllIY ~ "
/'OOL
OIIIWl
I
,~"
Fig. 7.16 The main drive gaar with the roller bearings Installed (T14AfT1SAI ISec 9)
TOOL
La ....
FIg.7.H lnslalling the T14A1T1SA main drive gaa, bUlhlng (Sec 9)
Flg.7.18 Installing the maln,hett bearing (T14ArnSA) (Sec 9)
7A
7A-12
Chapter 7 Part A Manual transmission
plunger. Cover the poppet ball holes with 8 cloth dUflllg removal to prevent the loss 01 the ball and apring.
LOW-t;VNCHI'o..llE ..
41 Remove the first/reverse rllt by rot.ting it .way from the IIIC' ond/third fall while pushing toward the rBar of tha housing.
IIrv(I'SE GE .....
42 Withdrew the firstlsecood rail from the rear 01 the housing and Ihan remove the roll pin from the second/third shift fork and rail. Again, COVSI the poppet bill holes with 8 cloth to avoid 108S of the ball and spring. 43 Remoye the second/third shift fail, followed by the shift lever fe tainer spring and the lever. 44 To reassemble, install Ihe shift lever and relainer spring with tha cone against the lever ball and the spring snapped in behind the snouldel'3 In the cover.
45 Slide the second/third shift r8111n10 the housing to the poppet bo55 and insert tn. poppet ball and apring. Compress tne ball and spring, slide tne rail to a point just past tne boss and rotate tne rall to position tne Ihift lever llot toward tha centar of tha noWling. 46 Inltall the sacond/tligh fork, flangad sida toward tne front of tne noullng. and install tna roll pin. 47 Hold tne first/second anift fork in position witn tna flanga sida toward tha raar of tna nousing and slide tha first/second snih rail into tha noualng, througn tne fork, to tna poppet boss. Insert tne poppet ball and spring and compress tna spring. 48 Push the shift rail as far forward as it will go and install tna interlock plunger. Make sura tne second/tnird snift ra~ is in tne Neutral position and tnal the Interlock plunger contaCII tne rail. 49 Rotatalne first/rtwer58 shih rail until tna notcn in the interlock end of tha rod IS lecing away from tna nousing and tnan move tne rail backward until the end contacts the interlOCk plunger. 50 Rotate tne rd until the notcn aligns witn the intarlock plungar end move Ine rail as lar back as it will go. Align Ine roll pin holes and inslall tne roll pin. 51 Install tne shih rail sealing plug. and attach the switches to t ne nouling.
~
Of .....
OUR
FIg. 7 .19 n4Am SA IhrH -speed tran, mission with the malnl hah in tha nautra' po,ltio n ISec 9)
~'n ..... IL
(lOW·
.. EVERSEI
10
~~<)
n 50 three-apeed tran.ml.llon - dl..... mbly, Inspection . nd
f . . . .embly
Disassembly 1 2
Sep.rate the transmission from the Iransler case. Mova Iha secondltnird clutch sleeve forward and tne first/reverse lleeve to tha rear. 3 Ramove the transmission fill plug and drain tne lubricant into a IUllabla container. 4 Working through tne fill plug nole, usa a 3/16·lnch diameter punch to drive out the countershalt roll pin as snown in tne accomp!IIlVlIlg illustration. S Usa an arbor tool to remova tha counta rsnah and acc ess plug as shown in Ihe accompanying IlIuSlration. 6 Remove the countarshah Irom the rear of t he t ransmission case and allow the countersheft gear to remain in the case. 7 Remove the large lock ring from tha front bearing.
J;" " ISECOfjO-
1M'"
THI .. O I
R ... IL
UVER
"""''' Sl'1I1"'0
Fig . 7.20 n4AmSA I hih control hou ling components - ex ploded view (Sec 9 )
"'. .
m_.~ ACCUI I'LUO
Fig. 7 .21 Ramovlng tha countarahah roll pin (l150) ISec 10)
,U
SHIfT
Fig.7.22 Countera haft and acca .. plug removal In SOt (Sec 10)
7A- 13
,. ~ ~Yn'hronl:::~;,nr 'n,p~"ng ','~ 'yn,hronl", Ig 7.23
econdl third
thre e-speed
c mg rings
4
,p" .n9s ynchron;zer 5 Second/ 5 insert third 6 s",ondl'hlm hub econdlth"rd In .." ' ,yn,hronl,., 7 S,,,nd g,,,
9 e F,m... FI, """n'n 10 F" g'" g,,, Iobbod 9Ihrool w..h" , n .
'n.p~"ng " ;.m ,~U,,~~. ,,~~. F,,'U"~". 'n.p~"ng ~~ InStIrt sp . y ChronlZ8f
12 First". 13 .
ex ploded view IS ee 10)
n 50
1 Meinsheft'
rmg ,I. h .nd g'" u ",,,,;Ing
14
'''"'ml..I," " m,,",",' First/reverse, "'.."
-
yn,hrom<"
15 16 FirstA C,unlo~h," reverse hub 17 M,ln , h,1I " " " plug 18 M8insh f 19 R.., b ' 20 R.., ,'nadspter lock ring
,~ >P'"" b::7,~9g
""mb~
'P'"
2 ,a M"n,h." 22I Flot w"h ".,," ...1 23 Locknul "
24 Roll pin
.~". r B",h1nt~:';',
25 26 RThw" Idl" g .."h.1I 8 Reverse idt ' Idler gear} . ar geer
29 30 31 32 33
Trans . . Th mISSion case
"rust B . was h (!If ~ C8armg ,-.. t8InBr ountsrsheft ne ed/a beerings Countersheft 4 Fro geer 3 35 be8ring cap
Bof7'
36 Front be"rin9 cap oil s8e/ 37 Gasket 38 Front 39 Fro b Bering rBteiner 40 F nt bearing lock . snap-ring
c,;mt
b88ring rmg 41 42 u~ch sheft 43 Metnsheh Roll pin pi.,ot roller bellring 44 C S ount8fShllh
7A
7A-14
Chapter 7 Part A Manual transmission
8 Remove the clutch shaft, fronl bearing sud secondfthird synctuonizer blocking ring assembly. If it is necesSlry 10 dismantle this assembly, take the clutch shaft to IlIl automotive machine shop to hevll the bearing removed. 9 Use II brass drift end (I hemmer to drive out the rllaf bearing end adapter a8 shown In the Illustration. 10 Remove the mainshaft assembly by tilting the apline end down and lifting the forward end up and out of the transmission case. n Remove the countershaft gear and arbor tool, followed by the thrust washers, counters haft roll pin and any mains haft Dearing rollers which may have fallen Into the case. 12 Remove the reverse idler gear shaft and Insert a brass drift through the clutch shaft bore. Tap on the shaft until the end with the roll pin clears the counterbore In the rear of the case and then remove the shaft. followed by the reverse idler gaar and thrust washers. 13 To disessemble the mainshaft, remove the snap·ring from the front of the shaft, followed by the second/third synchronizer assembly and second gear. Marl!. the hub and sleeve to simplify reassembly. Also nOle the insert springa and inserls. 14 Remove the insert springs from the $Bcond/third synchronizer, remove the three inserts and separate the sleeve from the synchronizer
","
15 Remove the first gear, DIocking ring, tabbed thrust washer end snapring. 16 Note the positions of the inserts and spring, remove the snap-ring and remove the sleeve and gear, spring and inserts from the hub. Remove the spacer from the rear of the mainshaft. 17 Aemove the hub from the output shaft. A press will be required for this and if one Is not availabla, take the shaft to an automotive machine shop. Do not ettempt fO htlmm8r the hub off thlt shaft btlCause it will be damaged. 18 To disassemble the clutch shaft, remove the snap-ring ana any remaining roller bearings and remove the front bearing with a press. 19 To disassemble the reer bearing adapter, place the adapter securely in a vise. using wood blocks to protect the surface. Using a pointed tool, remove the rear beering snap-ring from the adapter. 20 Remave the adapter from the vise and press the bearing out of the adapter with a press. Removed the adaptar lock ring. 21 Wash all of the components with solvent. If compressed air is available, dry everything except the Dearings. The bearings should be air dried on a clean, lint-free cloth.
Inspection 22 Inspect the transmission case for cracks in the bares, sides, basses and bolt holes, and for stripped threads, nicks, burrs and tough surfaces in the shaft bores and on the gasket surfaces. 23 Inspect the gear and synchronizer assemblies for broken, chipped or worn teeth, damaged splines on the synchro hubs or sleeves, broken teeth or excessive wear of the blocking rings, bent or broken inserts
end damaged needle beerings or bearing bores in the countershaft gear. Check the countersheft, clutch and idler shafts for nicked, broken or worn splines. Inspect the snap-rings for distortion or lack of tension. Inspect the feverse idler geor for worn bushings end the front lind rear bearings for roughness, galling or damage. Replace any damaged or worn components with new ones.
Reassembly 24 Prior 10 reassembly, lubricate the reverse idler gear shaft bore and bushings with transmission lubricant. 25 Coat the transmission csse idler gear thrust washer surfaces with petroleum jelly (not chassis grease) and instell the thrust washers. Engage the thrust washer locating tabS securely in the case SIOls. 26 Install the reverse idler gear and align the idler gear bore. thrust weshers and transmission case bores. Insert the idler gear shelt from the raar of the case. Be sure to align and seat the roll pin in the shaft in the counterbare in the rear of the case. 27 Insert a feeler gauge between the thrust washer and the gear to check the end play and compare this measurement to tha Specifica· tions. If tha end play is not as specified, ramove the idler gear and replaca the Ihrust washers with new ones. 2B Coat the countershah needle bearings and bearing boras with petroleum jelly. Insert an arbor tool such as AMC 1001 J-25232 Into the gear bore and install the needle bearings and retainer in each end of the gear. 29 Coat the countershaft gaar thrust washer surfaces wilh petrolaum jelly and position the thrust washars in the case, making sura 10 engage the tabs securaly. 30 Insert the countershah ter enough into the rear case bore to hOld the rear thrust washer in place. This will kaep the thrust washer in place when tha countersheft geer is installed. 31 Install the countershaft gear, but do not install the roll pin. Align Ihe gear bore, thrust washers and case bores, then install the countershaft but do not remove tha arbor tool completely. 32 Insert a feeler gauge between the washer and countershaft gear to measure the end play. Compare the end play measurement to the Spacifications. If it Is axcessive, remove the gear and replace the Ihrust washers. After tha corract end play has been obtained, install the arbor tool completely" into the countershaft gear but leave tha gaar at the bottom of the case to provida clearance for mainshaft and clutch shaft installalion. Laava the countershaft in the rear case bore so Iha thrust washer will be held in place. 33 Coat tha mainshaft splines and machined surfaces with transmis· sian lubricant. Carefully start the first/reverse synchronizer hub onto the output shaft splines by hand with Ihe slotted end facing tha front of the shaft. An arbQr press must be used to press the hub onto the shaft, followed by installation of the snap·ring. 34 Coat the splines of the first!reverse hub with transmission lubricant and install the first/revarse sleeve and gear halfway onto tha hub
/
Fig. 7.24 Remove the rear bearing and adapter with e punch and hammer !T1501 (Sec 10)
Fig.7.25 Align the roll pin with the counterbQra when Installing the countarsheft (1150 and n76) (Sec 10)
Fig. 7.26 Flrst/ revarse synchronizer hub Insart Installation (11501 (Sac 10)
Chapter 7 Part A Manual transmission Wllh 11'11 glar Ind lacing Ihe rear of the shah. Align Ihe sleeve Ind hub marks made during disassembly. 35 Instill the insen spring in Ihe firsUrever81 hub. malting sure the .pring is bottomed in the hub and that it covers III three insert slots. Position thlthree T-shaped insens in the hubs with the small ends in the hub ,lot, Ind the large end6 inside the hub 9S shown in Ihe lIIustralion. 36 Push the insens completely inlo Ihe hub to sellihem on Ihe insert spring and Ihan slide the lirslfraversl sleevi Ind gear over the inserts unlll tha insens engage in Ihe sleeve. wbrlcale Ihe bore and blocking ring surllce ollirSI gesr With Iransmllll,on lubricant and place the Ii,.t gelr blocking ring on the Ispered surface 01 the gear_ 37 Instill the lirst gear on the output shaft, rOllle it until the blockng ring notches engage the insens in Ihe firslfrevlnle hub, install the tabbed Ihrust washe, with the sharp edgl facing out and install the anap-ring on the mlinshaft as shown In the illuSltation. 38 wbricIII the second gear bore and blocking ring surface with wansmission lubriClnt and place the blocking ring onto the tspared surflce of the gear. 39 Instalilhe second gear onto the output s haft with the tapered Burface facing the Iront of the mainshaft. 40 Install one insert spring into the second/third hub, making sura it covel1l.11 three insert slots. Line up the mark. made during disassembly 10 Ilign the aecondlthird sleeve with Ihe hub Ind Illrt Ihe sleeve onlo the hub. 41 Place Ihe Ihree inserts inlO the hub SlOtS and on lop of the insert 'pring, then push Ihe sleeve completely onto the hub and eng.ge the Inllrts In Ihe sleeve. Install the remlining inlert spring in exactly the sama poSition al the lirst spllng. The endl 01 both springs must cover the corresponding slots in the hub and the Insert lip must fit over the *pring as shown In the illustration. 42 InstIll the second/third synchronizer assembly onto the mlinshah and then rOlltl the second gesr until the nOlcherin the blocking ring
7A-15
engage the insert in the second/third .ynchtonizer assembly. 43 Inllailihe mainshlh snap-ring Ind measure the end play between the snap-ring end the second/third synchronizer hub with • feeler gauge as shown in the illustrltion. If the end plly exceeds thlspecified limit, replace the thrust washer and III the snap-rings on thl output shaft Issembly. Install the spacer onto the rear 01 the mainshaft. 44 Inst.1I Ihl main shah assembly in the CISe. making sure the fll1Ilfreverse sleave and gear is in the Neutrel {cantered! position on thl hub so the gear end of the sleeve will clear Ihe top of the cese when the output shaft is installed. 45 Inllall the rear bearing into Ihe beating adapter. An arbor press must be used lor this operation. Instill the rear bearlllg retaining ring and the besting adapter lock ring. 46 Support the mainsnaft assembly Ind install the rear belling and Idlpter in the case. using a soft-faced hammer to SIll thl adlpllr. 47 Press the front bearing onto the clutch shaft, install the snap-ring on the shaft and the lock ring in the front bearing groove. 48 Coat the clutch shah bearing bore with petroleum jelly {not chassis grease! and install the 15 rollor bearings. 49 Use tr.nsmission lubricant to coat the blocking ring surflCI 01 the clutch shaft Ind position tho blocking ring on the shaft. 50 Support the mainsnah assombly and Insert tha clutch sh.h through the Iront bearing bore in the case. Sell the mainshsft pilot in the clutch sh.ft roller beerings .nd tiP the bearings Into position using I softflced hammer. 51 Apply a thin coat of gasket sealer to the Iront bearing c.p gasket and place the gasket in position, making sure the notch aligns with the oil return hole in the transmission case. 52 Pry out thl old fronl bearing cap oUseal With a screwdriver. Install thl new seal using a large socket. 53 Inllall Ihe lront bearing c.p and bolts, tightening them to the specified to rque. Make sure the case Ind cap Ilignment marks er. lin ed up.
'NU~t"'~IN
tUHOU L"Of 'NU~nl
", Fl;. 7 .27 Proper instillation of Ihe flrst/rllt\lerse hub snip-ring and Insert spring (n50) (Sec '0)
7A
Fig. 7.28 Instilling the flllt gear thrust washer (TI50 and n78 J (See '0)
Fig. 7 .3' Tr.namlnlon shift I_r meehln.m eomponents - exploded (TI50) (See '0)
V"
Fig. 7 .29 Second/third .ynchronlzer assemb ly Insta llation dltall. In 50 end n78 ) (Sec '0)
Fig. 7.30 Measuring the mllnshlft gear treln end play (n50 and T176) (Sec 10)
7A-16
Chapter 7 Part A Manual transmission
54 FabrlCBte 8 loop of wire about 20 Inches long and pass it under the countarshah geBr assembly. Raise Ihe assembly with the wire and align the bore in the countershah gear with the front th rust washer end countersheft. Start the countershalt into the gear using II soft· faced hammer end elig" the roll pin holes in the countershaft and the case.
Ag.7.3 2 I
Third/fourth gear snap-ring ling
3 Thifdlfourth g8ar clutch
15 First geBr
" 17
essembly
4 Third/fourrh gear plate 5 Third geal synchronizar 7 8
•
10 11
12 13 14
punch to S8al the pin. InstaU the transmission tiller plug. 57 Check the operation of the synchronizer sleeves by shifting into ell geer positions. If it appesrs thet the clutch shaft lind malnshalt ara
T176 four-s peed tran s missio n com pona nts - up lo ded lI iaw !Sec 1 1)
2 Fourth gear synchronizer
•
55 Install the countershah access plug in the real of the case. using
II soft-faced hammer to sea! it. 56 Install the cQuntolllhah mil pin in the case, using II 1/2·inch diameter
ring Third speed gear Second geer snap-ling Second speed thrust washer Second spaad geer Second geal synchronizer ring Mainsheft snap-ling First/second synchronizer spring Low/second plete First gear synchronizer ring
18
"
20
21 22 23 24 25 2. 27 28 2, 30
31 32
Third/fourrh synchronizer spling First/second geBr clutch assembly From bearing cap Oil seal Gesket Snap·ring Lock ling From ba" bearing Clutch shaf t Rol/er beering Drsin plug Fil/plug Case Gesket Spline sheft First geaf thrust washer Rear ball bearing
33 34 35 3. 37 38 3. 40
41 42 43 44 45 4' 47 48 4'
SnBp -ring AdBptel pfBte AdBpter seBI From coumelshBft gear thfUst washel Roller wesher ReBI rol/er bearing Coumershaft geal Rear countersheft thrust washer Coumersheft
An
Idler g8ar shaft P;n
Idler gear rol/er beefing Reverse idler sliding geer Reverse idlel geef Idler geaf washel Idler geel thrust washer
Chapter 7 Part A Manual tran smission binding, check for slicking of Iha blocking rings on Iha fllSl and sec ond speed gear lapers 58 In,tall the meinshaft rear seal into the bearing edapter using alerge .b:e socket. 59 Shift both svnchroni~els Into geer so the gears won't turn, install me trensfer casa drive gear and locknut end tighten the nut to the specified torque. Shift the transmission Into Neutrel before installing it. 60 To dlSlssemble the shift control housing, remove the backup light Ind TCS SWitches (If so equipped l, unthread thl shift control housing cap and remove the cep, gasket, spllng rete lner and lever assemblV. Turn the housing over and mount it in a vise by clamping the shift lever tower, using blocks of wood to protect the surface. 61 Move the seCOnd/third shift rail to the rear 01 me hoUSIng and rotate me shift fork toward the first/rlVerse rail until the loll pin is accessible, Drive the rOll pin out of tha fork end reil wllh a punch and hammer, Remove thl shift 10lk and roll pin. 62 Use a hammer and brass drift to remove the second/thild shift lail, tlklng clle to catch the rail plug as the reil dllveslt out of the hOUSing. Don' t lose the poppet ball as the rail is removed . Cover the poppet ball holes in the houelng with tape befole removing tha shift rail and mark the location of the rail for ease of installation. 63 Rotate the first/reverse shift lork away Irom the housing notch to upose the roll pin. Drive the roll pin out with a punch and hammer .nd remove the fork . Bacause the loll pin hole i s offset, mark the shift fork POSI tiOn to simplifV installation. 64 Use a hammel and brass dlitt to remove the first/reverse shift rail, cllching the plug as it is dllven out, 00 not lose the poppel ball. Cover the shift lower and poppet ball holes with cloth 01 lepe balore lemoving the shift rail end mark its locatIOn. Remove the poppel balls, springs, and interlock hOUSing plunger from the housing. 65 To assemble. inltaM Iha poppet springs .nd detent plug in the housIng and Insert the first/reverse shift reil into the housing. Install the shih lork onto the shift rail and the poppet ball on topof the spring in the first/reverse shift rail bore. 66 Push the poppet ball end spring down into the hOUSing bore. usIng a punch or wooden dowel, end install the first/reverse shift rail . 67 line up the loll pin holes in the first/leverse shift rail and shift fork, Install the roll pin and mova tha rail to the center 01 Neutral position. 68 Insert the second/third shih rail inlO the hauling. Install the poppet ball on top of the spring In the second/ third shift rail bora. 69 Pu sh the poppet ball and spring down Into the hOUSing With a wooden dowel or punch and install the second/third shift rail . 70 Line UP the roll pin holes In the second/ third shih rail and the shift fork and Inst.1I the loll pin. Move Ihe shih lail into the center INeutral) datant. 71 Install the shllt rail plugs in the housing. Remove the shift contro l housing Irom the VISe. 72 As an assamblv, install the shift lever. lever spring, spring ratainer, gasket end shift control housing, tightening the cap secure IV. 73 Install the backup light and TeS switc hes.
11 1176 four·.pHd trln.mistlon Ind 1..... mbIV
dlUSlembly, In spection
Disassembly 1 Separate the transmission from the trensfer case. 2 Unbolt and lemove the shift contro l housing. 3 Two of tile hOUSing anachment bolts are do_l·type alignment bolts and it Is important to note their location during removal so they can be instelled in the same place during reessemblv. 4 Drain the lubricant into a suitable container. 5 Remove the countersha!t using an arbor tool such as AMC tool J·28342 or equivalent. Tap Iha countershah out of tile rear of Ihe case. 6 Remove the locating and snap -ringl from the rear bearing and remove the bearing with a puner. 7 Mark the relallVe position of the front bearing cap on the tr8nsmistiDn case for ease of installation and remove the bearing cap and gasi<.eL 6 Use a screwdriver to pry the oil seal out of the front bearing cap. 9 Remove the .nap-flng from the front bearing and remove the clutch sh.ft end front bearing. This operation requires the use of a special puller (AMC tool J · 25152 with adapter J -293441. 10 Remove the thlrdlfourth blocking ring flom the clutch shaft or the synchronizer hub. 11 Remova the front bearing from tha clutch sheft, using a puller.
7A -17
12 Remove the mainshah pilot roller bearings from the clutch sheft. 13 Remove the mainshaft and gear train assemblV and move the thlldlfourth synchronizer sleeve to the rear, into the third gear position. 1111 the rear end of the shaft down and lift the front end up and out of the case. 14 Remove the countershah gear and arbor 1001. 15 Remove the countershaft gear thrust washers as well IS any pltot bearing rollers which mav havII fellen into the case. 16 Remove the rlVerse idler gear assembly and tap the idler gear shah out of the rear of the case. Remove the gear assemblv thrust washers. 17 Remove the needle bearings and baaring retainers flam the rever.e idler geer essemblV. Remove the sliding g88r from the idler gear, noting its position for reference during reassembly. 18 Remove the arbor tool and needle bearings and retainers from the counterahaft gear. 19 Remove the thirdlfourth svnchronl~er and snap-ring from the malll' shaft. Slide the hub out of the sleeve end remove the inset! springs, inserts and blocking ring . Note the poSition of the Insert spring posl· tion for reference during installetlon. 20 Remove the third gear from the melnaheft. 21 Remove the second gear, blocking ring and snap-ring from the mainshaft. 22 Remove the tabbed thrust wesher from the mlinshaft. 23 Remove the firat/second sVnchronl~er hub snap-ring. Remove the hub end r_rse gear and .leeve assembly, marking tllem lor reference during reassembly. Remove the insert .prlngs from the hub, followed by the three inserts. Remove the .leeve end gear flam the hub. 24 Remove the first gear thrust WISher from the rear of tha shaft and (if still installed!. the fitst gear and blocking ring .
Inspection 25 Wash all of the components thoroughly with solvenL If compressed air is available, dry all components eltcept tha Dearings. The beerings should be air dried on a clean, lint· free cloth. 26 Inspect the transmission case for crecks in the bores, sides, bosses and bolt holas. Check the shaft bores, bolt hole. and gasket surfaces for stripped threads, nicQ, bUffS end rough .urfaces. 27 Inspect the gear and synchronizer assemblies for broken, chipped or worn teeth, damaged splines on the SVnchlo hubs or sleeves, broken teeth or eltcessive wear of the blocking rings, bent or broken insert. and damage to the needle bearngs or bearing bores.. Check the countershaft, clutch and idler shafts for nicked, broken Of wom splines. Inspect the snap·rings for dIStortion and lack of tension.
Reassembly 28 Coat the f8V8fS8 idler gear shah bore and sliding gear with transmis· sion lubricant. Install the sliding gear onto the reverse idler gear. 29 Install the arbor tool in the reverse Idler gear end install the needle bearings end the beering retainer on one end. 30 Coat the reverse idler gear thrust weshers with petroleum jellv Inot chasSIS grease) and install them in the case. These washers have flats which must be installed facing the mainan.h. The thrust washer locating tabs must engage the locating slots in the case. 31 Instd the reverse idler gear assemblV. Line up the gear bore. thrust washers .nd case bores end Insta" the revlrse idler gear shaft from the rear of the case. Be sure to seat the roll pin in the shaft, elign the roll pin with the notch in the case and push the shaft into the rear of the case. 32 Measure the end plav of the revelle idler gear by inserting a feeler gauge between the thrust washer and the gear. Compare the measurement to the Specifications. If the end plev eltceeds the specified limit, remove the Idler gear and repiaci the thrust washers with new ones. 33 Coet the countershaft, gear bore, needle bearings and gear with petroleum jellv. Piace the thrust washers in position in the case, mak· ing sUle to engage the locating tab. in the case. 34 Insert the countersheft into the rear case bore far enough t o re t'in the rear thrust washer in piece. 35 Install the countetshaft geer, line up the gear bore, thrust weaners and bores in the case and install the countersheft part way. Make sure the arbor tool entars the front sh.ft bore in the case and is not removed completelV. 36 Insert a feeler gauge between the washer and countersheft gear to measure the end plav. Compare thi. measurement to the Specification • • If the end plav is beyond the limit, remove the gear and replace the thrust washers with new ones. Aher the correct end plav has Deen obtained, reinstall the arbor tool end allow the gear to remain In the
7A
7A-18
Chapter 7 Part A
bottom of the case. Make sure the countershal! remains in the reef caS8 bore to hold the thrust washer in place. 37 Lubricate the mainshah, synchroniler assemblies Bnd gsal bores with transmission lubricant. 38 Assemble the first/second synchronizllr hub, reverse g011f and sleeve. Install the gear and sleeve on the hub end place the assembly flet on II workbench. Drop the inserts into the hub slots and Install the
Manual transmission tapered ponion of the gears if the clutch shaft and mainshaft appear to bind in Neutral. Free any sticking blocking rings with a screwdriver. 61 Fill the transmission with the specified lubricant and tighten the filler plug securely. 62 Install the shih control housing and a new gasket, tightening the bolts to the specified torque.
insert spring. Place the looped end of Ihe spring in one insert, com-
press the spring ends and insert Ihe spring ends under the lips of the two remaining inserts. Make sure the spring is under the lip of each insert. Turn the assembly over and install the remaining Insert. This spring must be installed so the open end is 180" opposite the first spring. 39 Install the assembled first/second synchronizer hub and reverse gear sleeve and snap-ring on the mainshaft. 40 Install the first gear and blocking ring onto the rear of the mainshaft. followed by the thrust washer. 41 Install a new tabbed thrust washer on the mainshaft, making sure the tab is seated In the mainshaft tab. 42 Install the second gear and blocking ring onto the mainshaft and secure it with a new snap-ring. 43 Install the third geal and blocking ring on the mainshaft. 44 Assemble the thirdlfourth synchronizer and install the sleava on the synchronizer hub, using the alignment marks made during disassembly, Place the hub and sleeve assembly flat on a workbench, drop the InSerts into the hub slots and install the insert spring. Position the looped end of the spring in one insert, compress the spring ends lind insert the spring ends under the remaining two insert lips. After turning the IIssembly over, install the remainIng spring liS described IIbove, but with the open end 1800 opposite the first spring. 45 Install the third/fourth synchronizer assembly on the mainshaft, followed by a new snap-ring. 46 Measure the end plsy between the synchronizer hub and snap-ring with a feeler gauge. Compare this measurement to the Specifications. It the end play is greater then that Shown in the Specifications, replace the thrust washers and snap·ring with new ones. 47 Install the mainshaft geartrain assembly in the transmission case, makIng sure the synchronizers are in the Neutral position so the sleeves will clear the top of the case when the assembly is instlliled. 48 Install the snap-ring on the front bearing and partly instllil the front bearing on the clutch shllft. The bellring should not be completely installed at this time or the shaft will not clear the countershaft gear. 49 Coat the clutc h shelt bearing bore and the mainshaft pilot bearing rollers with petroleum jelly (not chassis greese) and install the rollers in the bore. 50 Use trllnsmlssion lubricant to coat tl)e blocking ling surface of the clutch shalt lind pillce the blocking ring in position on the shaft. 51 Support the mainshaft assembly and carefully insert tha clutch shaft into the case through the front bearing bore. Seat the mainshaft pilot hub in the clutch shaft roller bearings and use a soft-faced hammer to tap the front Dearing and the clutch shaft into the case. 52 Install the front bearing cap and bolts finger tight. 53 Position the rear bearing on the mainsheft but do not inSlll1l the localing ring. Start the bellring onto the shllit with AMC 1001 J -29345 or eQuivlllent Isuch as II piece of rod). Remove the tool and use e soft faced hammer to complete the installation. With the bearing seated on the shaft, instell the retaining snap-ring. 54 Remove tha front bellting cap and seat the front bearing on the clutch shaft. Install the retaining snap-ring. 55 Apply a thin coat of gllsket sealer to the front bearing cap gasket and place it in position on the case with the notch aligned with the oil return hole. 56 Pry the front bearing oil seal out with a screwdriver. Install a new oil seal using AMC tool J-25233 or the proper diameter socket. 57 Install the front bearing cap and bolts, tightening them to the specified torque. 58 Install the locating ring on the rear bearing, reseating the bearing if necessary with II soft-faced hammer. 59 Turn the transmission case on end, at the edge of a workbench, with the clutch shllft pointing down. Make sure the counte rshaft bore is accessible and have an assistant hold the case in pOSItion. Carefully align the countershaft gear bores with the thrust washers and cllse bores and tap the sheft into place. taking care not to let the arbor tool drop onto the lIoor as the shaft is installed. 60 Check the operation of the synchronizer sleeves by shifting into all the gear positions. Check the blocking rings for sticking on the
'2 SR4 four·speed transmission - disassembty, Inspection end reassembly
Disassembly 1 2 3
Separate the transmission from the transfer case. Place a drain pan under the transmission lind adapter housing, Remove the drain bolt Ithe bottom adapter housing mounting bolt) and drain the trllnsmlssion lubricant. 4 Remove the flanged nut which IIttaches the shift rllil to the offset lever. Remove the offset lever. 5 Remove the rest of the extension housing mounting bolts. Remove the housing. 6 Remove the transmission shift control housing and gllsket. Note the locations of the two alignment (dowel) bolts. Discard the transmission cover gasket. SHIFT RAIL OIL SEAL
TRANSMISSION COVER
~~:;; /
"" \
OETENT SPRING \ / / 'H,",
~ .~"" r;:/:::. • __"':
~
o
~
o RING
OETENT PLUNGER
_
'
.'
.'"
"oo
~ SHIFT RAIL
GASI(ET~PIN SHECTOR r.-:~ ~I ,~
. ~ %"f ~
ARM PLATE ........
~ I .
M
V
@\
V
INSERTS
l
SelECTOR
.eM " . "
SElECTOR
V"
0 ,., SHIFT FORK
.eM
INTERLOCI( PLATE
INSERTS
SHIFT FORK
Fig. 7 .33 SR4 transmission cover assembly components - exploded view (Sec 121 7 Remove the C·clip that attaches the reverse lever to the reverse lever pivot bolt. 8 Remove the reverse lever pivot bolt. Remove the reverse lever and reverse lever fork as an assembly. 9 Punch or scribe some alignment mllrks in the front bearing cap and transmission case. 10 Remove the bearing cap and gasket. Discard the gasket. '1 Remove the speedometer gear snap-ring from the rear of the output shaft. Remove the speedometer gear and drive ball . 12 Remove the retaining snap-rings and the locating snap-rings from the front and fear bearings. 13 Remove the front beaTIng from the clutch shaft uSing AMC bear· ing remover J-8151·01. puller bolts J -26636, puller assembly J-25152 or equivalent. 14 Remove the clutch shaft from the transmission case. 15 Using the same bearing remov'al tool, remove the rear bearing from the output shaft. 16 Remove the output shllft with the geanrain intact. Do not let the first/second or thirdllounh synchronizer sleeves separate from the hubs during shaft removal. 11 Push the reverse idler gear shaft out of the back of the transmis· sion case. Remove the shaft and reverse idler gear. 18 Remove the countershaft from the back of the transmission case using AMC countershaft tool J -2B624 or a suitable length of pipe of the proper dillmeter.
7A-19
, 2 3 4 5 6 7 8 9 10
"
12
'3 '4 '5
,. "'9
18
20 2'
FIg. 7.34 Thirdlfourth shif t InSllft Thirdlfourth shift fork Salec tof interlock pillte Selector afm plste Selector arm Selector arm roll pm First/second shift fork insert First/second shif t fork Shif t rsil plug Trllnsmission cover gllskel Tf/lnsmission cover Trllnsmission cover dowelOOft Clip Trllnsmission COVflr bolt Shif t fsil O-ong seal Shif t fll;1 011 selll Shift fllif Detent plunger Detent spring Detent plug Filf plug
S R4 fo ur'lpeed tranl mlillo n co mponents - aKplodad vlaw (S ec 121
22 RevtJrse lever piVOf bolt 23 24 25 26 27 28 29 30 3' 32 33 34 35 36 37 38 39 40
C·clip Reverse /tNfJr fork Reverse lever Trlfnsmlssion cese Gaske t AdllpUIf housing Offset lever Offset lever Insert Ex tension housmg oil selll Reverse idler shll! t Reverse idlef shllft roll pin Reverse idlef gellr Reverse ItNfJr pivol bolt Backup light switch First/second synchronizer insert '3} Firs t gellr rof/ pin Rellf bearing retaining snap'fing Rellr bearing retaining snap -rmg Rear beering localing snllP-ring
41 Rear belfring
56 Thirdlfourth synchroniur
42 First gelfr thrust wlfsher 43 First gellr 44 Flrsl/second synchronizer
57 Countershaft geaf ffJlfr
45 46 47 48 49 50 5' 52 53 54 55
blocking ring (2) Firs t/reverse sleeve end gear Fifst/second synchronizer insert spring (2) Second gellr Silcond gellr thrust washer Itllbbed) Second gellr snlfp-ring Third gellr Thirdlfourth synchronizer blocking ring 121 Thirdlfourth synchronizer sleeve Thirdlfourth synchronizer insert spnng Th;rdlfourth synchronizer hub Ou tput shllft snap·ring
insert thrust WlIsher (mete/J
58 Countershllft needle bellring ffJtlliner
59 Countershaft needle bellflng
60 Countershllft gesr 6' Countershllft gellr front thrust wllsher (pIlls tic} Countershaft roN pin Countershllft Clutch shllft rof/er bellnngs Clutch shaft Front beefing Front bearing locstlng sntJP -rmg 68 Front be.ring ffJtlllning sntlp-ring 69 Front be.ring CliP 011 slllli 70 Front beaflng Clip gasket Front beering cap
62 63 '4 65 66 67
"
7A
7A-20
Chapter 7 Part A Manual transmission
19 Re move the countershaft gear and loading tool as an assembly. Remove the counters haft gear thrust washers and any clutch shah pilot bushings that fell into the transmission during disassembly. Note; The front countershaft gear thrust washer is plastic. The rear washer is metal. 20 Remove the countershah loading tool from the countershaft gear. Remove the needle bearing retainers and needle bearings. 21 Before dismentling the output shaft geartrain, scribe alignment marks on the third/fourth synchronizer hub and sleeve for essemblv reference. 22 Remove the snsp-ring from the front of the output shalt. Remove the th ird/fourth synchronizer assembly. 23 Ramove the blocking rings from the third/fourth synchroni~er assembly. Remove the insert springs and inserts. Separate the synchron i~er sleeve Irom the hub. 24 Remove third gear from the output shalt. 25 Remove the second gear retaining snap-ring and thrust washer. Remove second gear and the blocking ring . 26 Using a pair of side cuners, remove the first gear roll pin from the output shaft. 2 7 Remove first gear and the first gear blocking ring. 28 Scribe alignment marks on the first/second synchronizel slaeve and the output shaft for essembly reference. 29 Remove the insert spring and the inserts from the output shaft. Note: The first/second/reverse hub is essamb/ed end machined with the output sheft and is not removable. 30 Remove the detent plug, spring and plunger. Place the selector arm plates and the shift rail In the Neutral (cantered) position. 31 Rotate the shift rail counterclockwise until the selactor arm disengages and the selector arm roll pin is accessible. 32 Remove the shift rail until the selector arm contacts the first/second shift fork. 33 Using a 3/'6-inch pin punch, remove the roll pin and remove the shilt rail . 34 Remove the shih forks. selector arm plates, selector arm and interlock plate. 35 Pry out tha shift rail oil seal and O·ring with a screwdriver. 36 Using a hammer and punch, remove the shift rail plug . 37 Remove the nylon inserts and selector arm plates from the shift forkS. Note their positions for assembly refarence.
Inspection 38 Wash the transmission components thoroughly with solvent. Inspect the transmission cese for cracks in the bores, sides, bosses and bolt holes and fOI stripped threads in the bolt holes. Check the gear· trein and shih mechanism for broken, chipped or worn gear teeth, bent or broken inserts, waak or broken insert springs, damaged roller or needle bearings and bearing bores in the countersheh and hub, clutch shah or reverse idler gear shaft. Che-ck the snap·rings for distortion and lack 01 tension. Inspect the front and rear bearings for galling, damage end roughness. Inspect the shilt mechanism lor worn. damsged or bent inserts, forks, rails. arms, plates, interlocks end levers.
Re8ssembly 39 Install the nylon inserts end selector 8rm platas in the shih lorks. 40 Apply sealer to the shih rail plug and install it. 41 Coat the shift rail and rail bores with petrolaum jelly and insert the shift re il into the cover until the reil is flush with the inside edge of the covar. 42 Install the first/second shih fork (the lerger of the two forks) in tha cover and push the shift rail through the fork. 43 Position the selector arm and the C-shaped interlock plate in the cover. Insert the shift rail through the arm. 44 Position the thirdffourth shift fork with the selector arm plate under the first/second plete. 45 Push the shift rail through the transmission cover bore. 46 Rotata the shift rail until the forward arm plate faces away from, but is parallel to, tha cover. 47 Align the rOll pin holes and instalilhe roll pin. Be SUfe the pin is ffush with the selector arm surfaca. 48 Instell tha detent plunger. spring and plug. 49 Install the shift rail O-ring. 50 Install the shih rail oil seal by first placing an oil seal protector tool such as AMC J -26628 -2 over the threeded end of the shift rail. 51 Lubricate the lip of the oil seel snd slide it over the protector and
onto the shilt rail. 52 Seat the oil seal in the transmission cover using en oil s8al installer 1001 such as AMC J-26628-1. 53 Coat the output shaft end gear bores with transmission lubricant. 54 Install the first/second synchronizer sleeve on the output shah using the reference marks for alignment. 55 InSlelithe three synchronizer inserts end two insert springs in the first/second synchronizer sleeve. The inslln spring tangs engage in the same synchronizer insert. but the open ends of the springs iece away from each other. 56 Assemble firSI gear end the blocking ring and install them on the output shaft. 86 sure the synchronizer inserts engage Ihe blocking fing notches. 57 Install the first gear roll pin and Ihen instell the second gear end blocking ring on the output shaft. Be sure to engage the blocking ring notches. 58 Install the second gear thrust washer and snap -ring. The sharp edge 01 the washer faces out. Also. be sure t o engage the washer tab in the output shaft notch. 59 Using a feeler gauge, measure se-cond gear end play between the gear and thrust washer. End play should be 0.004 to 0 .014 -inch (0.1016 to 0.3556 mml. II end play exceeds the limit, replace the thrust washer, snap-ring and, if necessary, the synchronizer hub. Note: If any output shaft gear is replaced, the couMarshaft gear must also be replllctld. 60 Assemble third gear and the blocking ring and install them on the output shaft. 61 Install the third/fourth synchronizer sleeve on the output shaft using the reference marks lor alignment. 82 Install three synchronizer inserts and two insert springs in the third/ fourth synchronizer sleeve. Install the insert springs as described in Step
55. 63 Install the third /fourth synchronizer assembly with the machined groove in the synchronizer hub facing forward and install the snap-ring. 64 Measure the thirdffourth synchronizer end play. End play should be 0.004 to 0.014 -inch (0.106 to 0 .3556 mml. If end play eKceads the limit, replace the snap -ring and inspe-ct the synchronizer hub for excessive wear on the thrust faces. 65 Coat the countershah gear washers with petroleum jelly and position them in the transmission case. Install the plastic washer in the lront of the case. • 66 Insert the countershah loading 1001 in the countershaft gear, in· sTall the 50 needle bearings in the fronl and rear of the gear and install the needle bearing retainers. Coat the bearings with petroleum jelly during installation. 67 Install the countershaft gear from the rear of the case. Be careful not to displace the thrust washers. 68 Install the reverse idler gear from the rear of the case. The shift lever groove faces the front of the case. 69 Install the output shaft and gear train. Be carelul not to displace the synchronizer assemblies. 70 Install the fourth gear blocking ring in the thlrdffourth sychronizar sleeve. 71 Coat the pilot roller bearing bore of the clutch shaft with petroleum jelly and install 15 roller bearings. Install the clutch shaft and engage it with the third/fourth synchronizer sleeve and the blocking ring. 72 Using a bearing installation tool such as AMC J -22697, install the front bearing. Position the output shaft first gear against the rear of the case. align the bearing and install it complately onto the clutch shaft and into the case. Note: The front bean"ng does not havtJ an iden· tifying notch in the rece. The reer been"ng hes e notch. 73 Install the front bearing retaining and locating snap-rings. 74 Using an oil seal installation tool such as AMC J·26625, install the front bearing cep oil seal. 75 Install the front bearing cap gasket and front bearing cap. Be sura to align the groove in the cap and the cutout in the gasket with the oil hole in the case. Coat the bearing cap bolts with non-hardening gasket sealer and install the bolts. TIghten the bolts to 13 ft -Ibs (17.6 Nml. 76 Install the first gear thrust washer on the output shaft, facing the oil groove toward first gear. 77 Install the rear bearing using a bearing installation tool such as AMC J·25234. 78 Install the retaining and locating snap-rings on tha rear baaring. 79 Install the speedometar gear drive ball, gear and snap-ring. 80 Apply non-hardening gasket sealer to the threads of the reversa
Chapter 7 Part A Manual transmission lever pivot oolt. Install the reverse lever and pivot oolt in the case and install the spring clip. Tighten the pivot oolt to 20 It-Ibs (27.1 Nm). Be sure the reverse lever fork is engaged in the reverse idler gear. 81 Use a punch or screwdriver to remove the adapter housing oil seal, Install the new seal so that the metal face 01 the seal is Ilush with or slightly below the edge of the seal bore. 82 Rotate the clutch shaft and observe the blocking rings. II they tend to stick on the ge'H cones, gently pry them off the cones with a screwdriver. 83 Place the reverse lever in the Neutral position and install the cover gasket and cover on the case. Install the cover bolts and tighten each one alternately until the final torQue of 10 ft-Ibs (13.5 Nm) is achieved. Be sure the two dowel bolts are in their proper locations. 84 Carefully install the adapter housing and gasket. 85 Fill the transmission with the specified lubricant and tighten the filler plug to 23 It-Ibs 131.1 NmJ. 86 Attach Ihe transmission to Ihe transfer case.
13 T4 four-.peed transmission - dlsassambly, Inspection and ",assembly
Disassembly 1 Using a pin punch and hammer. remove the roll pin which anaches the offset lever to the shift rail. 2 Unbolt and ramove the edapter housing from the transmission case. 3 Remove Ihe detenl ball and spring from the offset lever, followed by the roll pin from Ihe adapter housing or offset lever. 4 Remove the counters haft rear thrust bearing and race. 5 Remove the transmission cover and shih fork assembly. 6 Remove the C-clip which retains the reverse lever 10 the reverse lever pivot bolt. 7 Rdmove Ihe reverse lever pivot bolt. reverse lever and reverse lever lark as an assembly. 8 Punch alignment marks on the front bearing cap and the transmission case and rem ova the front bearing cap. 9 Remove the front bearing race and end pley shims. pry out the oil seal wilh a screwdriver. 10 Rotate the clutch shaft until the gear flat faces the counte rshaft and remove the clutch shalt. 11 Remove the thrust bearing end the roller bearings. 12 Remove the output shaft bearing race by tapping the front of the shaft with a solt-feced hammer. 13 Lift out the shaft assembly. 14 Remove the countersheft rear bearing using a brass drift and an arbor press. 15 Move the counters haft to the rear and lift the shaft out of the case. Remove the countershaft front washer from the case. 16 Remove the countershalt rear bearing spacer. 17 Remove the reverse idler shaft roll pin and remove the reverse idler shaft and gear. 18 Remove the countershaft rear bearing using an arbor press. 19 Remove the clutCh shaft from the front bearing using a bearing removal 1001 such as AMC J ·29721 and J-22912. 20 Remove Ihe extension housing rear seal using a flat drift and a hammer. 21 Remove tha backup light switch from the case. 22 To disassemble the outPUI shaft gear train, first remove the thrust beefing washer from the fronl of Ihe output shaft. 23 Remove the third/fourth synchronizer blocking ring, sleeve and hub as an assembly after scribing alignment marks on the sleeve and hub. 24 Remove the thlrdlfourth synchronizer springs and inserts. Separate the synchroniter from the sleeve. 25 Remove the third gear from the shaft. 26 Remove the second gear snap -ring and thrust washer and remove second gear. 27 Remove the output shaft bearing using AMC puller J-29721 and A.MC adapters 293-39 or a similar bearing puller set. 28 Remove the first gear thrust washer. roll pin !using diagonal pliers), first gear and the blocking ring . 29 Scribe alignment marks on the first/second gear synchronizer sleeve and the output shaft and remove the insert spring and inserts from the first/reverse sliding gear. Remove the gear from the outpul shaft. Nota: The first/second/reverse hub is parr of rhe output shaft and is nor
7A-21
removable. 30 Place the selector arm plates and shift rail in the Neutral (centered ! position. 31 Rotate the shift rail cou'1terclockwise until the selector arm disengages from the selector arm plates and the selector arm roll pin is accessible. 32 Pull back on the shift rail until the selector arm contacts the first/second shift fork. 33 Remove the roll pin using a 3116·inch pin punch and remove the shift rail. 34 Remove the shift forks. selector arm plates. selector arm and interlock plate. 35 Pry oul Ihe shift rail oil seal and O' ring using a screwdriver. 36 Remove the shift rail plug using a hammer and punch . 37 Remove the nylon inserts and selector arm plates from the shift forks, noting their pOsitions for assembly reference.
Inspection 38 Refer to Section 12, Step 38 for transmission inspection pro cedures.
Reassembly 39 InSlall the nylon inserts and selector arm plates in the shift forks. 40 Coat Ihe edgea of the shift rail plug with sealer and install the plug. 41 Coat tha shift rail end shift rail oores with petroleum jetty and insert the rail in the cover until the end is flush with the inside edge of the cover. 42 Position the first/second shilt fork in the cover and push the shift rail th rough the fork. Nota: The first/second shift fork is the larger of the two shift forks. 43 Position Ihe selector arm and interlock plate and insert the shift rail. The widest part of the plate faces away from the cover and the roll pin faces down and toward the reer of the cover. 44 Position the thirdlfounh shift fork with the selector arm plate under the first/second shift fork selector arm plate. 45 Insen the shift rail through the third/fourth shift fork and into the shift rail bore in the cover. 46 Rotate the shift rail until the selector arm plate at the forward end laces away from, but parallel to, the cover. 47 Align the roll pin holes and install the roll pin. 8e sure It is installed flush with the selector arm surface. 46 Install the O-ring in the shift rail oil seal groove. 49 Install the shift fail oil seal by first placing an oil 88al protector tool such as AMC J-26628-2 over the threaded end of the shift reil.
14 T6 flve-.peed transmission reassembly
dl18ssembly. Inspa-ctlon and
Disassembly 1 Remove the tran smission filler plug and remove the lubricant us· ing a siphon pump. 2 Remove the offset lever roll pin using a pin punch and hammer. 3 Remove the eKtension Ilousing-to-transmission case bolts. Remove the housing and offset lever as an assembly. 4 Ramove the detent bait, spring and roll pin from the offset lever. 5 Remova the plastic funnel, thrust bearing race and thrust bearing from the end of the countersheft or the inside of the eKtension housing. 6 Remove the transmission cover mounting baits and remove the cover. Note the location of the dowel-type alignment bolts for assembly reference. 7 Remove the roll pin from the fifth gear shift fork using a hammer and punch. Not.: To prevent damage to the fflvers8 shift fBil, plllce a wood block under the fifth gear shifr fork during roll pin fflmova/. 8 Remove the fifth geer synchronil:er snap-ring and shift fork . Remove the fifth gear synchronizer assembly and detach fifth gear from the rear of the countershaft. 9 Remove the insert retainer, insert springs and inserts from the fifth gear synchronizer sleeve. Mark the position of the sleeve and hub for assembly refe re nce. 10 Remove the snap-ring and separate the fifth speed driven gear from the rear of the output shah using a tool such as AMC puller assembly No. J -25215. 11 Punch alignment marlta on the front Maring cap and the transmis·
7A
7A-22
Chapter 7 Part A Manual transmission
lion case for assembly reference. 12 RemoYe the beering cap mounting boItI and detach the bearing cap. 13 Remove the beerlng race and end play shlml from the cap. Pry out the bearing cap 011 lIal wllh a screwdriver. 14 Rotate the clutch shaft until the gear flat faces the counlerahaft and femove the clutch ahaft Irom the transmialion case. Remove the clutch shaft needle bearings, thrust bearing and race. 15 Remollil the output shaft fear bearing race and lift the shaft alsembly out of the case. 16 Unhook the overcenter link spring from Ihe rear of the cese. A homemade spring removal tool made of welding rod or wife would be helpful here. 17 Remove the rellilrse lever C·clip. 18 Rotate the reverse shift "il until it disengages from the reverse lever end remove the rail from the rear of the CISe. 19 Remove the reverse lever pivol pin. disengage the rlM'lrse IlM'Ir from the idler gear and remove the reversalever and fork assembly from lhe Iransmiesion case. 20 Remove the relf countershaft snap-flng and spacef. 21 Using an arbor preIS and a brass drift Inserted through the clutch shaft opening in the front of the case. carefully pre .. the countershaft assembly to the rear to remove the countershelt bearing. 22 Move the COunlershaft ISsembly to the rear and lift il 01,.11 of the tranlmission case. 23 Remove the countershaft rear bearing Ipacer. 24 Remove the idler shaft foil pin. 25 Remove the Idler shaft and geaf from the transmission case. 26 Using an arbOf preIS. remove the countershaft front bearing from the case. 27 Remove Ihe clutch ehaft front bearing using a bearing removal tool lueh as AMC No. J · 29721 and J·22912·01. 28 Remove the rur extenlion housing seal using a flat drift and a hammer. 29 Remove the thrust bearing washer from the output shaft. 30 Remove the thirdJfourtn synehroniler anembly and blocking ring. Mark Ihe eleeve end hub for assembly reference. 31 Remove the thlrdlfourth synchroniler insert springs and inserts and remove the sleeve Irom the hub. 32 Remove third gear ffom the output shaft. 33 Remove tha second geer snap·ring, tabbed Ihrull washer end eec· ond gear from Ihe shaft. 34 Remove the output shaft bearing using a puller such as AMC No. J · 29721 and adapter No. 293·39. 35 Remow the first gear thrull washer. roll pin !using diagonal cut· ters l. fifSt gear and blocking ring . 36 Scribe alignment mllrU on the firstJsecond gear synchronizer sleeve and the output shaft hub for assembly reference. 37 Remove the In.art spring and inserts from the first/reverse sliding gear end remove the gear from the output shaft hub. Note: The first/second/reverslt hub is pMr of rhe output shltfr and Is not removable. 38 Place the selector arm plates and shift fail in the Neuual (centerad) position. 39 Rotate the shift rail counterclockwise until the selectof arm disengages flom the selector arm platea and the selector arm roll pin is accessible. 40 Pull bllCk on the shift re~ until the selector arm contacts the first/sec· ond shift lork. 41 Remove Ihe roll pin using a 3116·1nch pin punch and remove the shift fail . 42 Remollil the shift fOlks. selector arm plates. salector arm and in· lerlock plate. 43 Pry out the shift rail oil seal and O·ring using a ecrewdriver. 44 Remove the shift rail plug using a hammer and punch. 45 Remove the nylon Inserts and seleclor arm plates from the shift forks. nntinll Iheir position 'or assembly reference.
Inspection 48 See Section 12, Step 38 fOf information on inspecting the transmis· lion components.
Reassembly 47 Install the nylon Insertl and selector arm plates in the shilt lorks. 48 Coat the edges of the shift rail plug with sealer and Install the plug. 49 Coet the shilt rail and shift rail bores with petroleum jelly and in · ger! the rail into the cover unlil the end II lIulh with the inside edge
Jf the cover. 50 Position the fif1t/I&c:ond shift lark In the cover annd push the shilt reil through the fori!.. Note: The (irst!second shift fork is the lerger of the two shift forks. 51 Position the selector arm and interlock plate and insert the shift fail. The widest pert of the plate faces away from the cover and the
roll pin faces down and toward Ihe real of the cover. 52 Position the thirdlfounh shift lark with the selector arm plate under the first/slcond shilt fOlk selector arm ph'llfl. 53 Insert the ShIft rail through the thlrd l fourth shift fork lind into the shilt rail bore in Ihe cover. 54 Rotate the shift rail until the setector 8rm plate at Ihe forward end laces away from, but parallel to. the cover. 55 Align the roll pin holes and install the loll pin. Be surll it is Installed flush with the selector arm surface. 56 Install Ihe O' ring in Ihe shift rail oil seal groove. 57 Install Ihe shift rail seal by lirSI placing an oil seal protector 1001 such as AMC No. J· 26628~2 over Ihe Ihreaded end 01 Ihe shift "II. 58 Lubricate the lip of the oil seal and slide It over the protector and onto the shift rail. 59 Seat the oil seal in the transmission cove r using an oil seal installer tool such as AMC No. J·26628·1. 60 Coat the output shaft and gear bores with transmission lubricant. 61 Install the lirst/sec:ond synchroniler sleeve on the output shaft using Ihe reference martr.s lor alignment. 62 Inslall three synchrOnizer Inserts and two insert springs in Ihe flrstJsecond synchronizer sleeve. The Insert spring tangs engage in the same synchronizer Insert but the open ends 01 the springs face away from each other. 63 Inslall the blocking ring and second gear on the oulput shaft. 64 Inslall the thrust washer and second gear snap·fing. Be sure Ihe washer tab is seated in Ihe output shaft notch. 65 Inllall Ihe blocking ring and first gear on the outpul shall. 66 Inslall the first gear ron pin. 67 Instell the real bearing on the output shaft using a bearing Installer such as AMC tool No. J·2995 and an arbor press. 68 Install the first geer thrust washer. 69 Install third gear, the third and fourth gear synchronizer hub inserts and the sleeve on Il'ie output shaft. The hub olfset faces forward . 70 Install the Ihrusl bearing washer on the output shaft. 71 Coat the counlershaft fronl beafing OUler cage wilh Locllte 601 !olthe equivalent) and install the countershaft Iront beering !lush with the case using an arbol press. 72 Coat the countershaft thrust wesher wllh petroleum jelly. lnSlal the washer with the tab corresponding to the depreSSion in the case. 73 Stand the CBSe on end and inslall the countershaft in the ffOnt bearing bOle. 74 Install the ountershaft rear bearing . pacer. 75 Coat the rear Dearing with petroleum jelly and install it wllh a bea,· ing installer such as AMC No. J · 29895 and a sleeve tool such as AMC No. J-33032. The installed beafing should extend 0.125·inch beyond the case sUfface. 76 Position Ihe leverse idler gear and inslall the idler shaft from the lear 01 the case. Install the roll pin. 77 Install Ihe output shaft. 78 Install the fronl clutCh shaft bearing on the clutch shaft using a Dearing Installer such as AMC tool No. J·2995 and an arbor pfess. 79 Coat 15 roller bearings wllh petroleum jelly and inslall them in the clutch shalt. 80 Install the clutch bearing and race in the clutch shah. 81 Install the rear output shaft bealing race cap. 82 Install the lourth gear blocking ling. 83 Install tha clulch shaft, engaging it in the third /fourth synchronizer sleeve and blocking ring. 84 Inslall Ihe front bearing cap oil seal using an oil seal Installation tool such as AMC No. J·26625. 85 Install Ihe front bearing race in the front bearing cap but do not vet inslall Ihe preload shims. 86 Temporafily install the ffont beallng cap. 87 Install the leverse lever. pivot boh and C·clip. Coat the pivot boh threads with non·hardening gasket sealer. Be sure the reverse lever fork engages the idler geal. 88 Inslall the fifth speed driven gear and snap·ring. 89 Install fifth geal on the counters haft. 90 Insert the reverse fail Irom Ihe rear 01 tha case and rotate it until
7A-23
lY,"AIL
0.1111,.0
fiRST .. SHIFT f~~OND
...1~ ,"LATE
/ ~ ",~'v_J,5;V' >l...
/
SELECTOR
I(
SHIFT
::.~'::~. .IIII,.:'"
THRUST"","
"""G'" ~~~".G '\
ep'Y
llilAHIM
COVER ,satON
"j',
"'mo
'
~
':\ ................
-.~
.EA. PO.
INTE"L~ ARM , !'LATE AN: 'IN
THIRD ·FDUtlT SHIFT fORI( H
THIRD
SVNCH":ONOUATH
HUI
.
IZEA
$UE~~S£"T AND
~FUNNEL
~
,~
~~\
HOUSING lEAL ~~~NTIFICATION
7A _ _ _...J~~
TRAHSMrss
CAlf.
ION
fifTH
twiTCH
Fig. 7 .35 T5 flve-,pHd 1rln.mllllon component, - eJiPloded vitlw ISee 14)
7A-24
Chapter 7 Part A Manu al transmission
It engage. If1 the filth speed reverse lever. 91 Install tha reverse lever overcentet link .pring. 92 U.ing reference mar1l.s for alignment, assemble thelifth gear syn insert springs and insert retainer. chlonizer 93 Install the plastic insens on each 'Ide 01 the fifth speed shilt fork. 94 Placa the fifth gear synchronizer assembly on the fifth speed shift lork snd slide them onto Ihe countarshaft and reverse rail 95 Place a wood block under the rail and fork assembly and instali the roll pin. 96 Install the thrust race agein.t the filth speed synchronizer hub and install the snap-ring. 97 Coat the thrust race and bearing with petroleum jelly and Install tha beSling agaln5t Ihe thrust race. 98 Install the lipped thrust race over the thrust beating and Install the plastic funnel in the end of the counlarshaft gear. 99 Temporarily install Iha extension housing. 100 Turn the transmission case on end aod mount a dial indicator on the extension hOU5ing with the iodocetof stylus on the end of the output shaft. 101 Rotate the output shaft and zero the dial indicator. 102 Pull up on tha output shaft until the end play Is removed. Read the dial indicator and use the dimension to determine the thickness of the beallng preload shim. 103 Select a shim pack measuring to 0 .005-inch (0.003 to 0.Q13 mm) thicker than the eod play.
.'eeve.
o.cxn
104 Set the transmIssion down on its s.de and remove the beanng ClP
and rece. 105 Add the necessary shim. to the bearing cap and install the clutch
shalt bearing race in the csp. 106 Apply some non-harden,ng gasket sealer to the case meting surface of the front bearing cap. InSlall the cap using the alignment mark' and 107 lOB 109 110
tighten the attaching bolts to 13 It-Ibs 11a NmJ. Recheck the end play. There mUll be no lind play. Remove the 8)(tllnsion housing . Move the shift forks and synchronizer rings to the Neutral position. Apply non-hardening gasket s8aler 10 the cover milling surface. 01 the transmission eeae. lower the COVlr assembly while aligning Ihe
shift forkS and synchronizer .Ieevll. Center the cover to engage Ihe
revene lever and install the two dowel bolts. 111 Install the remaining cover bolts and tighten them to 10 It-Ibs (14 Nml. Apply non-hardening gasket sellier to the extension hOUSing mating surface 01 the transmission case and install the extension housing to a poSition wherll the shilt rail JUSt enters the shift cover opening. 112 Install the offset lever and spring with the detent ball in the neutral guide plate detent. 113 Install the extension housing bohs end tighten them to 23 II-Ibs (31 Nml. 114 Install the roll pin and tha damper sleeve in the ollset lever. 115 Coat Ihe backup light switch With non·hardening gasket sealer and install the switch in the casa.
78-1
Chapter 7 Part B Automatic transmission Contents Automatic transmission -
diagnosis.
Automatic transmission fluid change. Automatic transmission removal and installation Fluid leval check General information
16
Neutral safety switch - check, adjustment and replacement •....•.. Throttle linkage - adjustment •. Transmission band - adjustment ... Transmission shift linkage - adjustment
Chapler 1 21 Chapter 1 15
,. 18
20 17
Specification,
Torque specifications Converter inspection cover bolts. Converter-to-driveplate bolts Cooler line fitting
Ft-Ib
•
Nm
33 15
4' 20
3
• ,
11
Front band adjustment screw
With adapter 1001 Without adapter tool Front band adjustment screw locknut Gearshift rod trunnion locknut
Rear band adjustment screw Rear band adjustment screw locknut. Neutral safety switch Oil pan bolts Manual lever-to·shaft nul Shift lever·lo-manual shalt linkage swivel clamp nul Transmission-Io-engine boils . Transmission-to-transler case bolts .
6 35
• 4
35
24 12
•
4
47 12 47 33 17 11 27
20 4
,
35
47
20
27
15 General Information Beginning with the 1976 model yeel, these vehicles were optionelly equipped with a three-speed automatic transmission. Power from the engine passes through a hydraulic torque converter to the transmission. On later models the torque converter incorporates a lock-up device providing a positive connection between the engine and transmission at certain speeds. Fluid from the transmission is circulated through an oil cooler loceted in the lower tank of the radielor. Due to the complexity of the automatiC transmission and the special tools required, an overhaul should not be underteken by the home
mechanic. Consequently, the procedures in this Chapter are limited to general diagnosis, routine maintenance and adjustment and transmission removal and installation. If the transmission requires major repeir work, it should be done by an AMC dealer or II reputable automotive or transmission repeir shop specializing in this type of work. You cen, however, remove and inslell the transmission yourself and save the expense, even if the repair work is done by a transmission specialist. Caution: If it becomes nacessary to tow a disabled vehicla, refar to the towing instn/ctions lit the front of this menual to avoid severe trensmission damage caused by lack of lubrication.
7B
78-2 16
Chapter 7 Part B Automatic transmission
Automatic tran.ml ..lon -
1980 through 1986 models
diagooal.
Automatic tren6lTlission malfunctions mav be cau.ed by four general conditions: poor engine performance. improper adjustments, hydraulic malfunctions and mechanical malfunctions. [)Iagnasl. of these problems should always begin With a check of the e8lUv repaired item.: fluid level and condition, lOih linkage adjustment and throttle linkage adjustment. Next, perform a roed test to determine if the problem ha. been corrected or if mOle diagnosis is necessary. If the problem par• istl eher the preliminary tests and corrections al8 completed, addi· tlonal diagnosis should be done by an AMC dealer service department or a reputable automotive or trensmlssion repair shop.
1976 through 1979 models 1
Place the gaarshift lever in Neutral, raise the vehicle end suPPOrt It securely on jackstands. 2 Loosen the gearshift rod trunnion locknut enough to permit movement of the rod in the trunnion. 3 Piece the outer ranga selector lever in the Neutral position and then tighten the trunnion locknut to the specified torque.. 4 LDwer the vehicle and check the operation of the gearshift lever in an positions. The vehicle should start onlv with the gearshift in the Park and Neutral poaltlona and the layer .hould engage prop· arly in all detent politions. Readjust the linkage, If necessary, to obtain the proper operation.
QUADRANT OIAL
erlv engaged . 10 Adjust the shift rod trunnion 8S necessary to obtsln 8 hee pin fit in the bellclank arm and then tighten the trunnion jam nuts. Hold the shift rod so that it doesn't IUrn 8S the jam nuts are tightened. When properlv adjusted there is no lash in the gearshift linkage. Lash i. eliminated by pulling down on the shift rod and presSing up on the outer bellcrank. " Check adjustment 01 the linkege by meking sure the engine sterts onlV when the gear.hlh is in Perk or Neuuel. If the engine doe. not stert or sterts in any geel other than PlIlk or Nautlel, the Neutlalseletv switch (Section 191 is defectiye or the edjustment is IncorreCt. 12 Check the Iteering lock to meke sure it operates smoothly and then lower the vehicle.
Thronle IInkag. -
1B
adjustment
The throttle linkage on 1979 through 19B3 models can be adjusted to correct hersh, delayed or erratic shifting and lack 01 kickdown.
QUADRANT
~ "
~ ~~UES~NG
7 Place the gearahift lever in Park and lock the 5111:11ing cOlumn. a Move the manual lever on the transmission all the way to the rllli into Ihe Park (lastl detent. 9 Check to make sure the pOlk lock is engaged by turning the driveshaft. The driv8snaft will not lurn when the park lock is prop-
~ I~ CLIPS ' q
~~~ /
5 Raise the vehicle and support it .ecurely on jackstands. 6 Loosen the shift rod trunnion jam nuts, remove the lock.pln an.d disengage the trunnion end shlfl rod 8t the bellcrank.
LIGHT
ASSEMBLY
..t\1 '€/...
~
/)~.J':\6'--~.J SHIFT
BOWL
NEUTRAL SWITCH SHIFT TUBE
/
®~~~ .~
GEARSHIFT_ LEVER
,
./?
(j
~
---
...........
~
...... ® ""-'
! IlXl®I
STEERING COLUMN SHIFT LEVER Ag . 7 .36
, 2 3
Typical earlier automallc uen.mlssion gearshlh componenllayo~t (Sac 171
Trunnion locknut Gearshift rod trunnion Gearshift rod
'''''''f
4
Trllnsmission s"l"ctor
5
Outef fange Self!CtOf f~f
Chapter 7 Part B Automatic transmission 151 cu in four-cylinder engine 2 Remove the air cleaner assembly, then remove the spark plug wire separator from the throttle bracket and secure it out of the way. 3 From under the vehicle, hold the throttle control lever all the way to the rear, against the stoP. and secure it with a spring. 4 In the engine compartment, block the throttle open and set the carburetor linkage completely off the fest idle cam. On air condition· ing equipped models. turn the ignition switch on to energile the throt tle stop solenoid . S Releese the T-shaped cable adjuster clamp and lift the clamp up with a smell screwdriver as shown in the illustration. 6 To remove the cable loed on the throttle cable bellcrank. grasp the outer ceble sheeth end move the ceble end sheath forward . Adjust the cebla until there rs no laSh between tha plastic ceble end bellcrank bell. When this is achieved. lock the cable by pressing the T-shaped cable adjuster clamp until it snaps into place.
78 ·3
7 Turn the ignition off, install the spark plug wires and separator, con nect the throttle stop solenoid on air conditioned models, install the air cleaner and remove the spring from the throttle control lever. Tesl drive the vehicle and check fc;r proper shifting operation. readjusting as necassary.
150 cu in four-cylinder and in-line six-cylinder engines 8 Remove the throttle control rod spring. On 1982 and laler models, use the spring to hold the adjusting link egainll the nylon washer, in the forward position. 9 Block the choke open and sat the throttle off the fast idla c am. On modals aquipped with a throttle-operated solenoid valve. turn the ignition switch on, to energile the solenoid, and open the throttle halfway to lock it. Return the throttle to the idle position. 10 Raise the vehicle and support it securaly with jackslands. 11 Loosen the retaining bolts on the throttle control adjusting link. 12 Use a spare spring to hold the transmission throttle lever all the way forward, against the stop. Hook the spring to the torque converter boss or the linkage bellcrank. 13 On earlier models, pull on the end of the link until the lesh is eliminated and then tightan the retaining bolt securely. On 1982 and later models, push on the end of the link to eliminate any lash, pull the clamp to the rear so the bolt bottoms in the rear of the rod slot. Tighten the forward clamp bolt. Pull the throttle control rod to tha rear until the rod bolt bottoms in the front rod slot and tighten the rear retaining bolt. 14 Install the throttle control rod , remove the spring from thalfansmission lever and lower the vehicle.
VB engine
Fig. 7.37 151 cu in four-cylinder engine throttle cable adjustment details (Sec 18) BEll.CRANK THROTTLE
)~,-~~~~:::~/' ~ ~g~Ts~~~NG
~
Y \
. / THRO TTLE CONTROL ROO SPRING HITCH PIN
15 Remove the throttle control rod spring, raise the vehicle and sup port it sacurely on jeckstands. 16 Secure the transmission throttle valve control lever forward against its stop, using the throttle control rod spring. 17 Block the choke open and set the throttle off of the fest idle cam. On throttle-operated, solenoid valve-equipped carburetor$, turn the ignition switch on to energile the solenoid, then open the throttle halfway to lOCk it. Return the throttle to the idle position. 18 Loosen the throttle control rod adjustment link retaining bolt. remove the spring clip and move the nylon washer to the rear of the link. 19 Push on the end of the fink until afllash has been eliminated, tighten the bolt and reinstall the nylon washer and cl ip. 20 Remove the spring from the linkage and reinstall it on the throttla control rod. 21 Lower the vehicle.
19
Fig.7.38
Neutral safety switch - check, edjustment and replacement
THROTTLE CONTROL
1976 through 1979 models
' 00
1 With the parking brake applied, check and adjust the shift linkage if necessary (Section 171. 2 Remove the switch from the base of the steering column. 3 Place the gearshift in the Park position and lOCk the steering column. 4 Move the actuating lever for the neutral switch until it aligns with the P stamped on the back of the switch. 5 Insert a 3/32-inch drill bit into the hole located below the N stamped on the back of the switch and mova the lever until it stops against the drill. 6 Place the switch in position on the staering column, instell the retaining screws and remove the drill bit. 7 Check the switch lor pfOper operation. The engine should start with the gearshift in the Neutral and Park positions only end the baCk-Up light should glow in Reverse.
Typical later six-cylinder throttle linkage component layout fSec 18)
1980 through 1986 models
Flg.7.39
1982 lind later model automatic transmlnlon throttle linkage adjustment (Sec 18)
8 The neutral and back-up light switches are combined into one unit. The switch has three terminals with the neutral switch being the center ona A ground for the starter solenoid circuit is provided through the gearshift lever in only the Neutral and Park positions. 9 Remove the wiring connector and test the switch terminal for continuity. Continuity should exist between the center terminal and transmission cese only when the gearshift is In Neutral and Park. If the switch appears to be faulty, cheCk the shift linkage (Section 171 before
7B
7B-4
Chapter 7 Part B Automatic transmission
replacing the sWitch. 10 Prior to replacing the switch, place a container under it to catch the transmission fluid . 11 Remove the switch and ellow the Iluid to drain into the container. 12 PIece the gearshift lever in Park and Neutral and ch8(:k the lever linger po.ition and lever and ,hatt alignment with the switch opening. 13 Install II'Ie switch and seal, tightening Ihe bolts to the s~cified torque. 14 Telt the switch for continuity and plug in the connector. 15 Check the transmlnlon ftuid levei lChapte( l ).lIddillg the specified fluid liS necessary.
20 Trln.mlnion bend - adjustment The transmission bands should be adjusted at the specified inter ...als or when the automatic upshifts or downshifts become conSl1Ilenlty halllh endlor erratic. AdjustmtJfIl is possible only on 1980 lind Illfer models. 2 Raise the vehicle and support it on jackstands.
FIg. 7 .40
Front band
Later model neutrel/back-up light switch (011 pan removed tor clarltyl !Sec 191
3 The ffont band adjustment screw is located on the lett side of the trensmiasioo, jUlt ebove the throttle control levers. 4 Loosen the IKIjustment screw locknut and beck it oH five (5) turns. Check the lKIiusting Icrew to make sure it turns freelv In the CIISe. lubricating it if necenary. 5 Using a torque wrench and AMC adapter J-24065 and II 5116-inch socket, tighten the adjustment screw to the specified torque. If the edapter tool is not used. the alternate torque must be used. S Back the screw off two (2) full turns. 7 Tighten the adjustment screw locknut to the specified torque while holding the screw so thaI it does not rotate.
Rear band 8 The rear band adju.tment screw is accessible atter removing the oil pan. Consequently. It i. convenient to make this edjustment at the time of the transmlllion fluid and filtar change ,Chapter 11. 9 Remove the all pen. 10 Remove the adjustment screw locknut. 11 TIghten the adjusting .crew to the specified torque with II torque wrench and 114-inch socket. 12 Back the adjultment screw off four (41 full turns. 13 Hold the SCf8'W so that it will nut tum. instllil the locknut and tighten it 10 the specified torque. 14 Install the oil pan and lower the vehicle.
21
Automatic tranlmlnloo - ramoval and Inltallation
Remove the fan Ihroud bolts (il equipped) and disconnect the transmissioo fill t\lbe from the upper bracket. 2 Raise the vehicle end support it on jackslands. 3 Remove the torque converter inspection cover, starter motor and filllub .. 4 Mark the drivesheftl and aKle yokes to simplify installation. Disconnect the driveshafll at the transfer case vokes and secure them out of the waV with wir.. 5 On va engines. unbolt the elChaust pipes from the manilolds. 6 Discoonect the gearshift and thronle linkaoge. neutral salety switch wire and speedometer cable. 7 Mark the relationship 01 the converter and drivep!ste for reference during reassembly. 8 Remove the converter-to-driveplate bolts, roteting tha crankShaft and drivaplata to gain accass to aach of them. 9 Support tha transmlllion/trans fer case allembly with a jack. It is a good idea to anach the assembly to the Jack with II chain. 10 Remove the rear CrOllmembef, lower the transmission slightlY and disconnect the fluid cooler lines. 11 Remove the tr8nsmis.ioo-to-engine mounting bolts and mo.... the transmission and converter far enough to the rear to clear the crankshaft. 12 Hold tha con .... rter In place and lower the Iransmission with the jack until the converter housing clears the engine.
Ag. 7.41 Front transmission band adjustment using e torque wrench and adapter tool (Sec 20)
Fig. 7.42
Rear tranlmlsslon band adjustment (Sec 201
Chapter 7 Part B Automatic transmission 13 Remove the transfer case from the trensmission. 14 To install, connect the transfer case to the transmission. Make sure the converter is securely engeged in the hub slots. 15 Raise the transmission/transfer case essembly into position and align the driveplate and converter marks made during removal. Move the engine as necessary to align the converter housing pilot holes with the dowels in the engine end install the two lower mounting bolts. TIghtan the bolts enough to draw the transmission up to the engine. 16 Install the driveplate~to -converter bolts and tighten them to the specified torque. 17 Inslall the remaining transmission-to-engine mounting bolts and tighten them to the specified torque.
76-5
la Connect the cooler lines lind install the rear support cushion on the transmission. 19 Raise the transmission into position, Install the croasmember and remove the jack. 20 Install the apeedometer cable and Ihe converter inspection cover. 21 Connect the exhaust pipes to the manifolds and install the starter motor. 22 Connect the gearshift and throttle linkage and the neutra l safety switch wires. 23 Connect the driveshafts, using tha alignment marks made during removal. 24 lower the vehicle and adjust the shift linkage (Section 17).
78
7C -O
Chapter 7 Part C
Transfer case
General information Model 18 transfer Clle - disassembly. inspection end reassembly . . . •. • •... . . . .•. . .•...•.. .... . . .. Model 20 transfer case - disassembly, inspection and f8a ...mblv .••••••.•.••.••••...•.••••.•.•••...• Model 300 transfer CII88 - disassembly, inspection and reassembly .•.••.•..•.•••..•.• . •.••.•.•..••
22 27
2.
Oil level cheCk . . .. .. .. . .. .. . .. . Chapter' Oil seal replacement . . . . 26 Cuadra-Tree - disassembly, inspection and reassembly 30 Quadra-Tree - Itick-sUp condition diagnosis end correction •• 24
Shift linkage - lubrication, check and adJustment . Transfer case laB models) - removal end installation . . • • • • .
29
Tlllnsier case lubricant change .
Speclflution.
Model 18 Mainshaft end play . .. . ......• . .• . .• . . . .. . .. . .. . .. End play adjustment shims . . . . ... • .•.. . .....•.. •
0 .004 to 0 .008 in 0 .003, 0.010.0.031 in
Model 20 Rear bearing cap end pley 1966 through 1978 ..... .
. ..• •. . •... . . . . .. .... 1979 . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . Front output shaft end play 1966 through 1978 ........... . 1979 .....
0 .001 to 0.003 In 0.002 to 0.005 In 0.001 to 0 .003 in 0 .002 to 0.005 In
Model 300 Input gaar-to-snap·rlng claaranca Rear output shaft end play. Front output shaft and play . .
0.003 in 0.00 1 to 0.005 In 0.001 to 0 .005 In
Torque specifications Model 18 Transfar case-to-tranllmillion bolts ..... • •. •. . .. . . .....
F10Ibs 28 to 32
Nm
28 to 32
38 to 43
225 to 250 90 to 150 28 to 32 12to15 12to15 28 to 32 12 to 15 28 to 30
306 to 340 122 to 203 38 to 43 17 to 20 17 to 20 38 to 43 $7t020 28 to 41
10 to 20 25 to 40 120 to 150 7 to 10 20 to 25
14t027 34 to 54 163 to 203 9 to 14 27 to 34
38 to 43
Madel 20 Transfar case-to-tranamillion bolts . . . ..... • . . .. . Front and rear output shaft yoke nuts 1966 through 1978 .. . .... . . . .......... .
1979 . . . . . . . . . . . . . . . . . . . . . . . ..... . ....... . Front output shaft rear bearing cover-Io -case bolts ....... . Intermediate sheft lockplate bolt . . . . . ........... . lower cover-to-caae bolts . . . . . . . . . . . ..... . Rear beering cap lSaembly-to-1;:ese bolts .. . . . Shift fork set screws . . . ...... . Shift rod housing-tO-ClSe bolts ..... . . ..... .
Model 300 Bonom covet bolta . . . . . . . . . . . . . . .. •. • . . •. . . Cover plate bolts .. . ................. .•. . .... . Front and rear output yoke nUls . . . . . . . . .. . ......... . Input shaft support bolts .. . .......... _ . •. . . .. . .. _ .. lockplate bolt . ......... . . .. . . . .. . .•.. . Front and reer bearing cap bolts ..... ........ . Shift fork set screws ..... . . ........ ...•. .
3' 12 to
47 18
16 to 24
... . . . . . .
25 23
Chapter 1
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Chapter 7 Part C Transfer c ase Quadra· Trac Tran.fer can Braather . . . .. . ........... . Differential end cap bolts . . . . . . . ............ . Drain and fill plugs ....................... • ... . Output shaft nut .......... , ............... . Power takaoff coyer'lo-transfer case bOlt 318 in bolts . . ............. . 5116 In bolts . . ... . . . Speedometer adapter Front coyer·to-rear coyer bolts Tran.fer cese-to-transmission bolls. RedocOon unit nl plug . . . . . . . . . . . . . . . . . . Power takeoff co yer -to-c ase bolts . Reduction unh·to -transfer case bohs 31B in bolt ....... . .........•. . ..•.• . .•.. 5116 in boll . ...... . . . ........ . .. • .•..... Shift lever·to -shaft nut. . ....•.......... . .. ... ..
5 to 10 24 to 30 15 to 25
8 to 14 33 to 41 20 to 34
90to150
12210203
15 to 25 10 to 20 20 to 30 15 to 25 30 to 50
20 to 30 14 to 27 27t041 20 to 34 41 to 68
151025 15 to 25
20 to 34 20 to 34
15 to 25 8 to 10
20 to 34 11 to 14 20 to 34
15 to 25
22 Gene,,1 information The tran.fer cese i. basically a trensmlssion which passes the power from the engine and transmission to the front and rear dri .... shafts and axles. Oyer the long production lile of Ihese vehicles, four model, of transfer ctl$es were used: Spicer Model, 18, 20 and 300 and the Wamer auadra -Trae. The Splcar tran.fer c.tes provide driye in two-wheel or four-wheel drive while the auadra -Trac provides full time four·wheel driye by means of an integral limited slip differential. An optional low r.nge reduction unit provides the auadra -Tree transfer case with maximum braking and torque at low apeeds. -,,_ _ _ SHiniNG I.(YIII
liNK
Fig. 7 .43
Model 20 tran.fer cen ,hlft mechani.m component. Is.<: 23 and 25)
WITH MANUA L TIIANDUlllON
23 Tran.fer ca., 'all mod,'a) - ramo....' and Installation 1 Raise the vehicle and support it on jackstands. 2 Drain tha transfer case lubricant into a suitable container. 3 Disconnect any component. which are attached to the transfer case (tueh as the speedometer cable. plH'king brake cable. eKMuat pipe brackell, vacuum hoses and, on some models, the shift levers). 4 Mark the relative positions of the driyeshaft flange, and transfer case yokes to simplify reinstallation . Disconnect tha driYBshaft. from Ihe tran.fe, case and fasten them out of the w.y with wire. S On later models. support the clutch hou.ing end remo .... the rur cross member. 6 Support the transfer case with a jeek and remove the transfer case to -transmission boill. 7 Separate the transfer case from the tr.nsmi,sion. On earlier model 18 and 20 lransfer cases, braca the end of the transmission sh.ft so that iI cannot move. Pull Ihe ttan.far case to Ihe raar to loosen the gear and Ihen withdraw the cale from the tran.mission. Make .ure the transm ission mainshaft bearing .Iayl in the transmission. 8 To inltaU the case. raise it into po.ition and align the inpul gear , pline. with Ihe transmission output sh.ft. Rotate the trensfer clle output shaft yoke to Une up the spllne., if necessary. 9 Make sure the holes are aligned, instaU the transfer case·to· tran.million attaching bolts and tighten them to the specified torque. 10 InstaU the driyeshafts, using Ihe alignment marks made during removal. l' Install any components which were disconnected from the Iransfer case during removal . 12 Fill Ihe transfer casa with the specified lubricant. 13 lower the vehicle.
24 SHIFT CONTROL LINK
fig . 7.44
Model 300 transfer can . hlft m echenism co mponents (Sec 23 end 25)
Quadrs-Trac stlck-.llp condition diagnolll. end correction
The stick·slip condition occur. when the clutch i. released .oddanly when driving at low speed,. The symptoms are e cons tent, pulsating, grunting or rasping noise ISlulng from the transfer case. The . tick-sllp condition is usually evident when turning the vehicle. 2 The stick-slip condition is caused by improper lubricant in the
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7C-2
Chapter 7 Part C Transfer case 25
tfllnsfer ease Of mismatched tire types or sizls. The condition will also occur if the vehicle has not bean driven lor a week or more. but in this instance it is normal. 3 To correct the condition, dram the case and fill it with the specified lubricant ,Chapter 11 and make sure all foul tires are of the slime type and size and equallv Inflated.
Check the shift linkege penodlcallv tOf looseness and binding. Inspect the mechanism lor worn, bent lind damaged components. Clean, lubricate and .djust UI possible) th.linkage and shift mechanism. Us.
uan,'.'
, 2 3 4 5 6 7 8
•
10
"
12 '3 14
15 16
,." '8
20
Fig. 7.45 ComplJn/on flilnge Braka drum Emergency brtJke Opera tmg lewl( Oil sui Lrttf!r stud Rear cap Shims Sc,.,w Lock washer Bolt Rear cover Gasket Lockplilte Trsnsfer cese Shift rod FbpPtJ I plug FbpPtJt spring FbpptJ t btJlI Interlock
Model 18 transfer
Cill .
penetrating oil when lubl'icatlng linkage components.
compo nent' - ' Kplo ded view (Sec 271
21 Gasket
22 23 24 25
Shirt IInbga - lubr lC lllo n, chICk and I djul lme"l
Fron t cap Breather Shift 18VfJr spnng Shif t l8VfJr 25A $hif t f8Ver fused with 4 -speed trsnsmissionl 26 Shif t lew!r knob 27 Shif t lever 27A Shif t lever (used wit h 4 -speed trsnsmissionl 28 Pivot pin 2. wbrication fitting 30 Se t screw 3 ' Oil seal 32 Fron t yoke 33 GtJsket 34 Bol t 35 Lock washer 36 Shift rod
37 38 39 40
Shif t fork Shift fork Filler pipe plug MamshtJfr gear 41 PltJm washer 42 Thrust wash., 43 In termediattJ gear 44 Snep-ring 45 Bearing
46 Nu ' 47 Washer
48 Output clu tch shaft 4' Output clutch gtJllr 50 Snap ·ring 51 Thrust wesh.,
52 53 54 55 56
Output shtJft getJr Sliding getJr Bushing Output shtJf t Cone tJnd rollelS
57 58 59 60
Bearing cup Speadome rer gear Needle beatings Bearing spacers 61 Intermediate shaft 62 Dram plug 63 Gasket
64 65 66 67 68 6. 70
"
Nu' Bottom cO'tfl8r Sleeve Speedometer gear Bushing Gllsket Bolt Bolt Bolt Bolt Lock washer
72 73 74 75 Nu' 76 Output Shaft seal
Chapter 7 Part C Transfer case Model 18 2 The linkege on early models can be adjusted atter loosening the locknut, Turn the adjuster in or out until there is ll2·inch clearance between the lloorpen and the shift IlIVer bend with the lever in the four· wheel·drive Low position.
Model 20 3 The linkage cannot be adjusted but capscrews retaining the shi ft lever support tube to the transler case should be checked to make sure they ara tightened securely.
Model3oo 4 The linkage is not adjustable but the shilter shalt nut should be checked to make sure it is tightened securely.
Quadra-Trac 5 The shilt mechanism for the Quadra-Trac transfer case is internal and not adjustable. The Emergency Orive control located in the glovebo)( directs engine vacuum to the control diaphragm on the trans ler case. The vacuum hosas must ba inspected periodically. Check for secure connections. crac ks end leaks.
26
OU I.al r. pllcemant
The seall lor the front and rear output shalts, as waUas the shift rods, can be replaced with the transler case in place in the vehicle. 2 Raise the vehicle and support it securely on jackstands.
Output shaft oil seals 3 Mark the relationship of the driveshaft flenge and out put shaft yoke to ensure reinstallation in the original position. 4 Oisconnect the driveshaft end fasten It ou t of the way with w ire. On some models it will ba necessary to support the transmission w ith a jeck or Jackatand and then remove the chassis crossmember to provida access. 5 Remove the ou tPUt shaft nut and washer, using a holding tool such lIS AMC No. C·32S1 or its equivalant. 6 Remova the driveshah yoke uSing a puller such IS AMC No. W-172 or its equivllent. 7 Remove the felt 58al, oil seal and gasket using a puller such as AMC No. W-172 or its equivalent. S Install the new seal with AMC driver W·143 or its equivalent, 101lowed by the gasket and felt seal. 9 Install the driveshah yoke. washers and nut. Tighten the nut to the specified torque. 10 Install tha drivesheft, tightaning the nuts to the specified torqua. Install tha crossmember Iii removed).
Shift rod oil seals 11 lithe lelt side shilt rod oil seal on 1977 and later model 20 and 300 transler ceses must be replaced. place the shift lever in the 4 L position. 12 Disconnect the shift lever linkage at the rods. 13 Use a puller such as AMC tool J -25175 or equivalent to remove the oil saal. 14 Install the replacement seal with AMC driver J·25167 or equivalent. 15 Connect the shift lever linkage. 16 Low!!r the vehicle.
27
Madella trllnsfllr Cll sa - disassembly, inspection and rl!llSMmbIy
Disassembly 1 Remove the transfer case drive gaar. 2 Remove the output shaft nuts. lollowed by the rear output shah lIange and brake drum !if equIpped) and the front output shal t yoke. 3 Remove the bonom cover and thlliockplete screw. lock w asher and Iockplate. 4 Drive out the intermediate shaft toward the reaf of the cese wi th a hammer and bralS drift, taking care not to losll the thrust washers. 5 Through tha bottom of the case. remove the interme diate gear, thrust washer •• needle bearings and spacers. 6 Remove the poppet plugs, springs and balls on both sides of the
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front beallng cap. Shift the Iront wheel shilt lever to the forward or engaged position. 1 Unbolt and remove the lront bearing cap complete with the clutch shaft, bearing, clutch gear, fork and shift rod. Take care not to lose the Interlock between the shift rods. 8 On models so equipped, remove tha parking brake backing plate and speedometer gear assembly. 9 With a soh-faced hammer, tap on the Iront end of the output shalt to drivlI the rear bearing cup from the case. 10 Use a wedge tool to pry the Iront bearing cone and roller assembly from its seat on the shaft. 11 PlaclI a bearing cup removing ring on tha output shah between the front bearing and thll gear. USII a soft-faced hammer to tap on the rear end of the output shah and remove thll bearing cup from the case. 12 Release the snap-ring, slide It forward on the shah and drive thll shaft through the case. The snap-ring. gears end thrust washer will remain .n the case as the shaft Is removed and can be removed from the bottom. Tap lightly on the end of the shaft (resting on a wooden blockl to remove the rear bearing cone and roller assembly. 13 Remove the sliding gear shift fork set screw and the shift rod . 14 Remove the ou tput shah oil seal and shift rod seals as deSCribed in Section 26. 15 Remove the shifting lork and shifting rod set screw and remove thll clutch gear and shifting fork as an assembly. 16 Remove the output clutch shalt by prassing it carefully through thll bearing, followed by the bearing retlinar snap·ring and the beallng. 17 Rllmove the output shaft oil seal as described in S!!ctlon 26 18 Remove the breke drum and companion lIange retainmg bolts and separate the drum from the flange. 19 Remove the oil seal as described in Section 26. 20 Remove the speedometer driven gear. 21 Remove the cap and brake backing plate from the transmiSSIOn case. taking ca re not to lose the bearing adjusting shims. 22 Remove t he speedometer gear.
Inspec tion 23 Wash the transfer cese and components thoroughly with solvent and dry them with compressed a;r il posaible. 24 Inspect all the bearings. thrust washers, shafts, gears and the casll for e)(cessive wear, pitting. scoring, cracks and damage. Replace any worn or damaged components with new ones.
Reassembly 25 Reassembly is basically the reverie of disassembly with anention paid to the procedures in the following steps. 26 Use a thimble end driver·type tool when Installing the snap-ring on the output shaft . 27 To prevent damage to the assemblies, use a piece of tubing when installing the cone and roller assemblies on the output shaft. 28 Early model transfer cases used 1-118 inch caged needle bearings on the intermediate shaft. When installing the intermediata gear in these cesas, Insen the gear and suppon the front thrust washers with a pilot pin tool. Position the gears and the rear thrult washer and insert the shaft Irom the rear of the cese. 29 On later model casas, a 1-114 inch diameter intermlldiate shah was used and the bearings ware of tha individual roller and spacer type. A dummy shah which is slightly smaller in diameter and sI"lorter in width than the intermediate shah is neclllilSlry lor installation. Load the bearing rollars and spacers in the gear using tha dummy shah. Suppon the front th rust washer w ith you r lingers. position the gears and rear thrust washer and insert th e sha ft from the rear of tha car>8, driving out the dummy shaft. 30 II the speedometer driven gear bushing ia replaced. use a bushing installing tool. 31 Check the end movement 01 the mainshaft when the rear beaflng cap is installed. This detemrines the adjustment of the tapered roller bearings. The shah end play must be within the specified fangll lor the bearing to be properly edjusted. Selective shims are u$lld for ad· justment end thll rear cap oil seal must not be installed until this Is done. Inslall the oil seals 8S described in SectIOn 26. 32 When the end yokes are installed on the output shafts, makll lure the feltaeals are installed in thll ollaeal guards. 33 When Installing the shilt rail oil seals in the Iront bearing cap, pro· tect them with a thimble tool when passing over the notches (Section 26).
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Chapter 7 Part C Transfer case
Disassembly
3 Remove the front output shaft nut, washer, shaft yoke and oil seal (Section 26). 4 Remove the cover plate. taking cere not to damage Ihe gl:lskets and shims.
1 Remove the shift lever assembly. bottom cover and reaf bearing cap. 2 Remove Ihe intermediate shaft lockplale and drive the shah out the reef of the case with 8 soft -faced hammer and an arbor tool such 8S AMC No. J -2S142.
shaft shilt rod to the rear and remove the set screw, poppet ball end spring plugs. 6 Insert a punch through the pin hole in the reBr output shaft shift
28
Model 20 transfer case - disassembly,
~spection
IIIOd reassembly
5
Remove the front output shah rear bearing, move the reaf output
®
Fig. 7 .48
2 3 4 5 6 7
••
10 11
12 13 14 15 16
Shift rod - f88f output shaft shift fork Shift rod - front output s~ft shift fork Shift rod oil seel Interlock plug Interlock Poppet bafl spring Poppet ball Front bearing cap Front bearing cap gasket Front output shaft thrust washer Front output shaft gear Front output shaft sliding gaar Set SC/lJW Front output shaft shift fork Front output shaft Front output sheft specer
Model 20 Iransf.r case component. - •• ploded view (Sec 281
17 Front output shaft front bearing cup 18 Front output shaft front bearing Filler plug 20 Transfer case 21 Thimble cover 22 Front output shaft rear bearing 23 Front output shaft feal bearing cup 24 Front output shaft feal bearing cup shims 25 Cover plate 26 Intelmediate shaft 27 Intermediate sheft D-ring 28 Lockplate 2' Lockplate bolt 30 Rear output shaft f,ont bearing 31 Rear output shaft front bearing cup
"
32 SpfJfJdometer drive gear 33 Rear output shaft 34 35 36 37 3. 3. 40 41 42 43 44 45 46 47 4. 4'
bearing shim Rear bearing cap gasket Real bearing cap Bfflather Rear output shaft fear bearing cup Reer output shaft (8ar bearing Real bearing cap oil seal Real yoke Rear yoke washer Rear yoke nut Speedometer sleeve Speedometer driven geer Speedometer bushing Bottom cover gasket Bottom cover Drain plug Rear output shaft
50 Rear output shaft sliding gear
51 Mainshaft gear 52 Set screw 53 Rear output sheft shift fork
54 Intelmediate geal thrust washar
55 Intermediate gaar bearing spacer
56 Intermediate gear shaft needle bearings
57 Intermediate gear
•• 5.
60 61 62
bearing spacer Intermediate gear Intermediate gear shaft needle bearings Intermediate gear bearing spacer Intermediate gear thrust washer Front beering cap
Chapter 7 Part C Transfer case rod, rotate the rod 1/4·lnch coumerr:lockwise and pull the rod from the case. Do not lose the poppet ball and spring. 7 Remove the front bearing cep retaining bOlts and slide the cap olf of the case and shift rod 8 Remove the rear output shaft sliding gear and the shift rod. 9 Place the transfor case on wood bklcks and drive the front output slullt out the rear 01 the case with a hammer and brass drift. 10 Remove the gears. spacer and bearing from the transler Cale. 11 Remove the front output shaft shift fork set screw and pull the shift rod out of the fork. 12 Remove the shift rod thimbles with a socket. 13 Remove the arbor tool. thruat washers. spacers and roller bearing from the intermediate gear. 14 Use a brass drift and hammer to remove the front output shaft beat· Ing cup, 15 Remove the shift rod seals {Section 261. 16 Remove the front output shaft rear bearing. using the sliding gear I I a support. Mount the gear securely in a visa. uSing wood blocks to protect the surface. The shaft lever groova must be lacing down. Insert the shalt through the gear splines and drive the shaft out of the bearing with a brass drift and hammer. 17 Remove thl! speedometer driven gear sle_ and gear from the cap. 18 Mount the bearing cap securely in a viae. using wood blocks. and rlmove the output shalt nut, voke and oil sial {Section 261. 19 Remove the cap hom the vise and. using the rear lace 01 the cap as a suppon. drive the output ahah from the cap with a hammer and bran drift. 20 Lift the tapered beefing and drive beering cup ou t of the bearing cap reer bOle. 21 Drive thl! front bearing cup from the front bore and remove the speedometer drive gear and shims from the shalt. Keep the shims together to ease reassembly. 22 Remove the front bearing from the shaft and. " necessary. remove the speedometer droven gear from the bearing cap.
Inspection 23 Wash the transfer case and components thoroughly with solvent and dry them with compressed air. Remove ali gasket material from the mating surfaces. 24 Inspect the bearings. thrust washers. shafta. gears and Ihl! transfer case and bearing caps for cracks. excessive wear. pitting or scoring. Replaca any unserviceable components with new ones.
Reassembly 25 Install the hont output shaft front bearing cup in the case with the cup flush with the exterior surface. 26 Install the shilt rail thimblea. 27 Install the front beaflng cap. 28 Suppon the front output shah rear bearing on a t /2-Inch socket and inatall the shaft In the bearing with a bran drift and hammer. 29 Install the front output shah shilt rail poppet ball and spring. compress them and install the shaft rod part way into the case. 30 Install the front output shaft shift forte and position it so the let screw offset faces the front of the case. 31 Insen the front output shaft shift rod through the shift fork. align the set screw holes In the fOlk and rod and install the set screw. tighten ing It to the specified torque. 32 In81all the front output shalt front bearing. spacer. sliding gear and output shaft gear with the shift fork groove in the sliding gear facing to the rear. 33 Insen the front output shelt thfOugh the gears. spacer and beating. 34 Suppon the case on wood blocks and dflve the front output shaft into the housing with a brass drift and hammel. making sure the bearing seats against thl! shoulder of the shalt. 35 Use a wood block and hammer to install the front output shalt rear bearing cup. 36 InStall the speedometer dflven gear bushing lif removedl in the rear beaflng cap. 37 Install the front bearing cup in the rear beaflng cap bOle. followed by the Iront bearing on the shaft and install the rear beaflng cup in the
""'.
38 Install the speedometer drive gear and shims on the shalt. 39 Place the output shaft In the bearing cap and position the end of the aha!t on a flat. firm surface. Place thl! rear cone and roller on the shalt. Drive the bearing onto the shaft and seal It against the shims.
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40 Install the yoke aeal. yoke, washer and nut {Section 261 and tighten the nut to the specified torque. 41 Clamp a dial Indicator to the rear bearing cap and check the bearIng cap end play by prying Ihe rear output ahalt back-and-forth. Com· pare this measurement to the Speciflcationa. 42 The Ind play can be adjusted by installing shims adjacent to the speedometer drive gear. 43 Place the speedometel driven gear in the beaflng cap and Install the sleeve. 44 Attach the rear bearing assembly and shlml to the transfer case. tightening the bolta to the specified torque. 45 Check the front output shaft end play by seating the rear bearing cup against the cover plate by striking the and of the front output shalt with a lead hammer. Mount a dial indicator on the front beating tap and place the indicator Slylus against the end 01 the output shalt_ Pry the shaft to the rear and zero the indicator. Pry the shalt lorward. observe the raading and compare it to the Specifications. 46 The end play I, adjusted by adding 01 removing shims between the cover plate and the case. Repeat the end play messurement and ad· iustment procedure until the measurement is within the Specifications. 47 In5tell the rear output shaft shift rail poppet ball and spring in the shift rod housing. compress the ball and spring and instaR the ahift shaft rail part wey into the case. The front output shaft shift rail must be in Neutral With the interlock seated in the housing bore before installation. 48 InSlall the rear output shaft shilt lork and sliding gear with the fOlk groove in the gear facing to the rear. 49 Align the set screw holes in the fork and fail and install the set screw. tightening It to the specified torque. 50 Assemble the intermediate gear roliers and spacers. using e suitable arbor tool. 51 Instell the intermediate gear thrust washers In the case. The front washer can be held In place with petroleum jelly and the rear can be held in position by startmg the shalt Into the case. 52 Install the O-ring on the Intermediate shaft and insen the intermediate gear into the case. 53 Insert the intermedlete shaft into the caae bore and tap the shaft into the gear. forcing the arbor tool out of the Iront. 54 Insen the Intermediate shaft lockplate. transfer case identification tag. lock washer and lockplate bolt. tightening the bolt to the specified torque. 55 Install the rear bearing cap and gasket and slide the rear output sheft through the gear. Ttghten the bearing cap bolts to the specified lorque. 56 Install the Iront driveshaft seal and yoke {Section 261. 57 Install the bottom cover and gasket. tightening the bolts 10 Ihe specified torqua. 58 Install the shllt rod seals {Section 26).
29 M odel 300 tranlf,r case - dllasHmbly. In.pection and reallembly
Disassembly 1 Remove the ahilt lever assembly and the bottom cover bolts. Remove the bottom cover by inserting a pully knife between the cover and the cese and working around the circumference to break the seal. 2 Ramo.." tl'Hl front and rear drive shaft yokel (Section 26) and discard the locknuts. 3 Remove the input shaft suppon attaching bolts and lemo.... the suppon. rear output shaft gear and input shaft assembly. It may be necessary to use a putty knife to break the seal around the support. 4 Remove the rear output sheft clutch .Ieeve from the transfer Clle. 5 Remove and dlacard the snap-ring which retains the rear output shalt gear to the Input shalt and remove the geer. 6 Remove and discard the input thaft bearing retaining snap-ring and remove the shaft and bearing from the support. Tap on the and of the shaft with a soft-faced hammer to aid In removal. 7 Use an arbor press to remove the input shaft bearing end end play shims from the shaft. 8 Remove end discard the input .haft leal. lollowed by tha In· termediate shaft lockplate and bolt. 9 Use a brass drift and hammer to tap the intermediate shaft out of the case. Discard the O-ring. 10 Remove the intermediate gear assembly thrust washers. needle
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L? ,
Fig . 7.47 Inter/ocks and plugs
2 Rear output sheft lork 3 4 5
•
7 8 9
shift rod Poppet balls and sprIngs Front output sh"fr fork shift rod Front output shaft shift (0'* Rallr output shafr shift fork Transf,r elise Thimble CQVltI$ Front output shtJfr clutch
,,....
'0 Front output sh.ft clutch
'.M
Front output sh6ft telJr bearing 12 Front output sh6ft belJflng
"
~.
'3 Front output shlJft end pl/IY shims 14 COvel plat. 15 LDckpJ6te, bolt .nd washer
Model 300 tran'fer cllle component layout !Sac 29)
,.
"'8
fntermtJdietB gtlef sh"f/
Thrust washer
Beering spacer 19 fnrermeditlte g88r shaft needle bes,;ngs 20 Beering spacer (th ick) 21 fnrerffl6d;at. gear
22 Bottom cover 23 Tf1Jnsfer ellse-I o-transmlssion stud
24 Front output shaft 25 Front output shaft gtU'( 2' Front output shaft front beafing 27 Front output shaft front be61ing rae. 28 Oil s81J1 29 Front rob
S."
30 31 Input shlJ't support
32 33 34 35 3' 37 38 39 40 41
Input sheft
Shims Input sheft belJrmg Input sheft bearing snl!Jp-ring Rear output shs fr ge8r Snap-ring Rear output Sh8f/ clutch sfetNfl Input shaft rear (pilaf! beering Reer output shaft
"',m
42 Rail' output sheh clutch gee, 43 Thrust w/lsher 44 Re.r output sh.ft front bearing Re.r output sh6ft bSlJring rlJce SpHdofflfJter drive gelJI End pi".,. shlfns RelJr yoke Rear output shlJ't oil seM RelJr outpu t shaft leal belJring 51 Be61ing r.ce 52 Rear belJling cap 53 Front beefing CIJP
45 4' 47 48 49 50
Chapter 7 Part C Transfer case bearings and boaring spacers. 11 Remove the roar bearing cap bolts and use a soft-laced hammer to tap on the cap to loosen it so It can be removed. 12 Remove the speedometer drive gear and end play shims from the rear output shaft. 13 Discard the rear OUtput shaft-oil seal and ramove tha bearings and races from the cap. 14 Remove the front and rear output shah shift fork set scrows. 15 Remove the shift rods by inserting a punch through tha clevis pin holas in the rods and rotating them while pulling them from the case. 16 Remove the shift forks. 17 Removo the front cap retaining bolts and use a putty knife inserted between the cap and case to break the seal. Remove the cap. 18 Remove the front output shaft and shift rod seals (Section 26) and discard them. 19 Remove the front beallng race from the cap. using a suitable tool. 20 Remove the cover plate assembly, making sure to keep the end play shims together to simplily reassembly. 21 Move the front output shaft toward the front of the case and remol/8 the rear bearing race from the casa 22 Remove the rear output shaft front baaring and support the case on wood blocks. Brace tho clutch goar on a firm surface such as a workbench and tap the shah out of the bearing with a soft-faced hammer. If the shaft does not come out easily it will be necessary to use an arbor press. 23 Remove the rear output shaft front bearing, thrust washer, clutch gear and output shaft from the case. 24 Remove the front output shaft using an arbor press. 25 Remove tho front output shah. clutch gear and sleeve and shaft rear bearing. 26 Remove the front output shaft front bearing using an arbor press and remove the front output shaft gear from the shaft. 27 Remove the input shaft rear needle bearing "from the rear output shaft, using a tool such as AMC No. J-29369-'. Remove the shift rod thimbles with a socket.
Inspection 28 Wash the transfer case and components thoroughly with solvent. Remove all traces of sealant material from the case and bearing cap mating surfaces. If compressed air is available. dry all components e)(cept the bearings. which must be dried with clean, lint·free cloths. 29 Inspect the components and case lor e)(cessive wear and damaga Inspectlhe gears for cracks, chips and broken or excessively worn teeth. Check the bearings for wear, pl\ling, scoring, flat spots and brinnel ing. Inspect the shafts for damaged splines, threads and bearing surfaces. Check the shilt rods and bores for wear and damage. Replace any damaged or worn components with new ones,
Reassembly 30 Install the shift rod thimbles, using thread locking compound . 31 Install the front output shaft gear on the output shaft, making sure the gear clutch teeth face the shaft gear teeth. 32 Press the front bearing onto the front output shaft with an arbor press, making sure the bearing seats against the gear. 33 Install the front output shaft in the case, lollowed by the clutch sleeve and gear on the shaft. 34 Install the front output shaft rear bearing using an arbor press. 35 Install the input shalt rear needle bearing in the rear output shaft using AMC tool J-29179 or Its equivalent. 36 Place the rear output shaft clutch gear in the case and insert the shaft into the gear. 37 Press the thrust washer and front bearing onto the rear output shalt using an arbor press and tool. 38 Press the shims and bearing onto the input shaft with an arbor press and tool. 39 Install a new input shaft oil seal in the input ahaft using AMC tool J ·29184 or its equivalent. 40 Install the input shaft and bearing in the support. using a new snap· ring. 41 Install the rear output shaft gear on the input gear with a new snapnng. 42 Use a feeler gauge 10 measure the clearance between the input gear and the retaining snap -ring . Check this measurement against the specifications. II the clearance is beyond the specified range. disassemble the input shaft and add shims between the input shalt and the shaft bearing.
7C-7
43 Install Ihe clutch sleeve onto the rear output shalt. 44 Apply sealant to the mating surface of the input shaft support and install the assembled support, shaft and gear In the case. Use two of the bolts to align the support on the case and tap it securely into posi· tion with a soft-faced hammer. Install the bolts and tighten them to the specjfied torque. 4S Install the rear bearing cap race with AMC tool J -9276 -3 or its eqUivalent. 46 Install the rear bearing cap rear bearing race with AMC tool J -29182 or its equivalent. 47 Position the rear output shaft rear bearing in the bearing cap and Install the driveshaft yoke seal (Section 26). 48 Install the speedometer gear and end play shims on the rear out put shaft. 49 Apply sealant to the rear bearing cap mating surfaces and align it on the case with two mounting bolts, Tap the cap into posi tion and install the bolts, tightening them to the specified torque. 50 Install the rear output shalt yoke and tighten the locknut to the specified torque (Section 261. 51 Clamp a dial indicator to the bearing cap. Pry the shaft back-and lorth to check the end play. If the end play is not within the specified range remove or add shims between the speedometer drive gear and output shaft rear bearing. 52 Install the front output shaft end play shims, the cover plate and the bolts, tightening the bolts to the specified torqua Apply thread lock· ing compound to the threads before installing the bolu. 53 Install the front output shaft front bearing race using AMC tools J-8092 and J29181 . 54 Install the front output shaft yoke oil seal and shih rod oil seals ISection 261. 55 Apply sealant to the mating surface of the front bearing cap. align it using two of the mounting bolts and tap the cap into position with a soft-laced hammer. Install the bolts and tighten them to the speCified torque. 56 Tap on the end of the front output shalt with a soft-faced hammer to seat the rear bearing cup against the cover plate. Mount a dial indicator on the front bearing cap and place the stylus against the out· put shaft. Pry back-and-forth on the shaft to determine the end play. If the end play is not as specified. add or remove shims betwean the cover plate and the case. 57 Install the front shaft yoke (Section 261 and tighten the new locknut 10 the specified torqua 58 Insert the front and rear output shaft shift forks into the casa 59 Install the front output shaft shilt rod poppet ball and spring in the front bearing cap, compress the ball and spring and install the front output shaft shilt rod part way into the case. 60 Insert the front output shaft shilt rod through the shift fork, align the set screw hole, install the set screw and tighten it to the specified torque. 61 Install the rear output shalt shift rod poppet ball and spring in the front bearing cap. compress the ball and spring and install the rear output shaft shift rail part way into the case. Make sura the front output shaft shih rod is in Neutral and the interlocks are seated in the cap bore. 62 Insert the rear output shaft shift rod through the shift fork, align the set screw hole, install the set screw and tighten it to the specified torqua 63 Install the needle bearing and spacers in the intermediate gear, using AMC tool J-25142 Of its equivalent. 64 Install the intermediate gear thrust washers In the case with the tangs aligned in the grooves. Petroleum jelly can be used to hold the washers in place. 65 Install the new O-ring on the Intermediate shalt and place the shaft in position in the casa Install the sheft in the case bore by tapping it into place until the arbor tool is forced out. 66 Install the shaft lockplate and bolt, tightening the bolt to the specified torque. 67 Install the bottom cover after applying sealant to the mating surface. Install the cover bolts and tighten them to the specified torque.
30
QUlildrlil-Trac - dl,assembly, inapection and rallHmbly
Disassembly Reduction unit 1 Remove the power takeoff cover and position an t11l6 -inch deep
7C
7C-8
Chapter 7 Part C Transfer case
SUN G EA R
CO,,,. . PLATE
SHIFT"O'CA'
'CCOCU," HU'
A"'UO.AA BEARING POWER TAKEOFF COVER
FIg. 7 .48
!'OWER TAKEOFF
COVER GASKET
Quadre-Tree reduction unit components -
IIIploded vie w ISl e 301
socket securelv In I vise, allowing two inches of the socket to protrude. Mount the reduction un!1 on the locket wilh the socket entering the bore of the sun geer. 2 Move the reduction uon control lever to the rear, into the High Renge
position, remove the mainahaft fetalning snap-ring Ind lift the reduction unit houling off the gear trein. 3 Remove the direct drive sleeve end needle bearing, shift coller hub end needle bearing, reduction collar hub. ring gear and needle bearing
as an ....mblv. 4 R.mo .... the pinion cage lockplate Ind the needle bearings. 5 Remow Ihe lun gear and main.haft from the pinion cage but do not dilassemble them. a Move the control level to the center or Neutrlll position lind disengllge the shllt cotlllr from the Ihift forK. 7 Move the control lever to the rellr, to the High position and aUgn the outer teeth on the Ihlft collar with the Inner teet h on the holding ptllte. 8 Move the Ihih fork and collar forwllrd to the Low RInge posi tion. Remove the Ihift colillr. 9 Remove the annular beerlng lind snap-ring. 10 Remove the Ihift fork locating pin by grasping it with pliers lind uling a pulling and rotllting motion. 11 Remove the large expllnsion plug lind Ihift rllil taper plugs. Remove the control lever and then ule a 3,16·lnch punch to drive out the Ihih fork retaining pin. 12 Slide the Ihlft filII forward lind out of the fork lind t hen remove the fork lind Ihift rail poppet bsll.
Fig. 7 .49 Mounting tha Qu. dra-Tra c reduction unit on an lil la-Inch locket . et In • vis. (See 301
7C-9
Chapter 7 Part C Transfer case S EA L RING
I I I I
I I
}
/ .... I
-- -----
_----/
ORI VE SPROCIC ET
DR IV E Sl'ROCkET REA R NEEDLE
DRI VE SPROCKET FRONT NEEDLE I
,
REAR COVER
I I I
I
, , _/
THR UST WASHER Sl'RING THRUST WASHER PINION MATE ...... - THRUST WASHERS ..... - -
---
SPRING WASHER
__ I
-".:'~-~---
~--
--, I
_-
..... _ -
BE ARING SNAP RING
_ - - - - :UTPUT SHAFT ",Oll S EAl ~ ( BEARINGSN APRING ~ ,~
lll~ '"
,
\YOKE" "
/
ANNUL AR BEARING THRUST WASHER
FRONT OUTPUT SHAFT
SEAL VO KE
~~
€I§) '~ ,
Flg. 7 .50 Quad,,-TrlC trlnlf.r CaH compo nents - axploded view (Sec 30[ •••• OUT"'''HA''
AN NULAR BEARING
OUTPUT SHAfT OIL SEAL
WOO<>
ILOCK
Flg. 7 .51 Using I wood block to pOl hlo n the Quedrl-Trlc Irlnlflr CI .. rear cover Ind d rlvI chlln for dls allembly [Sec 301
13 Drive the poppet taper plug into thl shift rail bore. remove the plug and thl poppet Ipring and thIn remove tha Ihift levlr 85sembly and retaining pin. 14 RemovI thl reduction holding pllte Ind Inap-rlng. Trl n. fer case 15 Remove the front and ",ar output shah yoke retaining nuts. washers and leals (Section 261. 16 On models not eq ui pped with I reduction unit. romove tho powor takeoff cover and soal ring. 17 Rlmove tho ,otaining bolts and separatl the front and foar tranlfer clSa COVOtl. 18 Placa the rear covlr asslmbly on a workbench with the drive sprocklt luppo rtld by I block of wood measuring 2 inchu by 4 inches by 6 inchel. 19 On non-reduction unit modlil. remove tha drivI hub and .Ieave by oxpanding the Inap-ring which il acce"ibla through the IJOt in the outside odge of thl sleeve. 20 On reduction unit-equipped modlll, remove tha pinion ceoefrom the d rive sprocket rear Iplinol. 21 Remove the casa cover from t he d rive Iprocket and difforontlal assambly. 22 Remove t he chain ahor slid ing tha drive Iprocket toward tho dil farontlal unit.
7C
7C-10
Chapter 7 Part C Transfer case
23 The differential should be serviced as an assembly by your dealer or a qualified repair shop with the specialized tools necessary to work on these units.
Inspection 24 Wash all components thoroughly with solvent. El(cept for the bear· ings, dry the components with compressed air, if available. Air dry the bearings or use lint-free cloths. 25 Inspect the reduction unit housing and transfer Clse covers for cracks and other damage. Remove all gasket material from the mating surfaces. 28 Inspect the shafts. gears, sprockets and and caps for cracks, el(cessive wear. pitting, galling and scoring. Check the drive chain for looseness and damage. Replece any unserviceable compone nts with new ones.
Reassembly Reduction unit 27 Instal! the holding plate in the case with the locating pins facing tha interior and indel(ed in the case and the shift fork locating pin holes aligned.
untillne groove in the collar 0lign5 with the fOlk . Engage the shih fork in the collar groove by moving the collar toward the fork. 42 Instali the needle bearing CInd coller hub on the shift collar hub. 43 Install the ring coliar, plate hub end retaining snap-rings. 44 Install the ring gear assembly on top of the collar hub with the ring gear open end facing up. 45 Install the needle bearing, pinion cage lockplate lind another needle bearing onto that part of the shift collar hub whiCh extends through the ring. 46 Slide the assembled perts toward the edge of the workbench far enough to a.pose the bore in the shift collar hub. 4 7 Support the assembly with one hand while inserting the meinsheft into the shift collar hub bore with the other, making sure the mainshaft and sun gear are completaly seated. 48 Install the mainshaft and sun gear through the open end of the ring gear and hold the parts firmly together. Raise the assembly and mount it on the socket in the vise used for disassembly. 49 Install the needle bearing and direct drive sleeve on the mains haft. 50 Align t he splines on the assembled parts and install the housing, making sure that it is seated against the direct drive sleeve. 51 Install the rear spacer and snap-ring. making sure the snap-ring seats completely in the groove. The snap-ring is a select fit and tha thickest snap-ring which will provide a 0.004 to O.OOS-inch spacer clearance should be used. 52 Install the power takeoff cover and gasket. tightening the bolts to the speci fied torque. 53 Remove the reduction unit from the socket and install the pinion cage. Transfer ce se 54 Lubricate the bearing and thrust washer surfaces with clean transfer case lubricant. 55 Position the differential and drive sprocket in the proper relationship on the workbench using a wood block.
w Ag. 7 .62 InatalUng the Quadra -Trac reduct ion unit holding plate ISac 30)
28 Install the snap·r ing with the tabs facing forw ard. Make sure the snap-ring seats securely In the groove and that it clears the shift fork. 29 Insert the shift fork locating pin, making sure it goes completely through Ihe holding phne and seats in the housing. 30 Insert the shift lever, without the O-ring, inlo the housing with the lever end of the fork facing to the rear. 31 Install the O-ring in the shift lever shaft groove. 32 Move the shift lever in far enough to allow installation of the shaft tapered pin, install the pin and then insert the shift rail into the shift fork and rail bore. grooved end first. 33 ROlate the shift rail so the flet on the side is adjacent to the poppet spring and slide the rail in far enough to allow the fork to mesh with the lever and rail. 34 Push the rail through the shift fork until the end of the rail is flush with the edge of the poppet bore. 35 Place the poppet ball on the end of the spring and compress the ball and spring using the shift fork retaining pin as a tool. 36 Slide the shift rail over the poppet ball as far as the retaining pin will allow, remove the pin and move the shi fl rail to Ihe firs t detent position. 37 Rotate the shift rail until the flal on the side faces the shift lever and the retaining pin bores in the rail and fotil. are aligned. 38 Slide the shift fork onto the shift rail, align t he pin holes and install the retaining pin until it is Ilush with the fork surface. 39 Install the shift rail taper plugs, the poppet bore taper plug and the shift rail cover expansion plug. 40 Install the shift fork locating pin lind I hen install the control lever on the !>hit! lever. 41 To install the shift collar, position the shift fork in the Neutrallcenter! position and place tha shift collar outer teeth in mesh with the holding plate inner teeth. The shift fork collar groove mU6t be positioned just forward of the shih fork. Move tha shift fork to tha rea r detent position and then move the shift collar to the reaf and away from the fork
Flg . 7.53 Positioning the differential and drlve sprocket for chain Installation lGuadra-Trac tran. fer ca.ellSec 301 56 Wi th the differentialapproximetely two inches away from the drive sprocket, install the drive chain. Make sure the chain is properly engaged in the differe nt ial and drive sprocket teeth and remove any slack. 57 Insert the rear output shaft into the differential and move the lockup hub to the rear in the case cove r. 58 Lubricate the drive sprocket thrust washer with transler case lubricant and install it on the rear cover. 59 Install the rear cover on the drive sprockat and differential. If necessary, rotate the output shaft to align it with the lockup hub. Be careful not to displace the drive sprocket thrust washer during installation. 60 Assemb!e the drive hub, sleeve and snap-ring. 81 On non-reduction unit-eQuipped models. install the drive sleeve and hub on the drive sprocket, making sure the snap-ring seats securely. 62 On reduction unit-eQuipped models, make sure the oil baff!e is in position and install the pinion case and snap-ring. 63 Apply a 1I16·inch bead of RTV-~ype sealant to the mating surfaces 01 the front and rear covers and ins tall the front output shalt and thrust washer in the cover. 64 Align and install the front cover on the reaf cover, install the attaching bolts and tighten them alternately and evenly to the specified torQUe. 65 Rotate the drive sleeve to make sure the drive sprocket turns treeIy. indicating the th rust washer was not displaced during assembly. 66 Install the power takeoff cover and !>eal ring. 67 Install the speedometer gear on the rear output shaft. 68 install the tront and rear output shaft seals and yokes (Section 26).
8 -1
Chapter 8
Driveline
torI.ant. Cnass., lubrication Clutch pedal free play chec k Clutch pedal free play adjustment . CIUICh -
removal, inspection and installation
Differential lubricant change Differential oil level check DnveshallS and universal joints - check Driveshalt - removal and installation Froot 8)(le assembly -
removal and Instella tion
Front exleshaft ojl seal - replacement Front axleshaft -
remOllal and installation.
Front wheel drive hub· removal and installation Full·floating 8)(18 bearings - lubrication and adjustment . . . . . . . . . . . . . ....... . Chapter General informetion ..............•. Pinion oil 5aal - replacement ..........•. Rear axle assembly - femoval and inllallation Reaf 8)t1e seals - replacement _ . __ . _ . _ .. _ ...... _... . Rear axleshaft - removal and installation ... Rear hub - removal and installation ............. _ .. . Universal jointa - disassembly. overhaul and reaasambly ... .
Chapter 1
Chapter 1
3 2 Chapter 1 Chapter 1 4
5 9 8 7
'5 "
,
13 14
"
'0 12 8
Specification.
Clutch Driven plate lining wear limit
", 6 in
Torque specifications
Front axle Pinion nut Imtial In-service reche<:k U·bolt Shackle nut Universal joint U·bolt nut Universal joint flange boit Drum braka backing plate Disc brske caliper support key retainmg screw Shock absorber nut Wheel nut Front wheel drive hub bolts
Ft-Ib
Nm
210
27'
200 to 220 45 to 65 25 to 40 15t020 25 to 45 25 to 35 15 to 18 35 to 50 65 to 90
285 to 298 61 to 81 34 to 54 20 to 27 34106' 34 to 47 2010 24 47 to 68 88 to 122
30
41
Rear axle Pinion bolt lali except tapered axleshaft! Initial In-service recheck U·bolt Shackle nut Umversal jOint U-bott nut Universal jOint flange boilS 8fake backlOg plate A~le8haft nut AMC/Jeep Dana /S picer Shock absorber nut Wheel nut
210
27'
200 10 220 45 to 65 25 to 40 15 to 20 25 to 45 25 to 40
258 to 298 61 to 81 34 to 54 20 to 27 34 to 47 34 to 54
250 '50
339 203
35 to 50
47 to 68 88 to 122
65 to 90
B
Clutch Clutch hOUSlng-to·englne boilS F- and l-head four ·cyllnder V6 . In·Una si~·cylinder Top . Bottom
VB 150 cu in and 151 cu in lour-cylinder Clutch cover·to-flywheel bOltS F· snd l-head 'our-cy~nder V6 In-hns six-cylinder
VB ISO cu in and 151 cu In four-cylinder
40
54
45 to 60
61 to 81
35 45 30
8' 4'
46 to 62
62 to 84
30 30 35 35 20
41 41 47 47 27
47
to to to 10 10
40 40 45 45 26
to to to to to
54 54 61 61 35
8-2
Chapter 8 Driveline 9
Generel information Power from the engine is passed through the clutch, into the transmission and !fanster case and then to the axles through the driveshahs. The clutch disc is held in place against the flywheel by the pressure plate springs. During disengagement for gear shifting, the clutch pedal is depressed and operates the linkage to pull on the throwout lever so the throwout bearing pushas on the pressure plate springs, disengaging the clutch. The driveshahs are one·piece construction with a universal joint at each end to allow for vertical movement of the axles. Each driveshaft is also equipped with a splined slip joint at ona end to compensate for variations in length during operation. 2
Lightly lubricate the Ihrowout lever pivot points with moly-based
grease.
Clutch - removlIl. Inspection and InstallatIon
lOOn models so equipped, Inslall the pilot bushing lubricating wick. 11 Insert a clutch alignment tool or equivalent (such as the proper size screwdriver handle) through Ihe clutch driven plate hub and use it to center the plate on the flywheel. 12 With the driven plale centered, place the clutch cover in position and install the mounting bolls finger tight. Tighten the bolts a little at a lime, following a crisscross pattern, to Ihe specified torque and remove the alignment tool. 13 Inslall the clutch housing and lighten the bolts to Ihe specified torque. 14 Install the starter motor. 15 Attach Ihe throwout bearing to the lever. Unless Ihe vehicle has very low mileage, it is a good practice to install a new throwout bearing whenever the clutch is replaced. 16 Install the transmission and transfer case and lower the vehicle.
Clutch pedal free play adjustment
Clutch removal, inspection and installation 1 Raise the vehicle and support It securely on jackstands. 2 Remove the transmission and transfer case (Chapter 7). 3 Remove the starter motor. throwout bearing and clutch housing. 4 Mark the relationship of the clutch cover and flywheel for reference during reinstelletion. S loosen the clutch cover bolts one turn at a time, following a crisscross pattern, so the spring tension will be released gradually. 6 Remove the clutch cover and bolts, taking care that the driven plate does not fall. Note the direction which the driven plate faces, to simplify reassembly. 7 Inspect the flywheel and pressure plate contact surfaces for score marks, cracks and damage. If necessary, have these surfaces machined smooth or replace the components with new ones. Check the clutch plate lining thickness and compare it to the Specifications. 8 If equipped, remove the pilot bushing lubricating wick and soak it in engine oil.
17 The clutch pedal free play should be checked (Chapter I) and adjusted at the specified interval, when the clutch doesn't engage properly or when new clutch parts have been installed. 1953 through 1971 models 18 Three types of clutch linkages were used on these models. Early model CJ-2A and CJ·3A vehicles used a combinallon cross lube and cable mechanism, while early model CJ·3B, CJ-5 and CJ·6 vehicles have a cross-shaft tube and lever-type linkage. V6 models were eQuipped with a cable-type clutch linkage. 19 To adjust the CJ-2A and CJ·3A linkage, loosen the clutch control lever cable adjusting locknut and use a wrench to unscrew the cable until the specified free play is achieved (Chapter 1). Tighten the locknut. 20 To adjust the cross· shaft lube and lever-type clutch linkage, loosen the jam nul on the cable clevis and lengthen or shorten the clutch fork cable to obtain the specified measurement. After adjust· ment, tighten the jam nut securely.
CLUTCH COVER
I
THROWOUT BEARING
CLUTCH HOUSING
PILOT BUSHING LUBRICATING WICK
INSPECTION COVER
~ .
THROWOUT LEVER RHURN
• -..-.
0
":~::WOUT LEVEA~y THROWOUT LEVER PIVOT BALL
Fig. 8.1
Typical later modal In-line six-cylinder and V8 engine clutch components - exploded view
•
8-3
Chapter 8 Driveline CLUTCH
THROWOUT
Fig. 8.2 1980 and later lour-cylinder engine clutch assembly components exploded yiew
SEARING
HOUSING
,
LEVER SPRING
"
CLUTCH COYER
CLUTCH OtK
THROWOUT
UVER
WASHER
21 On the cable-type clutch linkage. loosen the cable locknut and adjust the ball adlustln9 nut with the pedal in the up (clutch engaged) posilion until the slack is gone Irom the cable. Back the ball adjusting nut off 2-112 turns to oblaln the specified free play Ti9hten the locknut after completlllQ the adjustment 1972 through 1975 models Adjust the bellcrank outer suppon bracket to provide about 1/8inch of bellcrank end play and lift the clutch pedal up against the stop. 23 Adjust the lower ball pivot assembly on the clutch pedal-Io-bellcrank pushrcd as necessary to position the bellcrank inner lever parallel to the front face of the clutCh houSIng. Adjust tl'!e clulch fork release rod to obtain the specified free play.
22
1976 through 1986 in-line and si x-cylinder and va models with mechanical release system 24 Loosen the release rod adjuster jam nut and have an assistant hold the clutch pedal up against the stop. Turn the release rod adjuster in or out to obtain the specilled free play. Alter adjustment, be sure to tighten the adjuster jam nut securely.
1980 and later four-cylinder models with hydraulic release system 25 All 1980 and later 4 cylinder models are equipped with a nonadJustable hydraulIC clutch release mechanism. Free-play adJustments are flOt required, nor are there any provisions for adjustment.
Clutch hydraulic release system - removal, installation and bleeding
3
1 II cJutch chatter, drag, or inadequate release condItions afe encoun tered, the hydraulic cylinders and connecting hne should be checked for damage or leakage and the laulty components replaced as necessary.
Master cylinder - removal and installation 2 Disconnect the hydraulic line at the clutch cylinder. Use a flarenut wrench 10 loosen and remove the lilting as the filting nut may be damaged by an open end wrench.
Fig. 8.3
•
"
" "
11
10
rJ
• " '!..-.-
.
Early model CJ-2A and CJ·3A clutch link.g. components {Sec 31 1 Brake pedtll ptld 2 Brake pedtll 3 Control ceble 4 Control ' - r 5 Release baenng 6 Release betlring cerrifl(" 7 Beering cemer spring 8 BtllI stud 9 Dust seel 10 Control tube reteiner 11 Control tube spring 12 Control tube end lever 13 &III stud nut 14 Frame imide' 15 Bracket-to-frame bolt 16 Pedel rod 17 Pedel clemp bolt 18 Pedal retracting spring 19 Clutch pedel 20 Pedel PlJd clemp bOlt 21 Clutch pede! ped 22 Pedel-to-shtlft key 23 Peritll shllh wlJ$her 24 Pedltl shltft 25 Brake mester cylinder T-bar 26 Adjusting yaklt locknut 27 Adjusting yoklt 28 Adjusting yaklt clevis Din
8
8-4
Chapter 8 Driveline
• • Fig , 8 .5 A
2 3 4
5
Cable·type linkage layout end adjustment details (Sec 3)
Top view, cable·to-clurch fork Clutch fork retracting spring Clutch fork 8a" adjusting nut Locknut Clutch cable
8 Side view, cable·to-clutcn
• 7
8 9
10
pedal Clut ch cable suppon bracket Clutch cable housing Anchor bracket·to·frame side rail Clutch pedlJl retracting spring Clutch pedal assembly
socket with chassis lubricant. 13 Fill the reservoir with brake fluid to level indicated on side of the reservoir. Replace the cap and bleed the hydraulic system of air (see Clutch hydraulIC system bleedIng).
Clutch hydraulic system bleeding
, 2 3 4 5 6 7 8 9
Fig. 8 .4 Early model CJ·3B. CJ-5 and CJ-6 cross-.haft tube and lever type clutch linkage ISec 3 1 Clutch release bearing
16 Pedal release rod
Carrier spring
"'8'9
8811 stud Dust seal
Pod RetfJiner Clevis yoke pin
Control tube spring Control lever and rube
10 8a/l stud and bracket
" '3
Frsme bf8ck.et
12 &11 stud nut Yoke locknut
14 Adjusting yoke
Pede' clamp bolt Control cable Clutch pedal 20 Screw 8nd lock w8sher
21 22 23 24 25 2. 27 28 29
Olliff pad
Peda' pad and shank Retfllcting spring Peda/-ro-shaft key W8sher Peda'shtlft
14 Fill the reservoir with brake fluid and replace the cap. 15 Raise the vehicle and support securely on jackstands. 16 Compress the slave cylinder plunger by pushing the throwout lever forward as far as possible. 17 Attach a rubber hose to Ihe slave cylinder bleeder screw and place the opposite end of the hose into a glass container 1/2 full of brake fluid . Be sure the hose end is submerged in fluid . 18 Loosen Ihe bleeder screw and have a helper press and hold the Clutch pedal to the floor. Tighten the bleeder screw and release the pedal.. Repeat th.is bleedtng operation until all fluid entering the container IS free of air bubbles. Note: Do not allow the reservoir to f1Jn ouI of fluid during the bleeding operation. 19 Lower the vehicle and fill the reservoir to level indicated on side 01 the reservoir .
Master cylinder tie bar
Control lever
4
Driveshafts end universal joints· check
Betlfing carrier
'5 80lt 3 Cap the hydraulic line and cylinder opening 10 prevent fluid spillage and dirt entry. 4 Remove the cotter pin and washer retaining the push-rod to clutch pedal and slide the rod off the pedal. 5 Remove the nuts retaining the clutch cylinder to the dash panel and remove the cylinder. Installation is reverse of removal. 6 7 Fill the cylinder reservoir wilh brake fluid to level indicated on side of the reservoir. Replace the reservoir cap and bleed hydraulic system of air (refer to Clutch hydraulic system bleeding).
Slave cylinder· removal and installation B Raise the vehicle and support seclJrely on jackslands. 9 Disconnect the hydraulic line from the cylinder and cap Ihe line and cylinder opening 10 prevent spillage and dirt entry. 10 Remo ve the Ihrowoul lever-Io-push rod retaining spring, if eQuipped. 11 Remove the bolts retaining the cylinder 10 clutch housing and remove the cylinder, heat shield, pivot, washer, and seal. 12 Installation is reverse of removal. Lubricate the throwout lever
The driveshafts should be checked periodicall y, usually at the time of chassis lubrication, when the vehicle is raised. Inspect the length of each driveshafl for damage, dents. under 2 coating material and mud and loose mounting nuts or bolts. Clean off any foreign material, as it could cause vibration. 3 Check the splines of the slip yoke to make sure the driveshafts move in and out smoothly, with no binding or looseness. A worn or damaged slip yoke will cause vibration when driving in Ihe 40 to 60 mph range. 4 Wear in the needle roller bearings is characterized by vibration or a clunking sound when accelerating. To check the needle roller bear· ings, try to turn the driveshaft with "One hand while holding the flange or coupling with the other. Any movement between the driveshaft and the couplings is an indication of excessive wear. 5
Driveshaft • removal and installation
Raise the vehicle and support it securely on jackstands. 2 Mark the relationship between the driveshafl and the companion flanges (photo).
8-5 '. REBOUND BUMPER
\ V .. / '
O\lERCENTEA SPRING
~~
" .. '"
'
CLUTCH ~ PUSHAOD
~
THROWOUT BEARING
~ Fig. 8 .8
1972 through 1975 model clutch linkage componant layout (Sec 3)
-
ClVTCH
'00
BEAAIJrIO$
8 THIIOWOUl LEYEII
'RDTECTIYE
'00' allACKlT
Fig.8.7
1976 through 1983 clutch linkage component layout (Sac 3)
8-6
Chapter 8 Driveline
5.2 Marking the drivesheft end pinion flange to simplifv installation
5.3 Removing iii U-bolt nUl, using 8 large screwdriver to lock the drives haft
/
vou
6.1 Using small pliers to remove the U-jolnt snap-rings
6 .3 Pressing the beering caps out of the U-joint with sockets and a vise
3 Disconnect the universel joints by removing the nuts from the U-bolts or strap retaining bolts (photo!. 4 Lower the driv8ahett and remove it from the vehicle. 5 Installation is the reverse of removal. Be sure to align the marks made during removal and lighten the retaining bolts snd nuts to Ihe specified torque.
6
Unlver •• 1 )olnta - dlll ••embly. overhaul and rellssembly
Carefully clean away all dirt from the ends of the bearings so the snap -rings can be removed. If the snap-rings are very tighl, tap the end of the bearing cap [Inside the snap-ringt to relieve the pressure Iphoto). 2 To remove the beerings from the yokes, you will need two sockets. One should be large enough to fit into the yoke where the snap -rings Wilre installed and the other should have an inside diameter just large enough for tha bearing caps to fit into when they are forced out of the yoke. 3 Mount the universal joint in a vise with the large socket on one side of the yoke and the small socket on the other side, pushing against the beering cap. Carefully tighten the vise until the bearing is pushed out of the yoke and into the large socket (photo). If it cannot be pushed all the way out, remove the universal joint from the vise and use a pliers to finish removing the bearing. 4 Reverse the sockets and push out the bearing on the other side of the yoke. This time. the small socket will be pushing against the crossshaped universal joint spider end. 5 Before pressing out the two remaining bearings, mark the spider
Fig. 8.8 Typ ical universe! joint co mponents ~ exploded view (Sec 6)
so it can be installed in the same relative position during reassembly. 6 The remaining universal joint can ba disassembled following the same procedure. Be sure to mark all components for each universal joint so that they can be kept together and reassemblad in the proper position. 7 Clean the driveshaft and universal joint components with solvent and dry them thoroughly. 8 Inspect the driveshaft lor cracks and damage. Have the drivashaft runout chacked with a dial indicator. Replace the driveshaft with a new one if any delects are found . 9 Check the spider journals for scoring. needle roller Impressions. rust and pitting. Replace it if any 01 the ebove cond itions exist. 10 Check the sleeve yoke splines lor wear and damage. 11 When reassembling the universal joint!s). replace all needle bearings, caps and dust seals with new ones. Many repair kits also contain new spiders. 12 Befora reassembly. pack each grease cavity in the spider ends with a small amount of grease. Attach the dust saals to the spider with the seal cavities facing in. 13 Apply a thin coat of greasa to the dust seal lips and install the bearIngs and spidar in the yoke using the vise and sockets that were usad to remove tha old bearings. Work slowly and be very careful not to damage the bearing caps as thay are being prassed into the yokes. 14 Using the vise, press one 01 the bearing caps into the yoke about 1/4-inch. 15 Install the needle bearings in the cap (use grease to hold them in place). 16 Insert the spider into tha partially installed beering cap, taking care not to displace the needle bearing rollers.
8-7
Chapter 8 Oriveline
®-...-
-
®-------,
"
,
,
Fig. 8 .9
Ty pical early model fr o nt ax le Iteering knuc kle componen ts - ex plod ed llle W ISec 7) 7 Bushing
Baaring adjusting nut
2 wck washer 3 wck washer
8 Fiflttr pfug 9 Ufr knuckle ttnd arm
4 Bttaring cone and rolfers 5 Bearing cup Spindle
•
10 Shims Upper bearing cap 12 Lock washer
"
,. ,. ",.
13 Boft Oil sea' and backing ring IS Thrust washer Axle pilot Oil seal BetJring cup
19 Btttmng cone and roffers
20 Oil saal 21 Rtttainttr
22 Bolt 23 Lower bunng cap 24 Bolt
T\lRNING " NOLIE
CJMODELS
'oc·z~ U O<
... HOLI
" 'HO U I ( "RIND
FIg. 8 .10
STEERI NO KNUCK LE
L--,
l ate mo del fr ont a xle ste ering knuckle "'embly components - expl.oded llleW ISec 7 )
17 Stick thl needle beanngs into the opposite cap. then, while holding the spio.r in correct alignment, press both caps into place in the jlws 01 thl lIisa. 18 Instill tha new snlp·rings and repeat the instlilition procedure for the rlmaining tWO caps. 19 In Ixtreml Clsel of wear or neglect, it is possibla Ihat the bearing cap housings In the yoke will have worn so much that the caps are al008e lit in the vokes. In such C8S98, replec, th' complete d rilleshaft assembly with a new one.
Removal Raise th' vehicle. aupport It 'ecurely on Jacutand8 and remove the front wheell. 1953 th rough 1979 model l 2 On disc braktt-equipped models. remove the celiper.
8
8-8
Chapter 8 Driveline
3 Remove the hub cap. followed by the drive flange snap-flng. 4 On disc braked equipped models. remove the rotor hub bolts, cover and gasket. S On drum broke equipped models. remove the 8xle flange bolts and use AMC puller 1001 J·25133 (or equivalent) to remove the 8xle flange.
6
j
.r
Straighten the lip of the lock washer and remove Ihe locknut us-
Ing AMC 1001 J-2S103 (or equivalent\. Remove the lock washer, Ihe
inner adjusting nul and the beering lock wesher. 7 On drum bmke equipp6d models, remove the wheel hub and drum assembly complete with bearings, taking cere not to damage the oil seal. II necessary. back off the brake adjuster sufficiently to allow removal of the drum. Remove the backing plate and brake line. a On disc bf'8ke equi'pped models. remove the outer bearing and brake rotor. followed by the adapter splash shield. 9 On all models. remove the spindle. grasp the axle shah assembly and carefully withdraw it from the axle housing. 1980 through 1986 modele 10 Remove the diSC brake caliper. 11 Remove the bolts attaChing the front hub to the axle and remove the hub body and gasket. 12 Remove the axleshaft retaining ring . 13 Straighten the lip 01 the lock washer and remove the outer locknut, lock washer. inner locknut and tabbed washer. Use AMC tool J-25103 lor equivalent) to remove the locknuts. 14 Remove the outer bearing, disc brake rotor, caliper adjuster and splash shield. 15 Remove the axle spindle. 16 Grasp the axleshaft securely and carefully withdraw it from the axle housing.
Installation 1953 through 1979 models 17 Insert the axleshah and universal joint assembly carefully into the axle housing. taking care not to damage the oil seal. Align the axleshalt and differential splines and push the shah into place. 18 Install the spindle and inner bearing. 19 On drum breke-equi'pped models, install the brake support plate. 20 On disc breke-eQui'pped models, install the splash shield and adapter. 21 Lubricate the outer wheel bearing IChapter 11) and install it in the brake drum or rotor. 22 Install the brake drum or rotor. washer and adjusting nut and adjust the bearing IChapter 111. Install the outer lock washer and nut. tighten the nut to the specified torque and bend the lip of the lock washer over the nut. 23 Install the drive flange. gasket, flange or brake rotor attaching bolts and snap·ring 24 Install the caliper. rotor hub cover and bolts. 25 Install the hub cap. 1980 through 1986 models 26 Install the axleshalt and universal joint assembly into the axle housing with the shaft splines in place in the differential side gear. 27 Install the axle spindle. followed by the splash shield and disc brake caliper adepter. 28 Lubflcate and install the outer bearing in the disc brake rotor and install the rotor on the spindle. 29 Instell the tabbed washer and inner locknut, seat the beaflngs (Chapter 11) and install the lock washer and outer locknut. Tighten the locknut to the specified torque and band the lip of the lock washer over the nut 30 lower the vehicle.
8
Front allieshah 011 seal - replacement
1 2
Raise the hont of the lI'ahicie and support it securely on jackstands. Remove the front allieshah (Section 7).
1953 through 1972 models 3 RamOll'e the old steering knuckle seal which is held in place with aight screws. On early models the seal consists of two halves. while on later models the seal is made up of a split oil seal, backing ring assambly, oil saal fait and two retainer plate halves. 4 Inspect tha spherical surface of the axleshah for scoring. nicks and scratches which could damage the seal. RemOll'a any minor im·
Fig. 8.'1
-
Late model front axle.haft seal replacement (Sec 8)
perfections with fine sandpapar or emery cloth. 5 Before installation of the oil seal felt, make a diagonal CUt across the top side so it can be slipped over the alliashaft. 6 Install the new seal and components and make SUfe the backing ring is toward the wheel. Install the axleshaft and lower the vehicle.
1973 through 1986 models 7 On these models the seal is located at the axlashalt stone shield. Slide the old seal off the exleshalt and discard it. 8 RamOll'e the bronle thrust washer and inspect it for waar and damage. Replace the washer with a new one if it is noticeably nickad. scored or worn. 9 Carefully clean the grease and dirt from tha thrust face aree 01 the allieshait. 10 tnstallthe bronze washer with the chamfered side facing the seal. " Install the seal with the lip toward the spindle as shown In the ac· companying illustration. 12 Pack the area around tha axleshah thrust face and then fill the seal erea 01 the spindle with wheel bearing greasa. 13 Install the axleshaft end lower the vehicle.
9
Front allie an'mbly - removal and installation
Raise the front of the vehicle and support it securely under the frame with jackstands. 2 Remove the front whaals. 3 Mark the relative positions of the ulllvarsal jOint and axle mating flange. disconnect the drill'eshaft and lasten it out of the way with B piece of wire. 4 Disconnect the steering linkaga from the front axle. 5 Disconnect tha shock absorbers at tha axle hOUSing. 6 Disconnect the breather tube lif equipped) from the axle housing. 7 Remove the disc brake calipers or drum brake backing plates and fasten them out of the way with wire. 8 Remove the axle U-bolt nuts and tie plete. 9 Place a jack undar the axle housing and raise it sufficiently to release the spring tension. 10 Leosen but do not remoll'a the uppar spring shackle bohs. 11 Remove the lower spring shackle bolts and nuts and lower the spring to the Iloor, 12 Roll the jeck and axle assembly calelulty out from under the vehicle. 13 To install tha axle, roll the jack and exle assembly into place und8f thl! vehicle. 14 Raise the springs into position and install the lower shackle bolts. 15 Rotate the axle assembly Into position while lowanng It Onto the springs. 16 Install the U-bolts. tie plates and nuts. 17 Tighten the upper and lowar shackle bolts and nuts. 18 Install the brake celipers or backing plates. 19 Connect the axle breather tube. 20 Connect the shock absorbers. steering linkage and dflll'eshah to the aKIe. 21 Install the wheels and lower the vehicle. With the vehicle weight rasting on the suspension. check the U·bolt nuts and spring shackle nuts and bolts for proper torque. 22 Bleed and adjust the brakes as necessasry IChaptar 9). 23 Check the axle lubricant level IChapter 1) and have the front end alignment chec ked by a properly eqUipped shop.
8-9 ·t
17
.t
" ..\ "\..~\.~'oF \-
>- ,1 0
"
nf~ ,.
Fig. 8 .12 Spicer/Dane nmj-floeting tapered ule,heft exle .... mbly component l\lYout - exploded view ISee 10 through 14)
, BelJ"ng cup 2 Cone lind rollers
3 Shims 4 Different/til CllSe
5 Ga., end pmion 6 Innfl' besring cone lind rollers 7 I"nfl' bHring cup
8 Shims 9 Flttmg
19 Pinion nut 20 Shims
10 Housing IT Outer bearing cup 12 Outer bearing cone . and roffers 13 Oil slinge,
22 Cornt lind rollers 23 Oil UM
14 aesket
24 Olein plug
15 16 17 18
25 Thrust Wluhf!{' 26 DiflerIJnti.' 91111rs 27 Thrust wasllM
33 Filler plug 34 Lock pin 35 Pinion shllf, 36 Lock strap
28 Axleshaft
37 Screw
29 $p8Ctlf
30 GIIsket 31 Housing cover 32 Screw IJnd lock
21 Cup
Oil stIal Dust shield End yoke Washer
wIJsher
FRONT 'INION BEP.RING PINION
DIFFERENTIAL CASE
'"'~
all SEAL DIFfERENTIAL SIDE GEAR
\
.. ...
~~~"~O ~ ""o~':i:::T: THAUSTBt.OCI(~ ~~
.~@ ..
0''''''"'''' .... G':::, PINIOHelf"" -(t" .~
~,
\"
~~.~.~~
C)))Q~1' ""G~?"~';;;:::::'"G ..
~
,,""''''ON ~;:T
\
\
GASKET
/
BEARING CAP
SHIM
~
8
\
SHIM DIFFERENTIAL BEAAING
COVEll
Fig . 8.13
~~;.':
I(W~ CUP
'"
AMCfJ.ep l.mI-tiol ting taperld IXI.shah IXI. ""mbly components - exploded view ISI<: '0 through 141
BEAAINC~~
'::--==..~~
SEAt.
_
SEAL RETAIHER
•
8-10
Chapter 8 Driveline
SIDE
o·
0: o~''-.....
YOKE "\.. DUSTeAP
SEAL PINION SEARING
PINION BEARING CUP BEARING
~
" " " '>''''0' BEARING CUP PtNION BEAFIING
SUl
J" "~ I RE~INER
BEARING RETAINER RING
GASKET AXLE SHAFT
/
Fig. 8.14 Da na flanged 8xlishaft semi· flo8ling reB r IXla assemb ly com ponen ts - 8)1ploded vie w (Sec 10 t hrough 14)
10
Raaf 811leshah - removal and installation
Most of these vehicles were equipped with semi-floating reafaxles, although early models of Ihe CJ-2 ithrough serial number 15453) used full-floating type axles. Two types of semi-floating ax' leshefts were used: tapered and flanged . Early models used Spicer/Dana tapered axles, while later models lafter 19761 were equipped with 8X les manufactured by AMC/Jeep. Vehicles using flanged 8xleshafts were equipped with Dana 44 rear 8)(les.
Full-ffoating axles 2 It is not necessary to raise the vehicle when removing a full -floating axleshaft. Remove the screws which retain the axle flange to the hub and Ihen screw Iwo of these screws Inlo the threaded holes in the flange 10 loosen Ihe shaft. Withdraw Ihe axleshefl from the housing. 3 To remove a broken axleshaft, firsl remove the ouler piece and Ihen loop a piece of sliff wire around Ihe broken piece. Use the wire 10 pull the broken section 01 axleshah from Ihe housing. As an alternetive, remove the other axle and use a rod or pieca of pipe to push the broken section 01 axle out of the housing.
Spicer/Dana tapered axles 4 Raise Ihe rear of Ihe vehicle, support it securely on jackstllnds lind remove Ihe wheel. 5 Remove the axleshaft colter piri, nUl and washer. 6 Back Ihe brake adjuster off sufficiently 10 allow Ihe drum to be removed. 7 Remove the hub ISection 12). 8 Remove the screws retaining the brake dust protector, grellsellnd Dearing relainers, brake and shim 10 Ihe axle housing. 9 DisconneCI and plug Ihe brake line. 10 Remove the dust and oil shields. 11 Use a slide hammer puller to remove the axleshaft, bearing cone,. roller and cup as shown in Ihe accompanying lliuslration. 12 Inspect Ihe oil selll 10 see if it is twisled, damaged or leaking. Replace it if necessary ISection 101. 13 A special puller is required 10 remove the bearing from the axle so this job should be left 10 a dealer or repair shop. 14 Installation of the axleshaft is the reverse of removal, taking care to install Ihe original shims and lighten Ihe axle nut 10 the specified torque.
Fig. 8 .15
Removing e l apered axleshaft w ith a alide hammer Cone end roller 2 Axlesha'l
3 Slide nammer
A M C/Jeep tapered axles 15 Remove Ihe axleshalt dust cap. nut and washer. 16 Raise the vehicle, support it securely and remove Ihe wheel. 17 Remove Ihe rear axle hub (Section 12). 18 Disconnect and plug the broke hose al the wheel cylinder and remove the brake support plate assembly, oil seal and shims from the axlesha ft . 19 Use a puller to remove the axleshaft and bearing from the housing as shown in the accompanying illustration. 20 An arbor press is required 10 remove the bearing Irom the axle so this job should be left to a dealer or repair shop. 2 1 Install a new oil seal ISection 11). 22 Insert Ihe axleshaft carafully into the housing, aligning the shaft splines with the differential gears. 23 Install I he bearing cup. 24 Apply a coat of sealant to the axle tube flange to prevent the en· Iry of dust and water into the housmg. 25 Inslall the o'i~inel shims. oil seal assembly, brake backing plale and
8-11
Chapter 8 Oriveline
FLANGE ADAPTER J.ZlilS,
.1/
~a:).'" -
.~~
AXLE
PULLER J.26 1e
Fig. 8.16 Removing the AMC/Jeep tapered aKlnhaft Ind bearing asaembly with I Ipeclal puUer ISec 10 through 131
Fig. 8 .17
Removing a flangad alliashaft with a pullar and adapter (Sec 10 through 13)
replacement on these models is beyond the scope of the home mechanic and the job should be left to a dealer or repair shop.
Spicer/Dana tapered axles 3 Remove the hub ISection 12) and exleshaft (Section 10). 4 Carefully pry the old seal tram the axle housing, noting Ihe direc· tion in which it is installed. Clean the seal seat in the axle housing with a clean, linl·free cloth. 5 Insert the new oil seal into Ihe housing. making sure Ihal it faces in the same direction as the original. Use a large socket to seat the seal in Ihe housing. tapping It into place with a hammer. 6 Install the axleshaft and hub.
AMC/Jeep tapered axles
Fig. 8 .18
Removing the hub using a puller ISpicer/Olnl tapered allieshlft) ISec 121
mounting bolts. Tighten the bolts to the specified torque. 26 Install the hub. brake drum and axle nut. 27 Install the wheel and hub cap and lower the vehicle.
Dana 44 flanged axles 28 Raise the vehicle. suPPOrt is securely on jackstands and remove the rear wheels. 29 Remove the brake drum. 30 Use a sharp tool to pierce the center of the axleshalt cup plug and pry the plug out. 31 Remove the nuts retaining the backing plate and retainer to the axle tube Ilange. working through the access hole in the shaft lIange. 32 Remova the axleshaft using a puller and lIange adapter such as AMC tools J·2619 and J·25156 lor equivalent) as shown in the ac· companying illustration. 33 Remove the old bearing cup and oil seel from the axle housing tube. 34 Carefully insert the axleshalt into the housing making sure not to contact the oil seal. Apply a thin coat of wheel bearing grease to the outside circumference of the bearing cup prior to installation in the hous· ing bearing bore. 35 Use a soft·laced hammer to tap the axleshaft flange and seat the bearing in the beering bore. 36 Inslall the axleshalt retainer and brake backing plate on the axle housing anti install a new cup plug in Ihe axleshaft flange hole. 37 Install the brake drum and wheel and lower the vehicle.
11
Rear axle seals - replacement
Raise the rear 01 the vehicle. support it securely on jackstands and remove the rear wheels.
7 Remove the hub ISection 12) and axleshaft ~Section 101. 8 Carefully pry the old seat from Ihe axle housing and wipe the seal cavity with a clean. lint·frae cloth. 9 Coat the outer circumference of the seal with light oil and insert it into the housing. Use a large socket and hammer to carefully tap the seal squarely inlO place until it is aeated completely. 10 Lightly coat the seal retainer with non·hardening sealant and in· stall the axleshaft and hub.
Dana 44 flanged axles 11 Remove the axleshaft (Section 10). 12 Remove Ihe otd oil seat Irom the axle housing using a slide ham· mer puller such as AMC tool C·637. 13 Wipe the seal bore out with a clean, linl-free cloth. 14 Install the new seal squarely in the housing using AMC tool W·186 o. a large sockeL Make sure it is completely seated. 15 Install the axleshaft.
12
Rellr hub - removal end Inltllilation
Raise the rear of the vehicle. suppon it securely on jackstands and remove the rear wheels.
Full-floating axles 2 Remove the axleshaft (Section 101. 3 Bend the lip of the lock washer away from the locknul and remove the locknut, washer and bearing adjusting nut and washer. Grasp the hub and rock it back and forth to dislodge the outer bearing. Remove the bearing and withdraw the hub from the axte. 4 Installalion is the reverse of removal. Be sure to adjust the bear· ings ~Chapter 11\.
Spicer/Dana tapered axles 5 Remove the axleshalt nut and use a puller to remove Ihe hub as shown in the accompanying illustration. 6 Place the hub and drum on the tapered portion of the axleshaft and insert the key Into the keyway. Install the axles haft nut and lighten it to the specified torque.
Full-floating axles 2 The seals on these axles are located at the dillarential and replace· ment requires disassembly of the axle assembly. Consequently, seal
AMC/Jeep tapered axles 7
Remove the axleshah dust. cap. cotter key, nul and washer.
8
8-12
Chapter 8
8 Remove the brake drum and mounting screws. 9 Remove the hub uSing a puller such as AMC tool J-25109-01 lor equivalentl as shown in the accompanying Illustration. 10 To install the original hub. align the key In the hub with tha keyway In the axleshaft, slide the hub onto the a)(leshah as lar as it will go and install the washer and nut. Tighten the nut to the specified torque after the vehicle has been lowered onto the wheels. If the cotter key hole is not aligned. tighten the nut sufficiently to allow Insertion of the key. Do not loosen the nut to align the cotter key hole. 11 To install a replacement hub. align the key in the hub with the a)(le· shah keyway and slide the hub onto the shaft. Install two well oiled washers, the a)(leshalt nut, the braka drum and screws end the whael. 12 lower the vehicle and tightan the axleshatt nut until the specified distance lrom the end at the a)(leshah to the hub outer face (1-5116-inchl is obtained as shown in the accompanying illustration. 13 Remove the axlashah nut and one washer. Install the nut end tighten It to the specified torque. To align the cotter key hole so the key can be inserted, tighten (never loosenl the nut.
13
Pinion all seal - replacement
1 Raise the vehicle and support it securely on jackstands. 2 On models equipped with semi· floating rear axles with tapered a)(leshafts, remove the wheels and brake drums. 3 Mark the relative positions of the driveshaft 8nd axle pinion yoke to simplify installation, then disconnect the driveshaft.
Driveline 4
On semi·lloating lesr axles with flanged sJ(leshaits, attach an in-
Ib torotJEI wrench snd socket to the pinion nut, rotate the pinion through ~Il\feral
revolutions ana record the torque reqUired to turn the nUl.
5 On ell models, remove the pinion nul using II yoke holding tool such as AMC tool J·8614·01 as shown in the accompanying illustration. S Mark the reilltive positions of the yoke and pinion for alignment reference during reinstallation. 7 Remove the yoke using a puller such as AMC tool J-8614·2 as shown in the accompanying illustration. S Inspect the yoke seal surface. If it is dllrnaged, burred or scored. replace the yoke with a new one. 9 Use AMC tool J-9233 to drew the pinion seal out 01 the housing. 10 Coat the lip of the new seal with a)(le lubricant prior to installation, Insert the seal into position and tap it squarely into the housing with a hammer and a large socket or 8n installation tool such as AMC tool J-22661. 11 Install the yoke using the alignment marks made during removal . 12 On seml·floating a)(les with taperad a)(leshafts, install a new pin· ion nut and tighten it only sufficiently to remove the pinion bearing end play. Attach the in-Ib torque wrench and rotate the pinion several times to determine an accurate reading of the torque required to initially turn it. Compare this reading with the one taken in Step 4 and add five (51 in-Ib to determine the proper preload torque. If the reading is less than this, tighten the nut slightly and reCheck the torque. Repeat this procedure and gradually tighten the nut until the proper torque is reached. Caution: 00 not over tighten the nut, as it will collapse the pinion spacer sleeve. The differentiel will then heve to be disassembled and II new specer installed.
f.---.., Fig. 8.19 Removing the AMC/Jeep tapered axlesheft hub using a puller ISec 121
1-61111
INCHES
Fig . 8 .20 The AMC/Jeep reer axle replacement hub mUlit be Instelled with tha specified dl.tance between the axle end and hub fece (Sec 12)
o 'd Fig. 8.21
Removing the a)(le pinion nut ISec 13)
Fig. 8.22
Removing the axle pinion flange (Sec 131
Chapter 8 13 On all other axles, Il'1stall the pinion nut and tighten it to the specilied torque. 14 Connect the driveshaft, Install the brake drums and wheels (il removed) and lower the vehicle.
14
8-13
Driveline 15
Front wheel drive hub - removal and installation
Raise the vehicle and sur-port it securely on jackstands, Remove the front wheels, if necessary. 2 Place the hub in the 2WO position. Remove the bolts and tabbed lockwashers retaining the hub body to the axle hUb. Remove the hub body and discard the gasket. 3 Using snap-ring pliers, remove the retaining ring from Ihe axleshaft and slide the hub clutch and bearing assembly from the axle shaft. Caution: Do no rotate the hub control dial with the hub removed or damage to the hub may occur. 4 Clean the hub components with solvent and dry them thoroughly. Make sure all dirt, water and old lubricant has been completely removed. Apply a light coat 01 EP-type waterproollithlum-based grease to 5 the hub internal components. Note: Do not apply an excessive amount of lubricant; apply B light coat only. 6 Place the hub clutch and bearing assembly on the axleshaft and install the retaining ring. 7 Using a new gasket, inslallthe hub body. 8 Align the bolt holes and install the tabbed washers and bolts Tighten the bolts to the specified torque. Inslall the Iront wheel. 9 Turn the hub control dial 10 the 4WD position and rotate the front wheel. The front axleshaft should be engaged with the hub. Turn the dial to the 2WD position, the wheel should rotate freely. If operation is not as described, make sure lhe control dial is fully engaged and the hub is properly assembled.
Rear axle assembly - removal and installation
Raise the rear of the vehicle, support it on jackstands and remove the rear wheels. 2 Disconnect the driveshaft from the axle and fasten it out of the
way. 3 Disconnect the shock absorbers from the axle, 4 Disconnect and plug the brake hose at the T-fitting. 5 Disconnect the parking brake cable (if equipped), Support the axle wIth a lack. 6 7 Remove the U-bolts and nuts. 8 Disconnect the rear shackles, slide the axle to the rear and remove it from the vehicle. 9 To instalilhe axle, raise it into position, align Ihe springs with the axel spring pads and inslall the U-bolts. Position the spring on Ihe shackles and Inslall the bolts finger tight. 10 Attach the brake line to the T-fitting and connect the parking brake cables. 11 Connect the drives haft and shock absorbers to the axle 12 Bleed and adjust Ihe brakes (Chapter 9). . 13 Install the wheels and lower the vehicle. TIghten the spring bolts 10 the specifIed torque.
4
;
2
/ 7
-
8,23 Front wheel drive hub exploded view I 2 3 4
5 6 7 B
9 10
"
12 13 14 15 I.
Retaining ring Bearing hub Wear washer Hub shaft Retaining ring Spring Ring clutch Retaining ring Clutch nut Dial screw O-ring Clutch cup Spring Hub body Control dial Screw
8
11
13
15
I.
9-0
Chapter 9
Brakes
Cootents Brake caliper - removal and installation 8 Brake caliper (1977 through 1979 models) - overhaul 9 Brake caliper j19aO through 1986 models) - overhaul 10 Brake check .•. _ • . • . . • . • . . • . . .. . . .. . . . Chapter 1 Brake disc - in~pection, removal and installation . . . . 7 Brake drum - removal, inspection and installation .. . 11 Brake system bleeding procedure .....•..•.•..•. 3 Brake vacuum booster - check . .. . .....•.•. 4 Brake vacuum booster - removal and installation 5 Disc brake pads - replacement . . •.• . .. . . . 8 Drum brake shoes - removal, installation and adjustment 12
Dual piston master cylinder - overhaul .. . 18 Fluid level check . . Chapter 1 General information 1 Hoses and brake lines - inspection end replacement .. . 2 Master cylinder - removal and installation . ....•..•. 18 Parking brake - adjustment ... .....•..... Single piston master cylinder - overhaul . 17 Transfer case mounted drum·type parking brake - shoe replacement . . .•..•.. 15 Wheel cylinder - removal , overhaul and Installation ...•.... 13
"
SpecHlcatlonl
Disc brakes Brake disc minimum thickness 1977 and 1978 .. . .. . . . 1979 through 1986 .. Brake disc thickness variation limit Brake disc runout limit
1.120in(28.5mmf 0 .815 in (20.7 mmf 0 .001 in (0.02 mm) 0.005 in (0. 12 mm)
Torque specifications
Ft-Ib
Brake booster-to -dash .••..••......•.••.•.••• . .. Master cylinder-to-booster •.•.•......•.•........... _ Brake pedal push rod nut _ . _.. .
18t025 20 to 30 25 to 40
34 to 54
20 to 30 151019
2710 41 201024
100 30 301035 4105
40 41 1047 5106
35 to 55 10 to 15 4 to 5 35 to 55
47 to 74 14 to 23 5 to 6 47 to 74
Nm 24 to 34 27 to 41
Front disc brakes Brake line-Ie-caliper fitting bolt •..•..•.•..• . . _.. Caliper support key retaining screw _ . Caliper anchor bracket-Io-steering knuckle Caliper mounting pins •• . .••.•..•..•..• . . Brake support plate mounting nuts and bolts ..•..• . BIee(!9f" screw . __ . _ . . ...•..•..•.••.
136
Front drum brakes Backing pllte bolts. _ . . . .. . ..•..•. __ . •.. Brake line-to-wh&el cylinder fitting nut ..•.•••.. • .• _ ...• Bleeder scrlw ....•.•..•.•........•.••...•......• Rear backing plate bolts/nuts .......... . . . 1
Ganlrat Information
These vehicles are equipped with four-wheel hydraulic brakes. later have separate systems for tha front and rear brakes. The parking brake is connected mechanicelly to a drum-type brake located on the driveshaft at the rear of the transfer case on early models and to the rear-wheel brakes on later models. Models manufactured through 1976 had drum brakes on all lour wh&els while later models had disc brakes at the front and drum brakes model~
at the reaf. Later model drum brakes are self -adjusting. A vacuum operated brake booster was available on later models. On 1974 and laler models, a combination valve is used. The combination valve serves as a front junction block for the brake hydraulic system and contains a brake pressure differential warning section and a brake proportioning section. A failure in either brake system will cause the piston to move and contact a switch pin, completing an electrical circuit and providing power to the warning light on the dash. The proportioner section provides balanced front-to-rear pressure during hard braking, reducing the rear line pressure so the wheels don't lock up.
Chapter 9 Brakes 2 Hoses and brake linel -
inlpection and replacament
The brake hvdraulic system has a series of flexible rubber hoses connecting the wheel cylinders or the calipers and the rear axle fitting to metal lines running the length 01 the frame. If an inspection IChapter 1) revaals a problem with either a rubber hose or a metal line. the component must be replaced immediately fOf continuad safe use of the vehicle. 2 Before replacing a line or hose. determine the cause of failure and remedy it or the hose or line will fail again. Often componants such as axhaust pipes have come loose end are rubbing tha lina, causing the braak Of tear. 3 Replacement steel and flexibla brake linas ale commonlv evailable from dealer parts departments and auto parts stores. Cauti on: Do nor, vnder any circumstances, use anything other then genuine steel or approved flexible brake hoses as replacement items. 4 Whan removing a brake line or flare-nut hose fitting. always use the proper flara-nut wrenches when loosening and tightening the connections. 5 At the junctIOn where a brake line meets a bracket supporting it and its connection, remove the spring clip with pliers or a vise grip after loosening the connection. 6 Steal brake lines are usually retained along their span with clips. Always remove thasa clips completely before removing any brake line that they are supporting. Always replace these clips when replecing a metel brake line. as they provida support and keep the lines from vibrating. which will fatigue and aventually braak the line. 7 Once a lina has been replaced. the hydraulic system must be bled \0 rid the system of any air bubbles. Refer to Section 3.
3 Brake 8Y8tem bleeding procedure If the brake system has air in it. operation of the brake pedal will be spongy and imprecise. Also, on later models with combination valves (1974 and later! tha warning Ught on the dash will go on if there is air in the velve. Air can enter the braka system whenever any part of the system is dismantl.uf or ilthe fluid 19Vil1 in the master cylinder reser-
A
B
voir runs low. Air can also leak into the system through a hole too small to allow fluid to leak out. In this case, it indicates that a generel overhaul of the brake system is required. Note: Inspect all brake line flexible hoses, steel lines lind connections. See Chepter , for visuel inspections before bleeding the system. By doing this, you will save a lot of rime and prevent fluid loss. 2 On models equipped with a combination valve. it will be necessary to bypass the valve. On 1974 through 1976 models with four-wheel df1Jm brakes. this is accomplished by removing the brake warning switch wire. switch terminal, plunger and spring from the combination valve. On models wirh front disc brakes, hold the metering velve section of the combination valve with AMC tool J-26869 {or equivelentles shown in the accompanying illustration. 3 To blead the brakes. you will need an assistant to pump the brake pedal. a supply of new brake fluid, an empty plastic container, a clear plastic or vinyl tube which will fit over the bleeder screw nipple and a wrench for the bleeder screw. 4 There are five locations at which tha brake system is bled: the master cylinder, each front brake wheel cylinder and each rear brake wheel cylinder. 5 Check the fluid level at the master cylinder reservoi r. Add fluid, if necessary. to bring the level up to the Full marlc.. Use only the recommended brake fluid, and do not mix different types. Never use fluid from a container that has bean standing uncapped. You will have to check the fluid level in the master cylinder reservoir often during the bleeding procedure. If the level drops too far, air will enter the system through the master cylinder. 6 Raise the vehicle and set it securely on jackstands lrefer to the J8Cking end towing procedures at the front of this manuall. 7 Remove the bleeder screw cap from the wheel cylinder or caliper assembly that is being bled. If more than one wheel must ba bled, start with the one farthest from the master cylinder. 8 Anech one end of tha clear plastic or vinyl tube to the bleeder screw nipple and place the other end .submerged in a smell amount of claan brake fluid! In the container. 9 loosen the bleeder screw slightly. then l ighten it to the point where it is snug yet easily loosened. 10 Have an assistant pump the brake pedal several times and hold it in tha fully depressed position. 11 With pressure on the brake pedal. open the bleeder screw approximately one-half turn. As the brake fluid is flowing through the tube and into the container. tighten the bleeder screw. Again, pump the brake pedal, hold it in the fully depressed position and loosen the bleeder screw momentarily. Do not allow the brake pedal to be released with the bleeder screw in the open position. 12 Rapeat Ihe procedure until no air bubbles are visible in the brake fluid flowing through the tube. Be sure to check the brake fluid level in the master cylinder reservoir while performing the bleeding operation. 13 Tighten the bleeder screw. remove the plestic or vinyl tube end install the bleeder screw cap. 14 Follow the same procedure to bleed the other wheel cylinder or celiper alsamblies. 15 To blaed the master cylinder. have an assistant pump and hold the brake pedal. Momentarily loosen the brake line littings, one at e lime. where they attach 10 the master cylinder. Any air in the master cylinder will escape when the fittings are loosened. Bnlke fluid will damage painted surfaces, so use paper lowals or rags 10 cover and protect the areas eround the mas ter cylinder. 16 Inslall the brake warning swilch wi re. terminal, plunger and spring or remove the metering tool on combinetion valve'aquipped vehicles. 17 Check the brake fluid level in the master cylinder to make sure it is adequate. then test drive the vehicle end check for proper brake operation.
4
Fig. 9.1
Combinetion valve metering val ve tool Inllallation ISec 3)
A
B
1977 and 1978 models 1979 through 1985 models
9-1
Brake vecuum bo08ter - ·check
Tha most common symptom of e fauh in the brake vacuum booster is lack of vacuu m assist when the brakes ere IIpplied, so thaI excessive pedal effort is requi red. 2 To check t he brake booster. tum the engine off and place the transmission in Neutral (manual transmission! or Park {automatic transmission!. Apply tha brakes several times to deplete the vecuum from the system and then. with light pressure, hold the pedal all the way down. Start the engine and verify thet the pedal tends to fall away
9
9-2
Chapter 9 Brakes
CALIPER
BLEEDER SCREW
SUPPORT SPRIHG RETAINING SCREW
~~
PISTON UAL OUTIIOARO
'RAKE SHOE
\
DUST BOOT
~
SUPPORT
'"
AHTI·RATTLE sPRING
'"0' FIg . 9 .2
1977 through 1981 disc brake caUper components - exploded view (Sec 6 through 10)
under toot pressure and require lass pressure for brake application, in· dicating thel the booster is working properlv. 3 If the vacuum booster presure is not felt, the system is not functioning. Inspect the vacuum hose for damage end IElClks. 4 If the vacuum booster operates properlv bullhe brake pedal returns slowlV or the brakes grab or drag. check the pedal mechanism and baoller unit be"erank and pivot pin •. lubricate the pedal pivot points and lemOVtl, clean, lubricate and install the bellcrank pivot pins. S If replacing the vacuum hose and cleaning and lubrication of the pedal mechanism and bellcrenk pivot pins does not correct the problem.. the booster is dafective and must be replaced with e new one ISeclion 5).
5
&ake vacuum booster - removel end Instellatlon
D,sconnect the booster pushrod at the brake pedal and discard the nut and bolt. 2 Disconnect the vacuum hose from the booster. 3 Remove the nuts and washers retaining the master cylinder to the booster and move the master cylinder out of the way. 4 Remove the mounting nuts and bolts and lift tha vacuum booster and bellcrenk assembly from the engIne compartment. 5 To install the booster, place the booster and bellcrank assembly ,n pOlltion on the engine compartment dash panel, install the mounting nuts and bolts end tighten them to the specified torque. 6 Connect the vacuum hose. 7 Attach the master cylinder to tha booster and tighten the nuts to tha spaclflad torque. 8 Align the pushrod with tha brake pedal, Install a new bolt and nut and l ighten them to the specified torque.
6
Dllc brag padl - replacement
1 Reier to Chapter 1 for a genera' inspectIon 01 the disc brake pads.. 2 Balore replacing the brake padl, siphOn 011 end discard two-thirds of Iha fluid in tha brake master cylindar reservoir. 3 Remova tha Ironl hub caps and loosen the wheel nuts. Raise the front 01 Ihe vehicle, support il on jack.stands and remove the wheels. Perform tha disc braka pad raplacemant on ona braka assembly at a time, using Iha assembled brake lor reference if necessary. 4 Use a C-clamp or large acrewdriver 10 bottom Ihe piSlon in ils bore
(photo). 5 Dn 1977 through 1981 models. remove the caliper support key screw with a 1/4-inch Allan wranch, use a hammer and punch toddv, the kev nl" and lift the callDer UP and out of the anchor platelphotoll. 6 On 1982 and later models, remove the two seven (7) millimeter hal( head mounllng pins located on the back of the caliper and then lilt the caliper off the anchor plate and rotor. 7 Fasten Ihe cali per out of the way, taking care not to Itretch or damage the brake hOle. 8 On 1977 through 1981 models. remove the 'nboard brake pad Irom the anchor plate. noting the location ollhe anti-rattle spring to sImplify Installation. Remove the outboard pad from the caliper. 9 On 1982 and 7983 models.. remove the outboard pad whIle holdl~ the anti-rattle clip. lollowad bV the Inboard pad and anti-rallie clip as shown in the accompanying illustrations. 10 On all models, carelully clean tha sliding surfaces of the callpar and anchor plate with a stiff brush or fine sandpaper to remove dirt end rust. Note: Make 8n effort not to inhale any dust raised by this operation, 8S if m8Y contain asbestos, which IS h8rmful to your health. Apply a thin coat of moly-based or h,gh-temperature grease to the caliper and enchor plate sliding lurfaces Iphoto). liOn 1977 through 1981 models. Instatlthe antl-raute spring on the reaf flange 01 the inboard pad so the looped end is facing away Irom the brake disc. Instatl the pad and spring in the anchor plete. laki~ care not to distodge the spring. Install the outboard pad in th e anchor ptate. Place the caliper in position over the anchor plata and braka diac:.. being careful not to tear or damage the pISton boot. Align the caliper and anchor plate, insert the support kay and spring and inllall the ratalnlnt! scraw, tightening it to the soecified tOfOU8. 12 un 1982 and later models, Install the anti-rattle clip on the tralli~ edge of the anchor plate WIth Ihe split end facing away from the disc. Hold the cl ip in the plate while Installing the inboard pad. Install tha outboard pad in the plate while holding the anti-rattle clip In place. Install the caliper over the anchor plate and brake disc, takIng care not to damage the piston boot. Align the caliper and anchor plate. then install the mounting pins and hohten them to Ihe spel':iliP.d torqUf' U On all mooels, 1111 tne master cylinder reservoIr 10 within 114-lOch of the ,im and depress the brake pedal several tImes to seat tha new pads. 14 Install the wheels. lower the vehiclfland check the master cylinder lIuid level. 15 Belore driving Ihe vehicle but with the engine running. chack lor a lirm brake pedal (if equipped with a vacuum booster) and bleed tha brakes (Section 3) if n&Cassary.
9-3
Chapter 9 Brakes
......,.
,.
6.4 Using a screwdriver to push the piston back into its bore
-
6.5A Removing the 1977 through 1981 caliper key retaining bolt with an Alten wrench
6.5B Drive the caliper key out with hammer and punch
8
auro'A sen .... AND
.,
'NIIDAAD
Fig. 9.3 1982 and later disc brake ca liper com ponents· exploded vie w (Sec 6)
Fig. 9.4 Remove the outboard disc brake pad (1 982 and leI te r m odel s) (Sec 6)
7
Fig. 9,5 1982 and later model inboard brake pad r emoval (Sec 6)
Brake di,c - Inapectlon. removel and in st allation
Inspection , Raise the front of the vehicle, support il securely on jackstands and remove the front wheels. 2 Remove the caliper and brake pads as described in Section 6. 3 Inspect the surface of the brake disc for sevilre score marks, cracks. chipped areas. excessive wear and alternate shiny/dark colored areas indicating hard spots. Moderate damage can be remedied by heving the disc resurfaced on a brake lathe. 4 Check the thickness of the disc at the center of the lining contact area with a micromatar. The disc must be replaced with a new one if the measurement is less than shown in the Specifications. 5 Mount a dial indicator on a support stand or the spindle and place the stylus in contact with the center of the pad contact affle on the disc. Zero the indicator, rotate the disc through one revolution and note the indicator reading. Compere this reading with the runout limit in the Specifications. If the nmool is excessive. the rotor should either be fflsurfaced on 8 brake lathe 01 replaced with a new one. 6. 10 Use your finger to lubricate the caliper and anchor plate sliding surfaces (arrows I with moly-based, hightemperature brake grease
Removal 6 To remove the disc on 1977 through 1979 models. remove the hub cap and hub cover assembly. Remove the drive flange snap-ring and flange. Straighten the lip of the outar locknut retaining washer and
9
9-4 SUPPORT
SPR'NG~ETAINING , ..... flEW
SUPPO'"
,ev ANCHOR
_
\
\
~ ~
PLAT\IE
J;J
INBOARO ANTI RATTLE SPRING
PAD
I
fJ \~
f
OUTBOARD
'AD
~~ ;~~ I ~@/ ~/'~t v,r';'~HUB 'NN'R LOCKNUT
' " , " '"
SPLASH SHIELD
1'-
HUB
'NBDARD
SPRING
SCRE\W
AN" RATTLE cu,
~~~
"ATE\
;t;;
r
~
.. o
•
0\:r.. . . . . .
DR'V'
fLANGE
t
CAe
SNAP RING
A'oded view IS&<:
'AD~ •• RETAINING
SUPPORT ev \
GASK
lET
1977 through 1979 disc brake an d hub eompon enll - ex",
SUPPORT
ANCHO:
WASHER
ROTOR
Ag . 9.6
'" t
BEARING TABBeD BE'-flING CUP
OUTER LOCKNUT
~
.
----------::_
0
MD
OUTBOARD
ANTI-
RATTLE
~R'N\
i'
7
INNER
OUTER N ",/oe'NU'
SPLASH SHIELD
! ~Or~'" Y'D /_~:~ \
BEARING CUP
BEAR'NO
WASHER GASKET
Fig. 9.7 1980 throug h 1986 disc brake and h ub components· exploded view (Sec 7)
HUB MBL Y ASSE
Chapter 9 Brakes remove Ihe ouler Iocknul and washer and Inner locknut and relalning washer. Grasp the brake disc and hub assembly firmly and withdraw h from the spindle. Remove the bearings from the hub. 7 On 19/$0 Ihrough 1986 models, remove the hub cap assembly from the hub. Remove the snap-nng retaining the hub to the axleshaft and straighten the lip on the outer locknut retaining washer. Remove the outer locknut and retaining washer, followed by the inner locknut and retaining washer, grasp the hub and disc assembly firmly and withdraw it from the spindle. Remove the bearings from the hub. 8 With the disc removed, It can be taken to /I properly aQulpped brake ahop to be resurfaced. Be sure to check the thickness of the disc Ifter machining to verily that it is still within the specil ied limit.
Installation 9 Lubricate the beanngs and install them in Ihe hub as described in Chapter 11 10 Instell Ihe hub and disc essembly on the spindle. 'IOn 1977 through 1979 models, ins talilhe inner re!einlng washer and locknut. TIghten the locknut to 50 ft-Ibs and then back the nut off 1I3-turn. Install the washer and outer locknut, tighten it to 50 ftIbs and then bend the washer lip over the nut. Install the drive flange and snap-ring, followed by the gasket hub cover. retaining bolts and huh r:ap. 1iI On 1980 through 1986 models, install Ihe tabbed Inner wasner and locknut and installlne wheel with the nuts finger tight. Ttghten the Inner locknut to 50 ft-Ibs whlte rotating the wheel to seat the bearings evenly. Back off the locknut l16-tum (approximately 45° to Install the outer tabbed washer and locknut, tighten the locknut to 50 n-Ibs and bend Ihe lip ollhe washer over the nut Inslall the snap-ring, new gaskel. hub cover assembly and relaining bolts. Remove Ihe wheel. 13 On all models, install the pads and calipers as described in Section 6. 14 Install the wheels and lower the vehicle.
65,.
Siphon off and discard two-thirds of the lIuid In the brake master cylinder reser,/oir. 2 Remove the front hub caps and loosen the wheel nuts. Raise the front 01 the vehicle. support It securel.,. on Jackstands and remove the wheels. 3 Boltom Ihe caliper piston in its bore as described In SeCIIon 6, Step 4 4 Thoroughly clean the area around the brake fitting. 5 Disconnect and plug the brake line Idiscarding the gaskets). 6 Remove the caliper as described in Section 6. Step 5 or 6, depend· ing on the year of the vehicle. 7 Install the caliper as descnbed in Section 6. Steps 10 through 12 . Conn8(;1 Ihe brake line to the caliper littlng lusing new gaskets). 8 F~I the master cylinder reservorr to wlthlfl 114-inch of the top and bleed the brakes {Section 31. 9 Install the wheels. lower Ihe vehicle and ch8(;k the master cylinder fluid level 10 Before driVing the vehicle, Check for a lirm brake pedal (with the engine running on vacuum booster-equipped models!.
PISTON
Fig . 9 .B
Using air pressure to remolle the piston Irom the caliper ISec 9)
9
9·5
Breke caliper 11977 through 1979 models' - o ....rh.ul
Drain any remaining fluid f~om the caliper into a conlalnllf and place the calipel on a clean work surface. 2 Pad the inside of the caliper with rags to protect the pill on. If compressed air is available, insert an eir noule in the celiper Ituld Inlet port and slowly apply just enough air pressure to ease lhe piston out of the bore as shown in the accompanying iliumretian. Caution: Do not place you, fingers in front of the piston to catch it becausa excassive air pressure could aject it with enough forca to causa inftJry. As an elternative method, strike the caliper sharpl y on a wood block to dislodge the piston from the bore. 3 Ramove the dust boot from the piston and discard II. 4 Remove the seal from the piston bore, using a wood Of plashC tool to avoid damaging the bore surface. Discard the seal. 5 Remove the bleeder screw from the caliper. 6 Remove any rust or corrosion from the caliper exterior With a wire brush. Clean the caliper and pillon with new brake fluid Inever use petroleum-based solvenrs to clean braka parts}. Inspect the piston for wear, damage and pitted areas. Inspect the caliper for damage. wear, nicks, pitted areas and corrosion in Ihe bore. Check the support spring and anti-raltle springs lor distonlon and lack of tension. Replece any damaged or worn components with new ones. 7 lubricate the piston and bore with clean brake fluid. S Install the seal in the grOOIl1:l in the bore by wor1l.ing it into pOSition using .,.our lingers only. 9 Install the bleeder screw in the caliper. 10 With the piston bore lubricated with clean brake fluid, position the dust boot on the bore. 00 not lUbricate the dust boot. Reach through the top of the boot and work the large lip Into the groove at the upper edge of the bore. The boot must be securely seated in the groove. 11 lubricate the pillon and Ihe smalt lip ollhe dust boot with clean brake fluid and position Ihe piston over the lip. 12 Hold the piston In position over the boot lip and direct low pressure air labout 15 psi) into the fluid inlet port. Turn the compressor valve off and then back on to about 7 psi. 13 As the air pressure expands the seal, carefully work the piston Into the boot until the boot seats in the piston groove. After the boot lip is seated In the piston groove. release the air pressure. The piston can now be pushed to Ihe bottom of the bore using a hammer handle.
10
Brake caliper (1980 through 1986 models)- overhaul
Drain any remaining fluid into a container and place the caliper on a clean working surface. 2 Remove Ihe piston Irom the caliper as described in Section 9, Step 2. 3 Remove the piston boot from the bore using a screwdnver to pry it oul (take care not to scratch the borel. Discard the boot. Remove the piston seal with a plastic or wooden tool end discard it. 4 5 Remove the bleeder screw from the caliper. 6 Remove the plastic sleeves and rubber bushings from the caliper mounting ears and discard them. 7 Wash the components thoroughly with clean brake fluid. Check the mounting pin. for demaged thread. and corrosion. Inspect the piston bore for heavy scre tches. corrosion, nicks, cracks, wear and damage. Minor imperfections can be removed with crocus cloth. Inspect the piston for heavy scralches, score merks. corrosion end wear. Replace eny worn or damaged components with new ones. 8 lubricate the pilton bore and the new seal w ith clean breke ttuid. 9 Install Ihe piston seal in the bore groove by working it Into piece With your fingers . 10 Lubricate the piston with clean brake fluid. 11 Install the repla cement dust boot on the piston and .lide the metal retaine r portion oller the open end 0 1 Ihe piston. P\JII the boot to the reer until the lip seats in the piston groove es shown in the eccompanying illustration. 12 Push the metal retainer portion of the boot lorward until it i. flush With the open end of Ihe piston and the fold can be snapped into place as shown in the accompanying Illustretion. 13 Insert the pislon carelully into the bore. taking care not to d i.place the piston seal. 14 Use a wooden hammer hendle to push the piston to the boltom
9
9-6
Chapter 9 Brakes
OUIT
M)CJT
'lU," WIni
•• Fig. 9 .9
Inttallng the caliper pl,ton
dust boot on the piston (1980 through 1983 model.) (Sac 10)
Fig. 9.10
Positioning the caliper piston
duat boot (1980 through 1983 modals)
(Sec 10) Fig . 9 .11 Seating the caHplr piston du.t boot in Ihe counterbore with an lnstaMlng looll1980 through 1983 mooel.) ISec 10)
01 the bore.
15 Use II dust boot installer tool such as AMC No. J·33Q28 (available
at your dealer) or equivalent (available at auto parts storesl to seat the metal feleiner portion of the dust boot In the counterbore at the upper end of the piston bore. 16 Install the bleeder screw and tighten it securely (but nOI to thll specified torque until aher the caliper has been installed and the brakes bled), 17 Instell the replacement plastic sleeves and rubbat bushings in the mounting ears on the caliper.
11
BllIke drum - removal, In.pection lind lo.tallation
Removal (front) 1 Raise Ihe fronl of Ihe vehicle. support il securely on jackstands and remove Ihe hub cap. 2 Remove Ihe drive flange snap-ring and axle flange bOlts. 3 Removelhe axle flange using a puller such as AMC 1001 J-25133 or its equivalent. 4 Bend back the lock wesher lip and remova Ihe outer nUl. lock washer, adjusting nut and bearing lock washer. Back off the brake adjustment, if necessary, and withdraw the brake drum and hub assembly from Ihe spindle.
Removal (rear) 5 Raise the rear of the vehicle. support it on jackstands and remove Ihe wheels. FuU-floatlng allie 6 Remove the Bl!leshaft and nUl (Chapter B). 7 Bend the lip of the lock washer back and remove Ihe locknut and lock washer. Remove the bearing adjusting nut and washer, grasp Ihe hub/brake drum assembly and move it Irom side-to-side until the outer bearing is free of the hub. Withdraw the hub/brake drum assembly from the allie. taking care not to drop the bearings. Semi-floating flanged axle S Remove the brake drum locknuts and remove the drum. Semi·flolltlng tapered ule 9 Remove the hub/brake drum assembly as described in Chapter B.
Inspection 10 Wipa tha brake drum out with a clean cloth. Note: Make an effort not to inhale this dust bactluse it contains asbestos, which is harmful to your health. Wash the drum Ihoroughly with soap and water and dry it with a clean, lint-free cloth. If the drum is contaminated with grease or oil. clean the surface with alcohol. 12 Inspect the drum for cracks, deep scoring, distortion and hard spots which appear as a series of shiny or dark-colored areas on the shoe contact surface. Replace the drum wilh a new one if any of these con· ditions are present.
1,
13 If the drum is oUI·ol-round or lightly scored. have it turned by a properly equipped shop.
Installation (front) 14 Lubricate the wheel bearings IChapter 111 and instaU the hub/drum assembly on the spindle. 15 Install the wheel washer and adjusting nul and tighten the nut while ·otating the hub until drag is felt on the bearings. Back the nut off lip· prollimately 1I6-turn. Install the lock washer and nut and bend the lip of the wesher over the nut. 16 Install Ihe drive flange and bolts, followed by the snap-ring and hub cap.
Installation (rear) Full-floating allie 17 Lubricate the wheel bearings (Chapter 111 and install the wash8f and nut. InstaU the wheel and spin it while lightening the nut until tha bearings start to bind. Back the nut oft approximately lIB·turn until the wheel turns freely. Install the lock washer and nut, bending Ihl lock washer lip over the nut. Remove the wheal and install the axlesha!t. Semi-floating flanged eKlI 18 Install the brake drum and locknuts. Semi-floating tapered alllie 19 Install the hub/drum assembly (Chapter 81.
Installation (all models) 20 On all models, install the wheels. adjusl the brakes and lower the vehicle. On fater models with self-adjusting brakes, it will not be necessary 10 adjust the brakes before lowering the vehicle. On Ihese models, drive the vehicle in lorward and reverse while making 10 or 15 brake applications 10 bring the pedal up to the proper level.
12
Drum brake shoes ~ removal. Installation and adjostmeM
Raise the vehicle. support it securely on jackstends and remove the wheels. 2 Remove the brake drums (Sec tion II!. 3 It is recommended that the old shoes be replaced with new or reo lined ones instead of new linings being installed on the original shoe •. Also, it is recommended Ihat shoes for both wheels on a particular IXIe be replaced at the same time.
Removal Non self-adjusting brakes 4 Turn the adjustment eccentrics to the lowest side of the cam and remove the brake shoe return springs. Remove the hold-down spring
9-7
ACCESS COVER
J
"-
ADJUSTER CASLE
I
'\
HOL D DOWN PIN
ADJUSTER SPAING
Fig.9.12
Typlce"ele model drum brake components - tJ)(ploded view ISec 121
':j:
"
I'-] _ _, ~
"
Flg. 9 .14
>
Typical early model
Hlf-edJu.tlng rear brake components - •• ploded view
(See 12) I AnChor block FIlii _ 9 .13
Typical .arly model ...' ·
IdJu.tlng fronl wh.. , drum brake componentl - exploded view (Sec 12)
I Prim/IfY shoe 2 Wheel cylinder 3 SecondlJfy shoe
•
Lev"r pl8 re
7 Uppef linkllge rod
8 Screw Ad;ustlng screw assembly 9 Lower linkege rod 5 Sleeve 10 Adjuster lever
•
2 Anchor plere 3 Pilricing br.ke Isver 8nd pin
•5
ShOB r.lurn spring
8rIJIt,e shoe C-wlIsh"f 7 Parking bfllk" strut 8 AnChor lind link
•
9 Actuator link
10 Lev., shoe tldjusting spring /I
Lev", lind sleeve screw
12 Srake adjUsting
$C~W
(lefr-hIJnd thft/edl
13 8,.k8 adjusting screw
" 17 "18
(dghr-hIJnd rhre6d1 Adjusting screw spring
15 Strut :spring Hold-down spring Backing p/lft8 Hold-down pin /9 Adjusting holtl plug
9
9-8
Chapter 9 Brakes
•
12.8A Inlert I screwdriver into the hold-down .pring used on some letor model brake shoes to disengage it
12.88 The hold-down spring used on some later model ael f-adjusting drum brake shoes
12.9A Removing the reer brake pllfking brake Ilrut
12.98 Oisengage the parking brake cable (arrow) from Ihe $1'108 lever .a the rellf brake ,hoe is removed
12.18 The adjuster screw muSI be installed in the lully retracted position
12.24 Whh the plug removed from the backing plate, the adjuster star whul (arrowl is accessible
cup (usmg a brake tool or pliers) and .epallile the shoes from the backIng plate. SeIf-adjul1lng brakes 5 Gnp the automatic adjuster lever with 8 pllors and remove the pivot hook from the hole in the secondary shoe. 6 Detach the shoe return springs. 7 Remove the adjuster cable. guide. lellef and spring. S Remolle the shoe hold-down springs. On some later models. this is accomplished by inserting a screwdriver and twisting the springs from Ihen enChor pletes Iphotos). 9 Remove the breke shoes. adjuster screw assemblv and. in the cese of the rear brakes. the parking brake strut (photo!. Detach the parking brake cable from the lever as the shoe assemblv is removed (130010). All modals 10 Placa a wide rubber band or pIece of wire around the wheel cVlinders to retain them while the shoe. are removed . 11 While all the brake parts are removed . carelully brush away any accumulations of dirt and dust from the backing plate and wheel cvlinder. Nota: MlJklJ sure thet no 9rease comes in contact with the bflJke shoes at any time. If it does. cfflen tham thoroughly with denatUlwd alcohol. 12 Prior to Installation. applv a small amount 01 high·temperature braka grease to the backing plate surfaces which come in contact with the side. ollhe brake shoes. Note: Make sure that no gl'8ase comes in contact with the brake shoes et any tima If it does. cwn them thoroughly With denatured alcohol. 13 Applv a small amount of high-temperature grease to the conlact paiOls of the brake shoes. parking brake and adjuster levers. struts and springs.
Installation Non self-adjusting brakes 14 Install tha brake shoes on the backing plete and remove the rubber band or wire from the wheel cvlinder.
15 Install the adjuster eccent"cs end brake shoe retelning spflngs. Sett-edJu.tlng brake. 16 PIece the brake shoes ,n position on the backing plate, remove the rubber band or wire from the wheel cylinder and ins ten the hold-down springs. 17 Install the primary shoe return spring and than place the adjuster cable eyele t on the enchor pin. position Ihe cable guide and install the secondary retu rn spring. 16 Install the adjuster screw. alter making sure that (on the rear brakesl the parking brake strut is correctly positioned and allached. Meke sure the adjuSler screw is threaded all the way iOlo the sleeve to the minimum adjustment (photol. 19 Place the small hookad end of the adjustar spring in tha large hole in the primary shoe and then place the large hooked end 01 the spring in the adjuster lever. 20 Engage the hooked end of the adtusler cable in the adjuster leyer and locate the adjuster cable oyer tha gu,de. 21 Pry the adjuster lever until the pivot hook engages in the large hole at the bottom of the secondary shoe. All modal. 22 Make sure the shoes are correctly centered and instell the brek. drum ISection 11).
Adjustment Non .elf-. dJulting brake. 23 Raler to Chapter 1 lor the adjustment procedure lor non saltadjulting brtkes. Selt -adJu.ting brake. 24 R.move the access plug from Ihe backing plate, insen a brake adjousting tool and, after depressing Ihe adjusting lever, rotate the Stlllr wheel until the brake shoes are lockad against the drum and the wheel won't turn (phot o). 25 Back off the star wheel unt,l the drum fotates freely and InstaM the access plug.
Chapter 9
9-9
Brakes ~
BLEE D ER SCREW
~ ~j)~
~
6Y~
-- t
LI NK
' ;P: 'J
dv-"""
OOM,.ES"ON SP RING AND
" "ON
WHEEl mAND'"
CUP
CYLINDER
PI ST ON
DUST
'00' Fig. 9 .16
Fig. 9 .15 Moving the brake adjus ter ster wh eel with a tool inserted through the hole in the backing plate while unseating the adjU5ter lever wit h a screwdriver iSec 121
Exploded view of a typical wh eel cylinder i Sec 13)
Fig. 9 .17 Earl y model t ransfer case mounted drum·type panting brake iSec 14)
,.
I
" "
• 5 6 7
8 9 10 /I
" AH models 26 Install the wheels and lower the vehicle. 27 On self·adjusting brake'equippad models, drive the vehicle in for· ward and reversa while applying the brakes 10 or 15 times to complete adjustment. 13
Wheel cy linder - removal. overhaul and installation
If the wheel cylinder is leaking fluid around the piston. it should be removed and overhauled to restore braking performanca. Befora disassembling it. read through this entire procedure and make SUfa you hava the corract rebuild kit. Also, you will nead some ne w, clean bra ka fluid of the recommended type and some clean rags. Nota: Disassembly, overhaul and reassembly of the wheel cylinder mus t be done in a spotlessly clean work erea to avoid contamination end possible failure of the brake hydraulic system components. If such a work area is not tIIIai/able, have it rebuilt by a dealer service department or a service station. 2 Refer to Section 12 fo r the brake shoa removal procedure. 3 Although It is possible to overhaul a wheel cylinder while it is still attached to the backing plate, it is recommended that it be re· moved. To do this, disconnect the brake line from the cylinder and either plug the line or seal the master cylinde r reservoir with a sheet of thin plastic to prevent loss of fluid and to keep conteminants from enter· ing the brake system. 4 Remove the two small bolts on the back side of the backing plate which hold the cylinder to the plate, Remove the cylinder. S Next, cerefully remove the rubber dust boot with your finoer!!
Cable and conduit
2 Hand brake clip 3 Hand brake bracket
12 13 I.
Hand brake handle assembly Rear cap Drive gear bushing Driven gear Driven gear sleeve Backing plate Brake shoe Lever end return spring Brake drum Bolt Rear companion flange
15 Washer Nu, 17 Driveshaft flange yoke 18 Rear driveshaft 19 Adjusting end spring 20 Adjusting screw bracket 21 Operating lever 22 Clevis 23 Retracting spring clip 24 Retractmg spring link
"
6 You can now remove all the remaining parts within the cylinder housing; both pistons, the cups and the compression spring and ex· panders. An easy w ay to remove thase parts is by tepping the cylinder on a piece of wood. 7 EJC amine the mating surfaces of the pistons and the cylinder walls. If thera is scoring, evidence of metal-to-metal contact Of bright wear ereas, replece the complete cylinder assembly with a new one. 8 If the metal components are in good condition, discard the rubber boots and the cylinder cups and replace them with the new parts from the rebuild kit. 9 Thoroughly clean all the parts with new brake fluid. When cleaning the brake cylinder walls, wrap a clean white cloth around a stick and soak it in new brake fluid. Insert the stick, fi rst in one side of the cylinde r and then the other, end rotate it several times. 00 not use a push·pull movement. 10 Jf tha bleeder screw is stripped or damaged, raplace it with a new one. Jf it is in good condition, use compressed lIir and blowout any foreign material that might block it and hinder the flow of brake flu id when bleeding the system. 11 You can now prepare the parts for reassembly. If your rebuild kit comes w ith a package of special grease, coat the piston cups, pistons and inside wells of the cylinder with it. If not, then coat these same parts with new, clean brake fluid . 12 Insert the spring first. Then, from either end of the cylinder, insert the piston cups, followed by the pistons. Note: Milke sure these p8rrs are inserted correctly. 13 Install the boots on the brake cylinder, then attach the cylinder to the backing plate and hook up the line. 14 Refer to Section 12 for the brake shoe installation procedure..
9
9-10 14
Chapter 9 Brakes
Parking brake - adjustment
Two types of parking brskes Bfe used on these models.. Early models used 8 drum brake located 8t the rear of the transfer case which locked the driveshaft and resr wheels when applied. On laler models, the rear brake shoes are actueted by a s~tem allevars and cables when the parking brake lever or foot pedal Is applied. 2 Before adjusting either type of parking brake, first inspect Iha cables, connections end mechanism for damage, binding and corro· sian. Replace any damaged components with new ones.
8 Tighten the equalizer nut until there is a slight drag when (ha rear wheels are turned. 9 Loosen the nut sufficiently to allow the rear wheels to turn freely and tighten the locknut. 10 Lower the vehicle.
Transfer case mounted drum-type parking brake 3 Make sure the brake handle is completely released and rotate the drum until one pair of the three sets of holes is over the adjusting screw star wheels in the brake. 4 Use the edge of the holes as a fulcrum for an adjusting (001 or screwdriver and rotate each star wheel by moving the tool away from the center of the driveshaft until the shoes are locked against the drum. S Back the star wheels off seven (7) notches to achieve the proper running clearance. The operating lever-to·backing plate clearance should be 3/32-inch as shown in the accompanying illustration.
Cable-operated rear brake shoe parking brake 6 Block the front wheels securelv. Raise the rear of the vehicle and suppa" it on jackstands. 7 Make sure the parking brake is released and loosen the parking brake cable equalizer locknut.
hi;T ...
.~~ '. ,
r
CLIP
Early model drum·type parking brake adjustment (Sec 14)
HANDLE
CLIP
•
Fig. 9 .18
CLIP
\
RELEASE CA8 L E
AND HANDLE
".
BRACKET
EQUALIZER
~
~ /-
PARKING BRAKE ASSEM8LV
/'
...
(!)
RIGHT REAR
FRONT CABLE
LEFT REAR CA8LE CLAMP
Fig. 9. 19
Typical hue model parking brake cable layout (Sec 14)
9·11
Chapter 9 Brakes
7 Instal! the master cylindel and, on non-vacuum booster·equlpped models. connect the pushlod to the brake pedal. B Connect the brake lines to the mailer cylinder. 9 Bleed the brake system (Section 31.
15
Tr.n.f.r cau mounted drum-type parlling brake - .hoe replacement Rllse tha rear of the vehicle and support it securely on jackslands. Remove the four mounting nulS and lower Ihe driveshafl OUI of the way. 3 Remove the retracting spring clevis pin and spring pin. followed by the locknut. nUl and washer from Ihe uansfar case output shalt. Use II puller to remove the universal joint companion Ilange and brake drum. 4 Remove thaletlacting springs and sepalale the blake shoes from the backing plate. 5 Carefully blush away any accumulations of din and dust flom the backing pla'e and adjusting screw mechanism. Nota: Make an effort not to inhale this dust; it conrains esbesto$, which is harmful to your health. 6 aefole Installing new shoes, back off Ihe adjusting star wheels 10 the fully off pOSition and lubricate Ihe contact surfaces ollhe backing plele. blake shoes and adjusler mechanism with a small amount 01 hightemperature grease. 7 Install Ihe blake shoes and IIltum springs. The yellow spring fits ne)(t to the notched adjusting wheel screw and the black spling next to the cam. Install the brake dlum and universal joint flal'lQ8 and adjust the brtIke (Section 14). 9 Install Ihe dliveshaft and lowel the vehicle.
1 2
17 Single piston master cyllnde, - overhaul Early models were equipped with alngla brake systems. which re ' quired only a single piston in the master cylinder. 2 Before the master cylinder is removed (Section 161. obtain the propel rebuild kit and read through the following procedure to make sure you have the correct kit. You will elso need .ome new brake fluid of the recommended type and some clean rags. Note: Disassembly, OVtJrhau/and rellssembly of the mIIster cylinder must be dOM in a spotlessly clean work llrea to llvold contllminetion and possible failure of the brake hydreulic system components. "such II work llree is not available, have It rebuilt by II dfHJler service depllrtment or e properly equipped shop. 3 Drain the fluid from Ihe reservoir into a container and wash the master cylinder with denatured eleohol or clean brake lIuid. 4 Dismantle the master cylinder by referring to the accompanying illustration. Wash the components with denal\Jred alcohol or clean brake flUid . 5 Inspect the cylinder bore for heavy sCOfing. scratches and corro'IOn. Make sure the passages between the reservoir and piston bore ale open lind free 01 foreign material. Clean them with a wire if necessary. light scratches or roughness in the bore can be removed by honing but a new unit should be obtained if the scoring or demage is extensive. The rebuild kit should contain a new piston. primary cup. valve and valve seat. 6 Install the valve seat in the end of the piston bore with the flat surlace facing the valve. 7 Install the valve assembly. lollowed by the return spring and primary cup with Ihe flat side of the cup toward the piSlon. InSlall the piston. stop plate and lock. wire retainer spring. 9 Install the fitting connection. using a new gaskel. 10 Fill the reservoir haff full 01 new. clean brake lIuid and bleed the master cylinder as described in Section 16.
a
16
M ester cylinder - removal and Installation
1 Place rags or newspapers under the master cylinder to catch and lOek up eny bleke fluid that might spill dutlng remOval . Note : Be careful not to spilf any fluid on rhe painred surfacfls of 'hI! vehicle as it will demage the p8inr. Wipe up any spilled fluid immediately. 2 On vehicles without a vacuum booster system, disconnect the blake ptJshrod flam the brake pedal. 3 Disconnect and plug the brake IlI'Ies at the master cylinder. 4 Unbolt the mastel cylindel and lift it from the engine compartment. S Check lor Iluid leakage around Ihe lIange area at the base 01 the piston. If thele is evidence of leakage, the master cylinder should be overhauled !Section 1701 IS) or replaced with a new or rebuilt unit. S PriOr to installation. the master cylinder should be bled. Connect two lengths of tubing and actuate the piston(s! until the unit is primed with clean fluid and all air is bled out as shown in the accompanying illustration. IIlhe master cylinder is not bled before Installation. it can be done later when the brakes are bled (Section 31. It is recommend · ed, however. that the unit be primed first .
e
IS
Dual pilton mastlt cyRnd.., - ovemaul
If the cylinder is leaking fluid around the piston, 1\ should be removed and overhauled to restore braking performance. Before disassembling il. lead through this procedure and make sure you have the correct rebuild kit. When you Durehase the rebuild kit Irom vour dealer, be sure
9 SUEO
TueES
Fig. 9.20
Sleeding air from the malter cylinder (Sec 16)
Fig . 9.21
Typlcalaingle piston mlStlt cylnder -
1 2 3 4 5 6 7
Pusflrod Boot Piston stop lock wire Stop pia,. Piston M8Stflf cylinder cup Return spring
exploded ...lew (Sec 17)
8 Piston VMve seet 9 Reservoir '0 Fil,., cap g8sker , 1 F,I,., CliP '2 Outlet fitting gasket '3 Outlet fitting 14 Outlet fItting bolt gasket
9-12
Ch apter 9 Brak es
to get two spare brake line l itting nuts elsa. You will need them to instell the new tube seats. Also, you will need some new, clean brake fluid of the recommended type end some clean fags. Note: Disassembly, overhaul end reassembly o( the master cylindllf must be done in 8 spotlessly clean work 8,8a to avoid contamination Bnd possible fll/lure of the brake hydfBulic system components. If such II work area is not available, heve it rebuilt by II dealer service department or 8 properly equipped shop.
2 On models built through 1975, unscrew Bnd remove the primary piSlOn stop bolt located on the bottom of the master cylinder. 3 On models with manulJl bruka$, slide the pushrad boot back and remove the retainer clip or snap-ring. pushrod and boot. 4 Press the primary spring in. using the pushrod or tool. Remove the snap-ring from the groove in the piston. 5 Remove and discard the primary piston assembly. A complete piston assembly is supplied with the rebuild kit. 6 Remove the secondery piston assembly by applying air pressure through the compensator port in the front reservoir. 7 On some models the residual check valves must be removed. To gain access to the check valves, the outlet tube sealS must be removed with the self-tapping screws supplied in the rebuild kit. Thread the self-tapping screws into the tube seats and place two screwdriver tips under the screw head. Carefully pry the screw up and remove the tube seat. Wash all metal parIS with clean brake fluid or brake cleaning solvent. Use air pressure to remova dirt and cleaning solvent from the recesses and internal passages. 9 On '976 and later models there are no check valves and the lube
a
seats rarely need replacement. If the seats are cracked, scored, loosa or cocked in the fluid outlet pOrt, they should be replaced. It might be preferable to buy a rebuilt master cylinder. Read through the entire procedure below be fore attempting to replace the tube seats on later modal master cylinders. a) Enlarge the holes in the tube seats using a 13164-inch drill bit. b) Place a flat washer on each tube seat and thread a '/4 -20 x 3/4 -inch screw into the seat. c) Tighten the screw until the tube seat is loose and remove the seet, screw and washer. d) Remove all chips using compressed air and alcohol or brake cleaning solvent. e) Install the tuba fitting seats using the spare brake line fitting nuts to press the seats into place_ Do not allow the seats to become cockad during installation and be sure the seats are completely bottomed. II Remove the brake line litting nuts, remove all chips or bUfrs and rinse the master cylinder with alcohol or brake cleaning solvent. Blowout all passages using fillered compressed air. 10 Inspect the master cylinder bore for severe scoring, corrosion, pitting and damage. Replace the master cylinde r wi th a new one if the imperfections in the bore cannot be removed by honing. 11 Before reassembly, dip each compon ent in clean brake fluid. 12 On models built through 1975, install the piston washer, rear seal. protector and return spring on the secondary piston. Install the O-ring and front seal on the secondary Piston. Be sure tha flat faces of both seals lace each other.
RE AR BFlA KE
MAS TER CYL· INDER ACTUATING U N'
FRONT BflAKE
.'
.'
o-RING
.'
OlJTLET
PISTON STOP
PISTON
Fig.9.22
Typical dual piston master cyl inder co mponents - explodad view (Sec ' S)
Ch apter 9 Brakes
Fig . 9.23
Tube seet reffiOvallSec 1S)
9-13
13 On 1975Ihrough 1986 models, ioslalllOO piS10ll cups on lhe secondary piston. The cup installed in the groove al the end 01 the piston should have its lip lacing away from Ihe piston and the ne)(t cup lip should face toward Ihe pislon. Install the seal protector. piston seal. spring relalner and spring on the secondary Piston. The piston seal lip should face the interior of Ihe cylinder bore when the assembly Is Installed. 14 Lubricate the piston bore and piston !l550mblie:> with cloan brake fluid. 15 Install the secondary piston assembly. spring end first, in tho piston bore. Press the primary piston in using tho push rod Of a 1001 Secure Ihe pistons in the bore wllh the snap-ring. 16 00 models so equipped. install the pilton stop, using a new O-nng. 17 On check valve-equipped models. place the new check valves over the check valve springs and install them in the fluid outlet holes. spring end lirst. 18 InstIll the lube seats iii removed) and press them into place with Ihe brake line litting nuts. 19 On vtJhicl8s without power brakes. Install the pushrod and boot assembly. 20 8elore tho master cylindor is inStllllod on the vehicle, the unit should be bled. Refer to Section 16 lor the master cylinder bleedlllg procedure.
9
10-0
Chapter 10
Chassis electrical system
Contents Batterv check and maintenance . . ...... • ... Bulb replacement ........ . . . . Directional switch - check end replacement . . . Electrical troubleshooting - general information Fuses and fusible links - general information General infannelion ......••.• . .. . .......... . Headlight dimmer switch - check, removal tlnd instililation ... .. . .. . . . .... . . . . . . Headlight switch - removal and installation
Chapter 1
Headlight feplacament ... . . . . . . .. . .... . . . Horn - check and replacement ....... . .. . . Ignition switch - ramoval and installation. Instrument cluster - removal and installation Neutral sa fety switch - check. adjustment and repl;lcemenl Speedometer - removal and installation Speedometer cable - check. removal and installation Windshield wiper motor - removal and installation
5 12 2
, , 7
Specifications
Bul b application F- and l ·head four·cvlinder engine (6-volt system) Headlight . . . ........ . Perking light Perk and directional signal light .. . . . .... . Stop, tail and directional signal light . • _ ... . Instrument cluster lights .. . ... .... . .. .. . . InSHument light . . . . . . . . . . . . . . . .. . .. . Flesher and directional signal lights .............. . F-head four-cvlinder and V6 engines 11 2-voh system) Headlight .. . .. .. .. .. .. . . .... . . ... . . . . Parking and directional signal lights Ucense plate light .. . Side marker light ... . Instrument cluster light Backup light indicator Hazilrd flasher light .. Brake warning light .. All others (1972 and 1973) Headlight ........ . Parking and directional SIgnal lights Side marker lights . Backup light . .. .. .. .. . . . . .. . . license plate light . . . . . . . . . . . . . .... . . . ... .. .. . Stop, tail and diractional signal light Brake failure light Charge. directionel signal and high beam lights Directional lignal flasher . . . . . .. .. Glove box light Hazard warning. heater controls. instrument cluster and oil pressure gauge lights ........ . All others (1974 through 1986) Headlight Parking and directional signal lights Side marker lights ...... . . . . .. . . ... .. . . . . Backup light . . .. . . . . . Stop, tail and directional signal light Instrument cluster lights ....••.•.... Indicator lights .. . .. .. .. . ... . .. . . ...... . Clock light ...... .. . . ... . .. . . .. . . . . . . Automatic transmission column light . ••.•.... Tachometer light . . . .. .. . .. . . . . •. . . ........ . Radio light
Bulb type 5040·5 or 6006
"
1158 1158 51
55 P229D 6012 1157NA 1155
194 57 " 56
57 57
6012 1157NA
19. 1156 1155 1157
57
"
Tvpe 144
170
57 6014 1157
19. 1156 1157
""
1892 1892 1895 1893
•
13 6 14
Chapter 76
10 11 9
Chapter 10 Chassis electrical system
10-1
Fuse app lication F- and l-head four-cylinder engine (6-volt system! Heater Directional signal F and L-head four-cylinder and V6 engines Healer . Backup light Windshield Wiper Directional signal 4-way flasher Brake warning light All others (1972 through 1914) Directional Signal Backup lights Brake warning light Cigar lighter Air-conditioner Heater 4-way flasher Headlight Circuit breaker Control panel circuit breaker All others n975 through 1977) Directional Signal Backup lights 1975 1976 and 1911 Brake warrllng light 1975 1976 and 1977 Cigar lighter All-conditioner Healer Headlight clrcun breaker Instrument cluster Windshield washer/Wiper Tall and stop lights RadiO Panel IiQhl~ All others (19781hrough 1986)
Amperage
14 14 9
14 14 9
14 9 9 9 9
14 25 15
14 25 25 10
9 15 9 3 15 25 25 24 3 10
20 10 (5 amp ill-line)
3 Refer to fuse panel
1 Genllr.1 Information This Chapter covers the repair and s9fvice procedures for the various electrical components nOt associated With the engine. as well as general inlormation coocermng troubleshooting the electrical circuits. loforma· tion about the battery, generetor or elternator, distributor end starter motor cen be found in Chapter 5. Thlt electrICal system IS a 6·volt (early models! or 12-volt, negetive ground type with power supplied by a generator (eady models! or alternator_ It should be noted thet whenever portions 01 the electrical system are worked on, the negetlve battltry cable should be disconnected to prevent electrical shOll!! endfOl fires.
2
Electrlcel tro ubleshooting - general Info rmation
A typical electrical cirCUit consists of all electrical component, elly .witches. relays, mOIOrs, etc. related 10 that component and the wlr· Ing and connectors that conllect the component 10 both the battery and the chassis. To aid 10 locating a problem in any electrical circuit, winng diagrams for each model are Included at the end o f this Chapter. Before tackling allY troublesome electrical circuit, first study the ap· proprlate diagrams to get a complete understanding 01 what makes up that IndiVidual Circuit. Trouble spots. for instance, can often be nar· rowed dowll by noting il other components related to that circuit are operating properly or not. If several componltnts or circuitslail at one time, chalices are the problem lies in the fuse Of ground connectioll, as several CIICU,IS often are routed through thlt same fuse and groulld connections. Electrical problems oftltn stem from Simple causes. such as loose or corroded connections. a blown fuse or meltad fusible link. Prior to
any electrical troubleshooting, always visually check the condition of the fuse. wires and connections In the problem circuit. If testlllg instrumellts are goillg to be utili:ted, use the diagrams to plao ahead of lime where you will make Ihe Ilecessary connections in order to accurately pillpoint the trouble spot. The basic tooll needed lor electrical troubleshooting include a cir· cuit tester or voltmeter Ie 12-volt bulb with a set of test leads can also be usedl. a continuity tester (which includes a bulb, battery and set of telt leads) alld a jumper wire. preferably with a circuit breaker incorporated, which can be used to bypass electrical components. Voltage checks should be perlormltd if a circuit is not fUllctioning properly. Connect olle lead of a circuit tester to either the negative bat· tery terminal or a known good ground. Connect the other lead to a Call· nectar in the circuit being tested, prelerebly nearest to the battery 01 fuse. II the bulb 01 the tester goet on, vohage it reaching that POlOt {which means the part of the circuit between that connector and the banery is problem free l. Continue checking along the entire circuit in the .ame fashion. When you reach I point where no voltage Is pres ent. the problem lies between there and the last good test point. Most of the time the problem is due to a loose connection. Keep In mmd thet .Omll circuits receive voltege only when the ignition kay is in the
Accl!t'$ory or Run position. A me thod of finding shorts in e circuit is to remove the fuse lind COIlnect a lest light or voltmeter in its place to the luse lerminals. There should be no load in the cirCUit. Move the wiring harness from side-toside while watching the test light. If the bulb goel on, there II a short to ground somewhere in that area. probably where Insulation has rubbed all of a wi re. The .ame test can be performed on other components of the circuit, including the switch. A ground check .hould be done to see if a component is groullded properly Disconnect the banery and COl1nect one lead of a sell-powered test light such 81 a continuity teSter to a known good ground. Connect the othltr lead to the wire or ground coonection being tested. It the bulb goes on. the groulld is good. If the bulb does nOI go on. the
10
10-2
Chapter 10 Chassis electrical syst em
ground IS not good. A continuity check is performed to see if a circuit, section of circuit or individual component is passing electricity through il properly. Disconnect the battery and connect one lead of II self-powered hIS! !tghl such as II continuity tester to one end 01 the circuit. II the bulb goes on, there is continuity. which means the circuit is passing electricity through it properly. Switches can be checked in Ihe same way. Remember Ihat all electrical circuits life composed basically of elec-
tricity running from the battery, through the wires, switches, relays, etc. 10 the electrical component (light bulb, motor, etc. I. From there it is run to the body Iground) where it is passed beck to the battery. Any electrical problem is basically lin interruption in the flow of electricity to and from the battery.
3
Fuses Ind fusible links
~
ganerll Information
The electrical circuits of the vehicle are protected by e combination of fuses lind fusible links. The fuse panel is located under the dash in the main electrical harness. Later models also incorporete circuit breakers for certain circuits and components. Elch of the fuses is designed to protect a specific circuit as identified on the fuse panel. If an electricel component has failed, your first check shold be the fuse. A fuse which has "blown" can be readily identified by inspecting the metal element inside the housing. If the element is broken, the fuse is inoperable end should be repleced with a new one. Circuit breakers reset automatically when the circuit is turned off. Fuses can be replaced by pulling out the old one and pushing in the new one. It is important that the correct fuse be installed. The different electrical circuits naed varying amounts of protection, indicated by the amperage rating on the fuse. A fuse with too Iowa rating will blow prematurely, while a fuse with too high 8 rating may not blow soon enough to avoid serious damage to other components or the wiring. Never bypess the fuse with metal or foil. Serious damage to the electrical system could result. If the repillcement fuse immediately fails, do not replace it with another until the cause of the problem is isolated and corrected. In most
Fig. 10.2
cases it will be II short cirCUli In the wiring caused by a broken or deteriorated wire. In addition to fuses, the electrical system incorporates fusible links for overload protection. These links are used in circuits which are not ordinarily fused. The fusible links are located in the engine compartment and are replaced by unsoldering the ends lind then soldering a 'eplacement in place. The link must be wrapped with electrical tape. If an electrical failure occurs in one of the circuits protected by a fusi· ble link, check the link first. If the link is melted, replace it with a new one, but only after checking snd correcting the electrical fault that cllused the failure.
Fig. 10.1
Typical late model f use psnel (Sec 3)
Typical later model headlight and perkingldlrectionel light components - elCploded view (Sec 41
Chapter 10 Chassis electrical system 4
Id
Headlight replacement
1 Remove the headlight door attaching screw. 2 Pull the headUght door out slightly at the bottom, push up to disengage the upper retaining tab and lift the door off. 3 Loosen the headlight retaining ring screws, rotete the ring to disengage it and lift it away. 4 Puilihe headlight out of the shell, unplug Ihe connector and remove the headlighl. 5 Plug Ihe connector securely into the new headlight. 6 Placa the headlight in the shell and instalilhe retaining ring and door.
Fig. 10.3 Early model parking light components - allploded view {Sec 51
3 tiUlO 4 Gasket
, Bezel 2 Lens
10-3
5 Housing 6 Screw
5
Bulb replacement
Parking/directional signa/light 1 Remova the retaining screws, bezel, lens and gasket. Remove Ihe bulb from Ihe housing. 2 Install the new bulb. followed by the gasket, lans and bezel.
Side marker light 3 4 5
Remova the retaining screws and lift off Ihe side marker light lens. Grasp the bulb firmly and pull it from the socket. Insert the naw bulb and install the lens and screws.
Tail, stop, license and backup light Fig. 10.4
Early model tail, stop and directional light compone nts {Sec 51 _
1 Screw 2 Lens 3 Gasket
4 Bulb
5 Housing and wire assembly
6 Nut and washer
6 Remove the taillight lens, screws and gasket. 7 On laler models, the backup light bulb is located in the taillight housing and the stop light bulb on the left side also illuminates the license plate. S On early models, the backup light is contained in 8 separate housing. Remove the snap·rlng, lens and gasket to gain access t o the bulb. 9 Replacement is the reverse of removal.
HOUSING
SIDE MARKER· RIGHT SIOIE !WITHSIDIE·MOUNTEO SPARE TIRE ONL YI SIDE MARIIlER lIGHT BUla
, MARKER LlGHTLEH SlOE
10 TAILSTOP. DIRECTIONAl lIGHT aula
ALSO illUMINATES lICENSE PlATE ON lEFT SIDE OF VEHIClE
Fig. 10.5
Typical latar model taillight allsembly component, (Sec 51
10-4 6
Chapter 10 Chassis electrical system
Ignition switch -
9 Remove the key end push on the switch body so the notched be~el can be easily installed with the notches aligned with the nOlch pins. 10 Rotate the bezel clockwise to lock it in position with the word
removal and installation
1953 through 1975 models
"Starter" at the lOp.
, The ignition switch on these models is localed in the instrument panel adjacent to the steering column. 2 The switch is held in place by 8 threaded bezel nut and, on leter models, e tension spring. To remove the switch, press the body 01 the switch toward the instrument penel until the bezel cen be turned counterclockwise and released from the notch pins. 3 Remove the bezel Bnd pull the switch body back to release the spring tension. 4 lower the switch from the dash and unplug it from the wiring harness. 5 To remove the cylinder from the switch, turn the switch to the On position and insert a piece of heavy wire through the cylinder release hole. Depress the spring loaded brass retainer ring until it clears the retaining ridge, allowing the cylinder to be withdrawn. 6 To Install the cylinder, align Ihe tang with the slot in the case. depress Ihe retainer and insert the cylinder until the retainer snaps into place. 7 To install Iha switch, place the main compression spring on the switch body and then install the body in the instrument panel from the rear. 8 Insert the ignition key in the Off position end turn the switch body unTil the key Is streight up end down.
1976 through 1986 models 11 The ignition switch on these models is located on the lower sec· tion of the steering column and is connected to the key lock assembly by a remote lock rod. Two types of ignition switches are used: one for standard steering columns and another for tilt columns. Removal 12 To remove either type of switch, place tha key in the Off/lack position and remove the two switch mounting screws. Disconnect the switch from tha remote rod, unplug the harness connector and remove the switch from the column. Installation Istandard column) 13 Position the switch as shown in the accompanying illustration, with the actuator rod disconnected. 14 Move the slider to the extreme left. or Accessory position, position the actuator rod in the slider hole and attach the switch to the steering column taking care not to move the slider out of the detent. The right side of the switch must be toward the steering wheel. 15 Hold the key in the Accessory position and then push the SWitch down the column slightly to remove the slack from the actuator rod. 16 Tighten the mounting screws securely and install the white connector, followed by the black connector.
BEZEL RETAINING TABS TENSION SPRING
-4')~~~\
BEZEL
FIg . l0.6 Early model backup light components - exploded viaw (Sec 5) , Snap-ring
2 Lens
3 Gasket 4 Bulb
5 Housing
LOCK ROLE,. .O HOLE Fig. 10.7
Typical dash mounted Ignition switch (Sec 61
and wire
STURING _ I l l
¢ TllTCOl~
STANOARD COLUMN
Fig.l0.8
1976 through 1983 modal Ignition switch actuator rod Installation datails - standard column (Sec 6)
Flg. 10.9
1976 through 1983 model Ignition switch actuator rod installation deleils -lill column (Sec 6)
Chapter 10 Chassis electrical system (tilt column) 17 With the actuator rod disconnected. place the SWitch in positIon as shown in the accompanying illustration. 18 Move the slider to the extreme right or Accessory position. the right side of the switch must lace down. eway Irom the steering column. 19 Position the actuator fod in the slider hole and attach the switch to the steering column wIth the screws finger tight. 20 Push the switch down lightly to remove the play from the actuator rod while holding the key in the Accessory position and taking care not to move the slider out 01 the detent. 21 Tighten the screws securely and plug in the white connector. fOllow· ed by the black connector. Inltll~lIjon
7 Headlight .wltch -
removal lind In.tllilation
1 2 3
Disconnect the negative bettery cable from the battery. Pull the light switch knob out to the On position. Remove the switch knob. On some models the knob is retained by a setscrew or locknut while on others the entire knob and stem essembly can be withdrawn from the switch aher pressing the release button on the switch. 4 Remove the switch retaining nut and bezel. 5 Lower the switch from the dllsh panel. disconnect it from the wir· ing harness and remove it. 6 To install the switch. connect the wi ring harness. place the switch
10-5
in position in the dash end install the nut and bezel. Install t he control knob. 7 Connect the battery cable.
8
Headlight dimmer switch - check. removil end lnltilletion
The switch operation can be checked with a test light. Connect one test light lead to the switch input terminel end probe each output terminal with the other lead as the switch is operated. The current flow should alternate from one output terminel to the other as the switch is operated. Replece a faulty switch with II new one as follows: 2 Disconnect the negative battery csble from the battery. 3 In the engine compsrtment, disconnect the wiring hsrness, remove the retsining screws and separate the dimmer switch from the flOOf~ board. 4 To install the switch. place it in position. install the retsining screws and connect the wiring harness. 5 Connect the battery cable to the battery. 9
Windshield wiper motor - removal and in.tallation
1953 through 1970 models 1 Disconnect the vscuum hose, remove the mounting screws and lift the motor away. Installation is the reverse of removal.
Fig. 10.10 Early model headlight switch termin als (Sec 7) 1 88rrery 2 Resr fights 3 Headlights
4 Parking fights 5 Au){ifisry
Fig. 10.11
late model headlight switch !Sec 71
I'1VOT SHAn '-NO ARM
10
Fig. 10.12
Headlight dimmer switch terminals (Sec 81
Flg.1 0.1 3 Windshield wlpar motor component layout {1970 through 1976 modalsl (Sac 9)
10-6
Chapter 10 Chassis electrical system
I'IVOT I""""
A N D ANM
C""NK M .. O MOTDII
Fig. 10.14 1977 through 1986 model windshield wiper components (Sec 9)
Fig. 10.15 Removing th e steering co lumn lock plate (Sec 121
Fig. 10.16 Directional signal assembly installation details [Sec 121
10
1971 through 1975 models Remove the desh crash pad iii equippedL J Remove the plastic hole plug from the extreme lefl side of the bottom of the windshield frame air duct. 4 Disconnect the drive link from the motor crank. 5 Mark their locations and disconnect the wires from the switch. 6 Remove the cover and mOlor 7 Prior to installation, apply 8 beed of waterproof sealant around the contact surface of the motor cover. Install the motor, followed by the 2
cover. 8
Speedometer - removal and installation
1 Remove the instrument cluster (Section 14). 2 Carefully uncrimp the bezel outer lip and remove the outer bezel. glass and retaining bezel 3 Remove the mountmg screws and separate the speedometer from the housing. 4 Install the speedometer in the housing. ChOCk the inSide of the glass to make sure it is clean and free of fingerprints and install it along With the bezels. Carefully crimp the outer bezel In place in four places. 5 Inslall the instumen! cluster.
Connect the wires to the switch and the drive link to t he motor
crank . 9 Install the plastic hole plug and !if equipped 1 the crash pad.
1976 through 1986 models 10 Remove the crash pad (if equippedl and wiper motor cover. 11 Remove the hold-down knobs and fold the windshield down. '2 Remove the left access hole cover and disconnect Ihe drive link from the left wiper pivot. 13 Unplug the wiring harness from the switch. 14 Remove the mounting screws and lift the motor from the vehicle. 15 Place the wipe r motor in position, install the screws and connect the wiring harness to the switch. 16 Install the access hole cover and raise the windShield. 17 Install the crash pad !if equipped) and motor cover.
11
Speedometer cable - check. removal and Installation
A damaged or kinked speedometer cable is indicated if the speedometer is noisy or the needle action is jerky. A lack of lubrication can also cause these symptoms and can be corrected by disconnecting the cable at the speedometer head and squirting powdarad graphite lubricant into the cable end and head contact surfaces. 2 To remove the speedometer. disconnect the cable at the speedome ter head and transmission. remove the grommet and pull the cable into the engine compartment. 3 To check the cable. place it in an inverted "U" shape on a flat surface and cross the ends. Hold one end of the cable core lightly while turning the other end. The turning action should be smooth: if the core jerks or jumps. the ceble should be replac ed with a new one. 4 Installalion is the reverse 01 removal. Be sure to lubricate the cable and speedometer head With graphite.
10-7
Chapter 10 Chassis electrical system
~A'D"fl
Fig. 10.18 1916 through 1986 relay equipped horn system tenninals !Sec 13) JUliN SIGNAL HARNESS Fig. 10.17 Typical non-relay equipped horn system leyout ISec 131
12
Directional .whch - check and replacement
Burned 01,11 bulbs and loose connections are the most common causes 01 problems in the directional Signal system. If the flashing fate is about tWice the normal rate, a shorted out bulb is Indicated. If there il no ,Ignal et any bulb, check the fuse. If the fu.e is good, install a Il8W flesher UnJ! 1I0cated in the luse panel on most modelsl. If the bulbs, fuse. flasher and wiring check out correctly, replace Ihe directional swilCh. 2 Disconnect the negative battery cable from the battery. 3 On models built through 1975, the directional SWitch Is clemped 10 the left Side of the steering column by two Allen head screws. Replecement is accomplished by unplugging the electrical connector, removing the screws and lifting the SWitch away Irom the steering colurnn. InStalialion is the reverse 01 removal. -4 On 1976 fhrough 1986 models, the switCh IS Iocaled in Ihe steering column. Remove the horn button by pulling straight oul. Remove the screws. bushing. receiver, spring and sleellng wheel and nut (Chapler HI. 5 Lilt the IClCk plate cover and use a comprassor 1001 (AMC J-23653) to depress the lock plate as shown In the Illustration. 6 Pry the round wire snap-ring from the steering shaft groove and remove the tool. snap·rlng. lock plate, directional signal canceling cam, upper bearing preload spring and thrust wesher hom the steering shalt. 7 Dapress the ha~ard warning light switch on the right side of the column and turn II in a counterclockwise dlrreclion to remove it. 8 Remove Ihe directional switch wire harnell connector block from the mounting bracket on Ihe right side ollhe column. On models equipped with aflauto~tic trlmsmisslofl. lr'IS8rt a stiff wire such as a paper clip Into the lock tab retaining the shift quadrant light wire In the conneclor block. 9 Remove the screws and separata the dlreclional SWitch and wirIng harness Irom the column. 10 To install the switch, guide the wiring hame6li inlO pOSition and align the SWitch assembly with the actuating lever pivot seated in the upper housing pivot boss and install the screws. 11 Inltall the switch laver and actuate the sWllch to meke sure Ihe assembly is properly instelled. 12 Piace the thrust washer, spring end directional signa! canceling cam in place on the upper end of the steeling she\t_ 13 Align the lOCk plale sp~rres with lhe steering shah splines and place the lock plate in pOSilion so the directional signal canceling cam shah protrudes through the dogleg opening in the lockplate. 14 Inllall Ihe snap-ring, lock plate cover and steering wheel. 15 Inllalilha steering wheel washer and nUl, followed by the spring wilh the raised side up 16 'nstall tha receivel and bushing, making sure Ihe receiver movas lreely aher Ihe bushing screws are tightened. 17 Align Ihe nOlch on the raceivar with Ihe nib on Iha horn bunon and push the bunon in unlil it snaps intO place.
Fig. 10.19 Instrument clustar IIsambly components (Sec 13) 13
Horn - ch9(:k and repla cement
All models a18 equIpped with a horn system consisting of • Single horn mounted on the left inner lender well. Battery power aClivates the horn when the horn button is deprassed. completing tha circuit. 2 If the horn does nOI sound. use a test Ilghl or voltmeter 10 chack the red (battery feed) wire. 3 A lack of vollage indicalas 8 shon circuit or, on later models laltel 19751, a burned out lusible link. 4 InspeCI the wiring between the horn. relay (on models after 1976\ end battery for loose connections, corroded terminals and Irayed wires. The horn assembly is attached to the lender well with cadmium platad Icorrosion resistant) scraws. Maka sure they hava not been repleced wilh non-plated scraws which may not ground the horn properly. 5 On relay equipped systems !'976 through 1986), ground the number 2 lermmal 01 the relay with a jumper wire. If the hom sounds. the relay and hom are operating properly. If the hom does not souod. ground the number 2 terminal and connect a jumper wire between lhe number I and number 3 terminals. If the horn sounds. the relay is faulty. The relay is encased in plastic aod is located in the w,ring harness under the leh side of the instrumenl panel. If the relay is good, connect a jumper wire from the horn base to a good ground and repeat the lesls. If the hom does not operate, it Is faulty aod must be replaced With a new one 6 On non-relay equipped models, if battery power is reaching the horn, ground the black wire with the yellow tracer. If the horn does nol sound, Ihe horn 8ssembly is faulty and should be replaced with a new one. If Ihe horn operates, there is a fault in the Iteering column wiring. 7 To check the steering column wiring on all models, disconnect the negative banery cable, remova the horn button and inspect the hom conlaCI and spring lor damege and corrosion. S To replace the horn, disconnect Ihe wiring harness plug. ramove the screws and lilt the assembly Irom the inner fender well. Installation is the revarse of removal.
14
Instrument cluster - removal and InstaUallon
I Olsconn.ect the negative bauery cabla from the battary. 2 Disconnect the speedometer cable ISection 11). 3 Remove Ihe cluster mounting screws or nuts aod lower the cluster assembly. On some models it will be necessary to remove twO Icrew. and lower Ihe healer control bracket, 4 Mark their locations and remove Ihe wires Bnd the light bulbi. 5 Separate the cluster from the da,h. 6 To InSlaH the cluster, connect the bulbs and wires. place the cluster assembly in position and instal! Ihe mount,ng screws or nuts. Connect Ihe speedometer cable. 7 Connect Ihe negative battery cable.
10
10-8
Chapter 10 Chassis electrical system
Fig. 10.20 Left headlIght
74
Left parking light RIghI parking 'Ight RIghi headlight
75 7.
5
Generatof
7'
6
Dlstnbulor Voltage regulator
•• 20
NegatIve ground cable Bartery PositIVe cable
Fuel gauge sending unil Tal/and Slop lIght
Starting SWitch
27 22 23 2' 25
Hom
26
JunctlOt1 bJocIc
7 2 3
• 7
••
7O
"
72 73
StartIng motor
Fig _ 10.21
CJ·2A wiring diagram
77
IgmtlOn COIl IgmllOfl sWItch
Ammeter Dash light rell-tale light Fue/gauge Ughl SWlreh
LIght SWItch CircUlI breaker DImmer SWItch
Stop light SWitch
Early model CJ-38 wiring diag,.m
7 Lelt headlight 2 Left parking fIght 3 Right pafking /lgM
•5 Generator
Right headlight
6 Valtage regula/or
73 Dash light 7' Indlcatof light 75 Fuel gauge 7' Igm tion SWitch 77 Ught switch
78 Fuel gauge sending
7 Negative grOlJnd
••
cBbl.
Distributor Igmtion call
7O Battery
""
Stafte, molor
Ammeter
7' 20 27 22 23
unit Tail and stop lIght
Dimmer SWitch Stop light switch Horn
Junction block
10-9
Chapter 10 Chassis electrical system
c;: .?
•
3,
-.'
w iri ng diagram I
2 3 4 5
• 7 8
•
/0 /I
12 13 14 15 /6
Utfr hetldlight /..iIft parking fight Right parking light Right headlight NegatlWJ ground cable Generator DlstributOf Battary PDs/flWJ c8ble Vol/8ge regula tor Starter motor Ignition coil Signal flasher Starter switch Ammeter Dash light
17 Indicator fight 18 Fuel gauge Ignition switch 20 Fuel gauge sending unit 21 Horn button 22 Directional signal sWitch 23 Light switch 24 Right ta;1 and stop light 25 Lef t tail and stop light 2. Dimmer switch 27 Stop light switch 28 Horn 2. Junction block
"
I
uft headlIght signal ligh t
3 Righ t parking and
• 7 8
•
10 /I
12 13 14 15 /6 17
18 79
c::::::- ----€
-
late r modlll CJ-3B (I her I lIrllll number 355 22) wiring diag ram
2 uft parking and
4 5
~~ = .ali
Fig . 10.23
l l t l ' model CJ-3 B (up t o .erlal numbe r 3552 2 1
0 ~
,"
,-'
~
Fig . 10.22
1
"'I . "
signal light Right headlight Bat/ery ground strap Gemuator Ignition coif Junction block Horn Dlstfibutor Battery Voltage regulatof Starter motor Oil pressure sending unit COO/8n! temperature sanding Unit Solftnoid switch Foot dimmer switch Stop fight sWitch Direc tion81 signal flaSher
20 Fusa 21 Light switch 22 Directional SJgnal switch
23 Horn button 24 Ignition and startar switch
25 Instrumen' cluster A Upper baam indica tor 8 Turn signal indicator C Instrument lights 0 Oil pressure indica/()I" E Ch8rg;ng indicetOf F Templlreture g8uge G Fuel gauge H Instrument voltage regulator 2' Fuel g8uge (8nk unit 27 Lsft tail and stop light 28 Right tall and stop light
10
10-10
Chapter 10 Chassis electrical system
"
Ag . 10.24 CJ· 5 )bafor, • • rlll number 49248) and CJ· 6 )befor' •• rlal number 1257711whh F-h •• d four-cylinder Inglnl' wiring diagram
,
lIIfr hetldlight 2 lIItr parking light
17 Ignition switch
3 Right perking light
19 Directional signal switch 20 Right tllif and stop light 2' aft tsil snd stop light 22 Fuel glJUge sending unit 23 Light switch 2' S top light switch 25 Dimmer switch 26 OJ( pressure sending unit 27 Horn 28 Junction block
•5
Right hHdfight N~.tiWJ ground cab/II
6 GaMr.tor 7 Distributor 8 EMttsry
•
'0
" '2
,.
'3 '5 '6
Positive csble Ignition coil Cool8nt tempfJlllturrt sending unit St8rter motor \IoIt8ge r8gu~tor 5t8rte, switch Fuse Instrument cluster
'8 Horn button
Fig. 10.25 CJ-5 tafte' ,erial number 49248) and CJ-6 )afta, •• tlal number 1257711wlth F-head four-cylinder angina) wiring diagram
,
Left hetldfighr
2 Left p"rk,ing (md 3
•5
dif6Criona/l,ght Right perking lind dlrtleriana/light Right headlight Battery ground cable Geneflltof
6 7 Disrributor 8 Ignition coil
•
'0
" A
B
C 0 E F G H
Stsrting motor \IoIts~ regul8tor Instrument cluster Upper bum Indicetor Turn sign81 indicator Instrument lights Oil pressure indicator Cherging indicetof TemperlJture gauge Fuel glJUge Instrument voltage regulator
12 RIght rail ana stop fight
'3 Left tai/and stop light
14 Fuel gauge tank unit
'5 Ignition and starter SWitch
'6 Horn button
17 Directional signsl switch '8 Light SWitch Stop light switch 20 Foot dimmer switch 2' Directional signal flasher 22 Fuse 23 Solenoid switch 2' Temperature sending unit 25 Oil pressure signel switch 26 Horn 27 Junction block
,.
10-11
Chapter 10 Chassis electrical system
~
~J; Fig. 10.26
, 2 3
•5
• 7
8
• '0 " '2 ,.'3
,. '5
17
'8
19 A
8 C 0
CJ· 5 and CJ·6 iwith later model F·head four cylinder englnel wiring diagram
Left headlight Left parking and Signal light Righ t parking and signal light RIght heedllght GenelatOf Ignition distfibutol Oil pressure sending unit Junction block Hom Foot dimmel switch St op ligh t switch - f ront Coolant tempelawre sending unit Ignition coil Staffer motOl Battery ground cable Battery ImItege regulator Fuse Instrument cluster Hi-beam Indicatol Auxiliary Instlument lights Oil pteSSUle indicalOl
E Charging indica t or F Tempera ture indicator G Fuel gauge H Inst rument voltage reguletol 20 IgnitIOn I!Jnd stl!Jlter swit ch 2' F~sher (direction81 signalJ 22 Horn burton 23 Directional signal SWitch 2' 4 -way f/ashel s w itch 25 Flasher /4-way) 2. Fuse 27 M ain light switch 28 St op light switch - reel 2' Fuel gauge tenk unit 30 BlICk·up light swit ch 3' Right tall and stop fight 32 Right back·up light 33 Lef t back-up light 3' Left tail and slop ligh t
Fig. 10.27
,
Earlv model with V6 engina wiring diagram
Lef t headligh t
2 Left plJfking and signal light
3 Right palking end
•5
•
7 8
•
10
"
,.,. '2 '3 '5
17
'8 19
20 A
8
signal light Right headlight ImIt age IBgU1atOl Alt erna tor Oil pffJssule sender Cooolant t empera/ule sendel Ignition dis tribu/ol Junct ion block Hom Igni tion coil Steffel mo tOl Battery ground ceblt! Foo t dimmer switch Stop ligh t sw i tch - front Balfast resis tor Flashel (directional signal) Fusa Inst rument cluster Hi-b eam indicator Auxiliary
Instrument lights Oil pressure indicator Charging indica tor Temperl!Jtute indicl!Jtor Fuel gauge H Instlument voltage regulatOf 2' Ignition and starter switch 22 Hom burton 23 Directional signal switch 2. 4 -way flasher switch 25 Flashal (4 -wey) 2. Fuse 27 M ain light switch 28 Stop light switch - lfIar 2' Fuel gllUge tenk unit 3D Back-up light SWitch 3 ' Right t all and stop light 32 Right bllCk-vp light 33 Le ft beck-up light 3' Left tall and Slap ligh t
C 0 E F G
10
10-12
Chapter 10 Chassis electrical system
Fig. 10.28
Typlcal leter
model with F·head fourcylinder englna wiring diagram
I Left headlight 2 LBft parking and signal light 3 Right parking end signa/light
4 5 6 7 8
Right headlight M8rlcer light - 8mbe' Generator Distributor Ignition coil
9 Starter motor 10 Ba1/ery ground cable " 12-volt battery 12 Flasher (directional signal)
13 Instrument cluster A Hi-beam indicator B Aul(iliary
C Instrument lights D Oif pressure indicator E Ch8f9m9 indicator
F Temperature indicator
G Fuel gauge indicator
H Instrument voltage indicator 14 Ignition and starter switch 15 Horn button 16 Directional signal switch 17 4-way flasher switch 18 Flesher (4-wayl 19 Windshield wiper motor switch
20 21 22 23 24 25 26 27 28 29 30
Main light switch Fuel gauge tank unit 8ack·up light switch Marker light - red Right tsil end stop light Right beck-up light Left back-up light Right tail and stop light Marker light - red Stop light switch Foot dimmer switch
31 Windshield wiper motor assembly 32 Voltage regulator 33 Coolant temperature sendmg umt 34 Oil pressure sending umt 35 Spark plugs and cables 36 Horn 37 Junction block 38 Marker light - amber
22 23 24 25 26 27 28 29 30
Marker light - amber Right tail and stop light Right back-up light Lsfr back·up light Left tail and stop light Marker light - red Stop light signal Foot dimmer switch Windshield wiper motor assembly
31 32 33 34
Fig. 10.29 later model with V6 engine wiring diagram ,
Left headlight
2 Left parking rmd signa/ light 3 Right parking and signal
light 4 RighI headlight 5
6 7 8 9 to 11
12 A 8 C D E F G
H 13
Merker light -
amber
Alternator Volrage regulator Starter motor Bllttery ground cable t2-volt battery Flasher (directional signal} Instrument cluster Hi-beam indicator Auxiliary Instrument lights Oil pressure indicator Charging indicator Temparature Indicator Fuel gauge indicator Instrument voltage regulator Ignition and starter switch
.~ 14 Horn button 15 Directional signal switch 16 4·way flasher switch 17 Flasher (4-wayJ 18 Windshield wiper motor switch 19 MaIn /fght SWitch 20 Fuel gauge tank unit 21 8ack·up light switch
35 36 37 38
8allast resistor Igmtion coil Spark plugs and cables Coolant temperature sending unit Oil pressure sending unit Horn Junction block Merker light - amber
10-13
Chapter 10 Chassis electrical syst em
, , 1>11 BEAMI TO I"STR CLUSTER IHI!!IE .. M INO I 1>11 BEAMI TO HE .. OL ...... P CONN 11'11 If"""l I IG'I SWITCH IIG'I HRM ITO INSTR.CLUSTER VOLT REGUL .. lOR CONN ~~~~:~~GHT TO ~~~~~~G SW TO ~II;~~~ SW 10 CLUSTER L.. MP RIGHT TURN CONN I.. LTERN .. TOR "'UII. lUIM.! TO INSTil CH ... RGE IND. TO INSTR VOLT REG. CONN lOlL PIIESS SENO ER ITOOIL PIIESS.INO TO IN5TII _ VOLT IIEG CONN
~~G~:~;fT
TO
~~~~~~G 5W
TO
~I(;~~~ SW
TOCLutTlII
LAM'~m
TURN
IOIlOUNO I fl"'~MTG TO LIGHT SW . WI'fIl' H.. ZAIIO LIOHT' CONN (FII .. ME H ... IIN G"'S G'" TANIe UNIT, TO INSTR CLutTlII G"S GA. INDICA TOil LIGHT S'rOITCH "I" TEIIM TO INSTR CLUSTER LIGHTS TO HE"'UR L...... ' LT SWlTCH iTEAM II 10 l ...... "SLIOHH::.i.~~ER TO INSTR ClUSHIIL",M' SPLICE TO CON ... IST ... IIT SOLENOID lI... n . lEIIM .! IGNITION SWITCH IIG1\I TEIIM.I TO CONN. COIL 101 HIIM IGNITION SWITCH IST ... RT HilMI 10 CONN IST,,"TMOTOR SOLENOID START TEIIM I fOOT DIMMER SWITCH ··B·· HRM TO LIGHT SWITCH "H'" TEIIM LIGHT SWITCH IAn II 21 TOCONN ISlO' LITE SW_I LIGHT SWITCH '" A" nllM TO CONN (f ll .. ME H.. RNESS·T... l l LIOHTSI LIGHT SWHCH ··R" TEIIM TO CONN. (P"'"Ie . TERM,
CONN"~~:~~~F"'T"N
TO HAZARD WARN SW TO DIRECT SIG SW ILEFT TURNI
CONN -FRAME HARN AE... A IIIGHT TO HAZAAD WAAN SW TO
~1';E5c..:- ·IAIOHT1U AN )
SPLICE TO CON'I IIGN SWIICH B" TT ) CIGAA llGHTEA SPLICE TO CONN IliGHT SW II 1 FOOT DIMMf.A SW ILO If ... M) TO .. fAOL .. MP CONN 1l00If ... M) HOAN TERM '0 CONN (HO AN IUTTON) lIGHT SW III 11 ~USlO TOCOfIN IH .. uo,AO FlASt-lEll1 FEED CONN UGN SWITCH ACC TEAM) 10 CONN IDIRECT SIGN"L FL ... ~(RI WfSWIPER SWITCH 10 Wf$ W"'~EA MOlOII WIS WIPEA S'" ·1· TO IGN (ACC lERM_1 CONN IBACK·UP LIGHT SW.I TO COfIN (fRAME KARN BACIe U, L TS ,J T_C SWITCH TO IGN. O~ IGN SW nGN TEAM.! T C. SW TO l ,C V"'CUUM SOLENOID HAuo,AO FlASHEA 10 H"Z .. RD SWllCH CONN (HOAN TERM .I TO SPlICE IGN !OwnCH (lGN TEIIM.I fUSED TO CONN IIiAC Ie UP LIGHT S"',I CONN (TUIIN I CONN HURN I
~US(O
CONN IHlliEAMl lO CON1\I ( HEAOLAMP HI BEAM_LT) TO CONN CONN iTURNSIGN"'~SW RT TURNI TO CONN 10lR SIGN ... L CONN (TURN SIGN"'l $W l T TURN) TO CONN (OlR SIGN"'L ~AM' LEn TURN) CONN (, ... RI( TER ... ) TO CONN. (' ... RI( L........ LT( TO CONN (' ... RI(. L........ RIGHl! CONN ILO Bl ...... ' TO CONN ( >lE ... OL ... M'
~O BEAM Ln
TOCONN
: ~~~~~!:':."Tt
CONN ISTEER COLUMN HORN BunONI TO >lORN TERM
~J~=~=~~~~~~~==~=l'!O~'~'~'!"~'~~~"~';"~'!O!'~'I'!'~M
~
CON1II
,
" "'"
" """ "" ,. ro ,., c-u "" '" "" C·I. ,~
C·ll
C-.l
1 ..
GII"'V ~APL[
'"
lT IIlUE BlACK OA"NGE
,
TO CONN . IH MP OVERRIDE $W I
~=====
C01ll1ll ICLUSTER "H" TERM 1 TO "LTER1IIATOR I"UI( I TO "'LTERN .. TOR R[OUL"TOR (H RM .! I"'UX. TERM I CO'lN lOlL 'RUSURE INOIC" TORI TO OIL PRESSURE $['1o[R START SOLE1II010 I"." TERMI TO CO'lN. ICI RCUIT 8R("I((R FUol C01llN.IIGN SW ST .. RT TERM.I TO SOLENOID (ST .. RT HRM.I CONN ITRANSMISSION SOLENOIDI IT.C.s.1 TO V ... CUUM SW CONN ISENWR SW I TO VACUUM SW. CONN (lGN SW ION TERM I TO COIL (01 YERM.-RESIST"NCE WIRE' J!I P. M.. II ST"RT SOLENOID (ION I TO "LTERN" TOR REGU~"TOR (lONITIONI COIL (0) TERM TO ST .. RTlNO SOLENOID IIO .. iTlONI "L 1£RN... TOR REGUL"TOR IOROUNO TUIM _I TO ... LTER ..... TOR (ORO I AL fERN"TOR REGUL"'OR IFIELO TERM.ITO"'L HRNATOR IFiELO TlRM I
n .c.s.)
""
VELLOW OAlEH ILACIe ORHN_
OVERRIDE SW 1
I
"
,.
-1~1-';'-1-;~~:'f-'ii;----r:,;0:'~':.11.!.~~N!'~';';0:'~L ., .." GII ... Y
~APLE
0 ·12 0 ·1 . O.
" ,., ro" ~,
0 _.3 0.' D·~~
." '" '" ." , .~
""" ""
" " """
'"
LT BLUE PINK VlLlOW GillEN IlACK GREEN WH. YELLOW
"
HIINATOII IAUX . TEAM. ) TO ... LTEAN .. TOR REO (FIElD TEAM .I CONN I INDICATORI TO OIL PIIESSURE SlNOIR START . SOLENOID 1"11" TEAM .I TO CONN. ICIRCUIT BAUI(EA fUOI CONN . IIONITION $W START nllM _1 TO$OLENOID (STAII T nAMJ CONN. (lONITlON $W IGN TEAM I TOCOI~ (0) TERM. IIESISTANCI WIAl uon ST ... AT SOLENOID (IGN.! fO .. l HIIH"TOIIREGUL .. TOII IIG N ) COIl (0) HIIM . TO $TA AT . SOLENOID I1ON.I "L TEAN"IOA AEGUlAlOR IGRo. TEIIMI TO ... LTERN ... TOR IGRD TERM.! "LTEAN"'OA I TEAM .I 5"I .. RT
,,
_IU
CONH (GAS GAOE INSlII UNIT,
YElLOW
CONN
lIGHT 'LUE OIlANGl GllnN WH TR .
CONN ITUIIN SIG N... L SW I TO CONN ( I l T.! CONN (TURH SlGN"L SW.I TO CONN (AT. STOI" SlONAL LIGHT, CONN (I .. CK U, LT SW I TO COHN. (I"CK lW LID"' (L f • RT I
1972 Ind 1973 model wi ring dllgram key
10
10-14
Chapter 10 Chassis electrical system
~;:::
.. "'''..
. ......-. -,
.H •• _ "
",
.-"
.-
-.. ~
Fig . 10.30
1972 and 1973 model wiring diagram
.,
.,
O•
'"
10-15
Chapter 10 Chassis electrical system
......
:-,:.
::!:' .... " .....
..~ I
~._J
"""
1.-
...
TJ
-_."
....':::.
."•. "".<'_........,
...."-".......... . ...... ....... .... ,.."., . . t! . .
,,,,,,-,,,,,,,,.,,,,. ''''''"",''-
,......',-...,...."' ," " , "'"
.... c·1 .... I
c~
~". ._.
......._
.:~ -.~
::e:D
c. ••"",
~$~O~"'~-~·~"~·~·~-~·~~~k$=~1tii----·-------ttr~'~:~::'~:',:,-'" • "-----
I
L"----1:>E=
...
""
I
...
,. "",
..... .-.
.-,~,,,..
o
...
..••
ill!j~~~~ ....-
I L.; " . c;_
..
,><.... ,,"""..
_...... ,10
Fig . 10.31
1972 lind 1973 model wiring dillgrllm Icontinuedl
10-16
Chapter 10 Chassis electrical system
,
•
•
•
. '... .
•
" . '*
o . •
•
. "
•
--- ~
o
""
I
_ J
•
WIRING DIAGRAM CJ MODELS
z
_.J~J ~_~ .••. -;...
--~'
Rg . 10.32 NOMENCLATURE Air &. Delroster Alternllor, V-8 (MOUN'oll)
Usn'
Ahtrnllor/Regulltor (Delco). 6 Cylinder
...'
", •. _.w....,._.
LOCATION C8 8·J CJ
Electron;c Ignition Pac!<, '0'·8
..,
Fuel Gauge
C8
Fuel Sende.
0 · 10
,.,
0-11
Fuel Sender Connector
Backup Lamp. Righi Rear
,., ,.,.
FUM Panel
Backup Lamp Switch, '0'-8
Sanery B.ttery Ground Clb'e .. k, F.i lu .. Switch
B·l1
D·'
Fusible Link, Ignition Circuli Haz.rd Light
Hu.rd Switch Headlamp, Left
D·J 0·8 0·8 0·8
Heidl.mp. Righi Headl,rnp Ground. Left
Coil. 6 Cylinder
'·8 D.
He.ter Blower SwitCh
Coil,V..a
c·,
H ig h Beam Irldicator Hom
Corostlrlt Voltlge RtgUlltor
C.
Horn Bunon
St,ke WarnIng Light Connector Brake Wlrning Ughl
Brlke W'fn,nll Ujlh! Ground
Ciit' Lilt>llt
Dimmer SWItch DirectiOl'llI SilJ'lll Switch Distributor, 6 Cyllrlder Distributor, V·8 ElectronIC IlJ'IitiOrll'Kk , 6 Cylinder
•
1974 and 1975 model wiring diagram
Back.up L.amp, Left Rear
Backup Lamp SWilch, 6 Cylinder
•
E< B·9 & B·IO
D·J C·J C·,
Heldl.mp Ground, Righi Hener Blower Molor
Ign itiorl SWItch Instrument GiustI' Instrument P,nel Liltrts Ground llltrt Switch li!1'rt Switch Ught
1974 and 1975 model wiring diagram key
E·l0
•• D, ' ·8 D·'
,., D·' ,.,
.,,.
,. C8
D.
A·8 & A·9
C·, 0·8 E·8 & E·g
'8
10 -17
Chapter 10 Chassis electrical system
•
•
•
1
~.,,-.-
.... " . ,.... 3·:-':· .
"
"
-
•
... '"'"""-.-, . ...• ...._.-,.......'_. ::::: ".;-:. ..... . ..,-,........ .. . ,.-,.......--"" ~
,
~:.:.::-::::;;::.,
, I·
'"
~
,- §
---.-~
,,,._-,-
.1 1
-
"',
..
.
.... '"'.
...--..... .,,-.. "--.,,._, ""-~-
_"
.. ';i,::,:,~:::; . ,,"
.. ........
,,::..--,'_...........
...- , '
"
1
. l
'''.,~
".,. , '"
... "..
"
"
,
....
,
..p
.
@>
''"'--'
.. ~
""'~~ ..-.... ....rk.!l!-
"' 0,,:::&/
~
"
'rl:lI ::,',~-'
".
,
1 Fig . 10.3 3
NOM EN CLATURE
_ ... .
~
"
.
'-----
J
~"
,.t.
..-..'. . , . ,. ...
•
... -.... -
"~
. "
•
1
1. •
J
'1
"
LOCATION
Splice "M"
Mi.ker 8. RenectOt . Right Fro nt
..,
Starte , Solenoid
Marker 8. R.n.ctQf . Right RUf
A· IO
Steering Column Conne<:IOt
Oil Gauge 0,1 Pr ... ufe Gauge Light
C·,
Sloplamp Switch
R~ netto •.
Left F.ont
M.,ker 8. Re llo;;tor, Left Rea.
E· 10
C.
Starting MotOl'
Tachometer Connector
C. C·, C·,
Tl il . Stop 8. Ucense li mp , Left Ru.
T,mplllitUft G. uge
Plrk 8. Signll Lamp. Right From
D· ' A·'
Spl ice " A "
C·,
,., ••• ,.,
T.ln.miS$lon Control SWItch
A·3
Voltage R"II"lalOt , V·S
Oi l Pre"ure Sender Panel Ughu , Left Panel Ughu , Right Park 8. Signll u mp . Left F,ont
Spl ice " 8" Spl ice " C" Splice "0 " Spl,ce "E "
"
1974 a nd 1975 m o del wiring dia g ram !continu a d )
E·'
Marker &
1
T" I 8. Stop Lamp, Riltot Ru. Tempefltuft 8. Fi n Light Tempe.-,uft Sender Turn Indi cator 8. Hlzard. ul! Turn Indicator 8. H.lI.d . Ri!tlt Vl cuum Solenoid
Splice "F "
A.
Splice "G "
C2
Voltmeter Light
Splice "H"
E'
Windshi.ld WHIle. MotOt Lead
SplIce "J"
D·'
Wlndshi"d Wipe. Motor
Splice "K "
A· '
Wind.hi . ld Wipe. & W.sher $wita.
Splice "L"
A-I
Windshield Wiper 8< Wisher Swila. Lights
Voltmete.
1974 an d 197 5 mode) wiring diagram key !contlnued)
0 '
•• C.
'·9 A·' A·' E·'1 A·11
C·. C, C·3
A·'
..
C·,
c.
' ·3 C·. C·.
D·' C·S 8< E·g
E·' D·,
10
10-18
Chapter 10 Chassis electrica l system
,
,
•
•
., r . . " .
,
4--...
•
,
Fig. 10.34 NOMENCLATURE
1976 and 1977 modal wi ring diag ram LOCATIOH
AI\ffn.,Ot, "'·8IMOlorenft)
Fuel Sender CoooectOt Connector
A1temator/R.I.tor )Delcol. 6Cyliode.
A·' D·'
FUHP_I
""II-Oltsel Sol_lei Soup l8ITIP. Left R... BKkup L..,..,p, Ri." RI ..
C4 0·11 C·'I
Fu.ible Link, Ignition Circuit, 6 Cvllnder Fu,lble Link, Ignition Circuit. V·8 H,ldl,mp. LIlt
FfirTIII Hlffle$$
88Ckup L.mp Switch, M.,. Tr ....
,.,
Hudle"",. Right
8K'kup L8I!Ip Switch, Auto. Trio •.
D·'
H..dl'lT\f) Ground, L.ft
Bamrv,6Cvlinder 8.ttefy, V..a
C·,
Headl'"", Ground, Righi
A4
,.,
Heater 810we. MoIO<"
8 ••• FIlIu.. Switch Brlke W.ming Light
C·9
Huter Blow.. Switch Helt'r Control Lighu
Cig¥ Lighter
D·'
High (!.elm Indicltor
Coil, 6 Cylinder
,.,
Hom
CoIl, '1-8 Dimmer Swi tch Dlrectlonlll Sign" Switch Oiwibulor, 6 CVlindet
0' 0< 0<
,.,
D·'
Horn R.I.v IgnitiOfl Switch
Instrument Clulle.
Olltributor, V-8 ElKtronic Ignition PICk, 6 C."linder
C·,
Inwumen! Clune' Ughu Instrument Pinel Li9h1s G.ound Kickdowfllnd Ou.,;:l ••Trec Switch Connector
ElKtronic Ignition PO, V-8
A·'
Light Switdl
F ... IG-..ge F ... I s.no..
8·10 0·10
Light Switdl Llli>t '-i •• ka.8I Aallecto., Lelt Front
1976 and 1977 model wiring diagram key
,.,
E· IO C·S So C-6
C·,
A.' D·'
,., ,.,D·'
A.' A.' "'_7 & A·8
,., '·9
C, C< 8 ·10
" ,.,., ,.,
C·,
E·281 E·3
10-19
Chapter 10 Chassis electrical system
•
•
,
•
•
•
Fig. 10.35 MOMENCLATURE
"
"
"
"
1976 and 1977 modal wiring diagram (continuad) LOCATION
,.,
Splice "M"
A.' A·'
Mlrk" 8c Reflector . tAft Rei'
E·l0
Splice "N"
M"k" 8c R,fl..:to'. Righi FrOf1I M., ke,8c Refl..:tor. Righi Rn,
A·'
Splice "0"
A· ll
Oil Pre",,", G.uge
A·l0
Splice ''P'' Splif;e "R"
Oil P'mure G.ugeLlght
A·l0
StarUr Solenoid
Oil P,nsu .. Sltndll,. 6 Cylindll' Oil P,mu,. s. ..... ,. V-8
04
,.,
St..-ting Motor Steering Column Connector
P.,k 8c Sign.,L."p. uft Fronl
D·'
Siopl."p Switch
P.. k & Signll L.... p. RighI Fronl Rlllltine. Wi... 6 Cylindll,
A·'
T.il. Stop 8c LiotnM L.... p. uft RII.
0 ·"
D·'
Tlli l & Stop L..mP. R~t RII' TCS Sysum Connector
C·" 04
Splice " "' '' Splice "8" Splice .'{:" Splice "0" Splice "E" Splioe "F" Splice "G" SpIIcl"H" Splioe "I"' Splice "J" Splice "K" Splice "L"
C. C.
C., 0., A·3 "C'3 B-i& O-i
0< 0<
,., ,.,
Temperttur. Gwge
B· l0
Tempe,.tu.. Sender. 6 Cyllndtr
D·'
C., C·,
Tu,n IndicltOf' & HIll.d. tAft
A.
Tem~nu ..
s.oo.r. V-8
Tum Indicttor & HIll.d.
R~t
A·'
Vol. R-e<.d.torConntaor. V-8 Vol_r
C·, C·, C·,
Windshield Wiper Motor WIndshield Wiper & WashoIr Switch
,.,
Voltmfl,., Light
Win
1976 and 1977 model wiring diagram key (continued)
,.,
C. C·,
,.,
A·'
A., 0< 0< 0<
10
10-20
Chapter 10 Chassis electrical system
•
,
."
,
' .- ,-
, ,
I
• Fig. 10.36
NOMENCLATURE .... ' ' ' ...101/11.11101 10010;0),
1978 model wiring diagram
LOCATION
V·,
A·'
F• .,... H....... CotIMcIor
F"" P...,
AUorn.torlRogulnOl (Dllcol. 41 c;.,lino:t.r Bodtup L""p. Lolt RI.'
F~.,bI. LI .....
'II"i.".n Clt""II, 8 CVlindor
0·,1
Fu.i~ L,n~.
I.,ilion Cireul. , v·e
iIM;IouP l _ . A~1 R••
C·II
Hoodl .... p. lll'
Bockup L""I>SW1td1. M .... T .....
8 .. ~up Lll'l'lp S,.;tdI, ......... T ...... 801~.
II C>illndo.
8on ...... V.a
arob F,ilur. Switch erlq Wltning L..,' c... Llthto. Ct.iI, 8 Cyl,ndo.
Coil. '0'-8 [)l.II.IO. Sw;K:h
D"...ionol S"".. Swj."" O1l\l'lbutor, 8 evll_ o<.tributor,lI-8
~,
,., ,., ,., ,. ,., ,., ,., ,.,,.,
Hoodl.""" RiI!h' Ii..dlome> Ground. Left
_limp C,,,,,n
Holto. 81_. Motor HNIe< 81""", Swlld'l HII.er " .. i.tor H..Io. ConlJoI Lillm HOgh 8 ..m IndH;oIO<
,. ,.
""m Ibn All..,.
" "
,,,lttumo,,! Clu .... 'Mtru""'nt Clunltl!ahu
EloctronH: 111"11..... P..... II Cylindtr EIoc .. ",,", Ignition PfCk. V-i
,., "'
F""IG.... F""I s.ndo, F""I s.ndo, Conner:tor
a ·l0 0·10 E·l0
Ignltio<> SWitch
I
..
C·S" C.e
",., ,.,
....
,., " ,.,
A'
,., ,., ,.,
"'·1 . A-8
",.,
8·HI
Imvumtnt p~ Lighll Groul'ld Kickdo'M> _ Ouodr.T,o< Switch ConMctor e.'180 £·3 Ugh1Sw,tch ligh1SwItch Ught M.,q,80 1I.1Ioaor. L.1t F""'t
1978 model wirin g diagram kay
",. ,., ,.,
•
-
10-21
Chapter 10 Chassis electrical system
•
,
•
"
..
'~Q;-"'l '-..~:.~ I [ ' ~ 0 ......,
,
....
",,:'; "
'. ~'...:.'"
'
.:..:.:"
"."',~.
c' .
M"'."~ -,-.. .... _ -
.
..
-
'
~
..-" '.
~,
.... .... -,.o-..
•
07 ~
"
._""
"
,
•
~,
~~~"=
~"
.... ".'
.-
:)
"""'''''
•
,
• Fig. 10.37
MOth, 8< A.fIKlor. ull RI., Mon. .. 8< AltfiK\o,. A,ght F,onl Morh, 8< R.IIeefo,. A,ght AI" Oll~,
E·1G
"A" '" ...·,G
....... ~
O,II' ......... ~Llght
o. ,.,
P, ...... So"""'.!! CyHtoao, 0" 1',...... ,. So"""'. V.a ~Ot~ 8< Slen" L.... p, ufl F,ont ~.~8<S. ' .oil Ra' Aighl F'onl ,,1_ Wi, .. AI",,,"to,. 6 C 11-~R''''I .nco WI ,.. AlIOr,,"to<. 8 evll_ Y ..... ' R""II""" Wo, .. CoII 6 C I -~. R . • v" ...... , O~'
0' A·'
.,
....P.
., "
...""nco Wi,..CoIl • B Cvli_
Spl ........ "
A.
,., ,., "
Splie. "8" SpI ...
"e"
Splle. "0"
51>1100 "E" Spne. "F" SpI .....O" SpI ... "Ii" Splle. SpI... "J"
H,"
,
C
"
"
."
1978 Model wiring d'lagram (continued)
LOCAflOfrj
"IOME"ICLATUAE
8
,., ",., ,., ,., "
Splle. "K" SpI"" ~L" SpI'" ''JoI'' Splie.'",," SpI ... "0"
.,
Splle. "'P' • Splioo
··A··
...·3 a.C·3
StMm, SoIonoid SI¥I'"'II MOlor Sto«lng CoI ..... n Connector
8~.0~
o.
O.
St(l9lomp Sw,tch
0 ·11
Tlil. SlOP 8< llc:enll L
foil. StOll
Urnp,
- , uft A...
A'-" RI"
C·"
o.
TCS S.,..totn eonr-to< T _ . I..... O. . . T.... poontu .. ~. 6 Cyl," T.... pt
8·10
,.,0·' ,., " ,., ,.
..
Vol_Light
WI_101d WIlli< Motor Wi'''''''101d Willi<. W_ Swi Wi_ Id'o loki Wi_. W..... Swltd'o Lit/>
978 model wiring diegram key (conllnuadl
o. O.
'
10
10-22
Chapter 10 Chassis electrical system
,
•
--.,.~"
A
..... .. ,
,-
.
,
, - 1...-:'.''(~
,. 'j
• 0
G'
-!l!IJ
,
, .....
-
"
, ,
• Fig. 10.38
,
•
1979 model wiring diagram
NOMENCLATURE
LOCATION
Acc.nory Feed
C~
Air Conditione. Comprano •. a·Cylinder AlllmllOt, 8·Cylinder
Altem.tor,6-Cylinder
B·3 B·' {)-3
Antl ·DIHel Solenoid, a·Cylinder
,~
Anti·Diu,1 $olenoid, 6-Cylinder Back·up lamp, Right Side
D·' C·l'
BKk·up lemp, Left Side
Coil, 6·Cylinder D,mme. SWitch Distrlbutor.8-Cyhnder
c·,
,., D·'
Distributor, S.Cylinder Electric Choke Fuel Gauge Fuel Sender
C·3 ,.,
{)-"
Ground AJr Lemp Feed Ground Defogger lImp Feed
'·7 '·7
Manu.1 Trlolmillion BKk·up Light $wlleh
C~
Gro ..md Temper,lurl lemp Feed
Menu.1 T.,nltTllSSlon e'"ery. 8-Cylinder
E·' A4
Headl,mp, left Side
B."ery,6-Cylinder Body,8-CylinOer Body, &-CylinOer Bra~e Failure SWItch Brake W.rning L.mp Capacilor Jumper, 8-Cvlinder C.pacitor Jumper, 6-CVlinder ChU"I, a-Cvllndel Ch ... il_ 6-Cvlinder Cigar ligh ter Feed Coil, a-Cylinder
C~
Ground fin LJmp Feed
Beck-up Ught SWi tch
Heedlemp, RighI Side
,~
C~
E·3 C·7 '·3 C·, ,~
C~
,., ()-.
He~Uet
Motor, a-Cylinder He.l.r MOIOl', 6-Cyhnd.r He.ler SwilCh High Beam IndIC.tor Horn Horn Rel.v IgMIOf\ SWitch K,ckdowf\ & Ouadra-Trac, 6-Cvlinder Left Turn Indlc.to, & Hazard Lamp Low Bellm LP
1979 model wiring diagrem kev
B~
D·' ,~
'·7 B·'
D·' B·3 {)-3
,.,
()-, E4 {)-7 C~
E·3 {)-B
D-6
10-23
Chapter 10 Chassis electrical system
,
•
•
•
"
.-
•.• -eI-_ ••• ' - 0
:::
" .,.."...
" "'" ....".
~
•
n' , .•• -£!
I.
•
-'
~ ,
• Fig. 10.39
NOMENCLATURE Marker &: Reflector. Right Side Marker &: Reflector, left Sida Marker & Reflector, Right Side Marker &: Reflector. left Side Module Assembly Ig',lition. a-Cylinder Module Assembly Ignition, s..Cylinder Neutral Safety SwitCh Oil lamp Gauge Oll Pressure Sender, a·Cylinder Oil Pressure Sender, 6-Cylinder Oil Pressure Switch Panallamp Panel lamp Park &: Signal lamp. Right Side Park &: Signal lamp. Left Side Parking Brake Quadra-Trae Lamp Resistor Heater Blower Motor Splice. a·Cylinder Splice. s..Cylinder Splice, 6-Cylinder Splice. s..Cylinder
•
,'.~
,
I
•
--- D ,... ,,,, . . .....
....
"
"
1979 model wiring diagram (continuedl
LOCATION
A·' E·'
a·l0 E-10
,., 0-3 C~
'·7 '·3
C4
A·' A·7 ' ·7 A·, 0-, C·7
,.,
'·7
'4 A·' C·, A·'
Splice. s..Cylindar Splice. 6-Cylinder Splice Splice Splice Splice SpliclI Starting Motor. B-Cyllndllr Starting Motor. s..Cylinder Starter Solenoid. B-eylinder Staner Solenoid. 6-Cylindar Stop Lamp Switch TIIII & Stop Lamp. Right Side Tall & Stop Lamp. Lett Side T.e,S, Menua' Trlnsmisslon Temperatura Gauge Temperlture Sender. a-Cylinder Temperature Sender, 6-Cylinder T,"nsmiuion Kiet:down Switch Turn Signal Switch Voltmeter Gauge Windshield Wiper & Washer Lamp Windshield Wiper Motor Windshield Wioer &: Washer Switch
1979 model wiring diagram key (contlnuedl
C·,
,.,
C·3
C·, C~
C·7 C·7 A4
C4
A·3
"" D·'
C-11
0-11
'4
C~
A4
C4 E~
0-7 '·7 0-, C·, D~
10
10-24
Chapter 10 Chassis electrical system
Fig . 10.40
1980 through 1983 model wiring diagram
Chapter 10 Chassis electrical system
... ",.". ........" ......... rt---:::'~:~" ..... ,.. - . . ,
'",-".,
, r ....-,_ '"
10-25
. _c_ .. -4--,9----33 ." ... .1•
,
----",.:.,,',:,_:--
_______ "",,,"",., . ---'-Co'-=" "
. -...
.~" . "-J.' -
10
Fig. 10.41
1980 through 1983 model wiring dlagrem (continued)
10-26
Chapter 10 Chassis electrical system
~
,, :i
I
•.
~.
~,, ~
!
\iJ-J
,, Ij
0-«>- ...,,_ .... I
--ft.....
W~~'~ ~
I',
~ .!
\', I, ~
(i!>--"
CLO< ' . _ . .
l
; ;
,;,
.:.
..--e
i:·
n ( j'' " .r. ~ _..... """""', ........
1
~-Ff!L..:'''_~._ -_. "'.-: ~~-...
.,. "._"..... "."',
....•.~•--.~ ...... n
"."
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10-27
Chapter 10 Chassis electrical system
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10-28
Chapter 10 Chassis electrical system
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10-29
Chapter 10 Chassis electrical system
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10-30
Chapter 10 Chassis electrical system
Fig. 10.46 1984 through 1986 model wiring diagram (continued)
10-31
Chapter 10 Chassis electrical system
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10-32
Chapter 10 Chassis electrical system
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10-33
Chapter 10 Chassis electrical system
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Chapter 10 Chassis electrical system
10-34
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10-35
Chapter 10 Chassis electrical system
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10-36
Chapter 10 Chassis electrical system
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10-37
Chapter 10 Chassis electrical system
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11-0
Chapter 11 Suspension and steering systems Contents Chassis lubrication
Chepte. 1
D.ag link - .emoval and installation
11 Chapler 1
D,jvebelt check and adjustment
Front hub - .emoval and in'talhnion Front spring - ,emoval and Installation. Front st8bili~er bar - "010\181 and installation General information . . •.... Power sleering fluid level Check Power stee.lng pump - removal and installation Power steeling system - bleeding procedure Rea. sp.lng - removal and instillation . Shock absorbe, - removal and Installation Spring bushing - check and replacement •.
Steering bellcrank - removal and Installation Steering connecting rod - removal and installation Ste~lfIng
damper - removal and installation
Sleeflng gear - removal and installatton Sleering knuckle - removal and installation Steering wheel - removal and installation Suspansion and steering check. Tie rod - removal and Instatlation Wheal alignment - general information Wheel bearing check Wheel bearings - adjustment Wheel bearings - Inspection and lubrlCll!ion
5 4
2 1 Chapler 1 17 18 6
3 7
Speclflc.dons
Torque specifications Bellcrenk shaft locknut Bellcrank 711S-inch locknut . Bellcrank support bracket . . .. Bellcrank-tO-lie-rod and .. Drag link ball adjusting nUl .. Drag link-to-bellcrank arm ... Pitman arm nul . .. Power steering pump Adjusting nuts and bolts Mounting bracket bolts Steering knuckle upper ball-stud split ring seat Upper ball·stud nut . lower ball-stud jam nut Steering connecting rod .. . . . . . . . .. . .... Steering us-rod end nut Steeflng gear-Io-frame bolts 1949 to 1971 models 7f16·inch bolts 318-inch bolts ._ 19721hrouqh 1986 models Steering gear-Io-bracket bolt (he)( head) Steenng gear-Io-bracket bolt (Tor)( head) .. Steering gear-Io-frame boll Steering shaft coupling bolt Steering arm-to-tie-rod Steering arm nut Sleering wheel nut. _ Wheel beaflng outer locknut Wheel lug nUls .
Ft-Ib 70 to 50 to 30 to 38 to
Nm
90 70 45 45
95 68 41 41
to to to to
122 95 61 61
20 20 18'
27 27 251
30 to 40 30 to 40
41 to 54 41 to 54
50 100 85 60 60
68 136 115 81 81
45 to 55 30 to 40
61 to 75 41 to 54.
70 55 55 45 50 150
'5 75 75 61 68 203
20 to 30
271041
50
68
65 to 80
88 t o 108
14
12 15 16 8 19 Chapter 1
13 20
,
Chapter 1
10
Chapter 11
Suspension and steering syst em s
11-1
J
1
Gana,.l Information
The front and rear suspension on all models consists 01 semi·ellrptic springs with tubular shock 8bsorbers. Th8 axles are attached to the spring~ with U-bohs and tie plates whiCh incorporate the lower shock absorber mounts. The springs are mounted parallel to the frame tails wrth the forward end of the front springs and the rear end of the rlUI, $prings attached with prvoting shackles. Later models are equipped with a front stabilizer bar. Steering is a recirculatrng ball type with power assist available on late, models. Late, models also feature an energy·absorbing steering column and optional tilt steering wheel. Some later models incorporale a shock absorber· like damper In the steering linkage to reduce steering wheel kickback while driving on rough terrain.
2
Front stablllzer bar - removal and installation Remove the connecting links from the spring tie pletes and stabilizer
bar.
2
Raise the IrMt of the vehicle and support it securelv on iackstands.
Remove the clamp nuts and separate the stabilizer bar from the vehicle. 4 Inspect Ihe slabilizer bar lor damage, distonion and cOffosion. Check the cushion5 lor creeks snd damage and the clamps and nuts for damage. corrosion and stripped threeds. Replace unserviceable componentS with new ones. S Place the stabilizer bar In position and Install the clamp snd bracket assembly with the nuts fingar tight. 6 lowsr the vehicle snd install the connecting links with the nuts finger tight. 7 TIghten Ihe stabilizer bar clamp nuts to the specified torQue. fol· lowed by the connecting link nuts.
J
Shock abl.Orber - removal an d Installation
Raise the vehicle, suppo" it securely on jaCkstands and remove the wheels. 2 Raise the 8xle with a jack Ju~1 enough to relieve the weight from the spring. J Remove Ihe upper and lower mounting nuts end washers and remove the shock absorber and bushings.
11 Fig .
n .l
Typical front suspension component layout
1 Sttuuing knuckle
4 Pitman arm and steering gear
7 Spring tie phlte
2 Sway bar
5 Steering damper 6 Spring
8
3 St"rlng connecting rod
TIfI -rod
9 Shock IIbsorbflr
11-2------------------------------------------------------"'
Rg. 11.2
Typic:. r••, IU.penskm eompOf'Iem Ir,oout
1 Shock ttbsorbef
3
2 Spring
4 Spring shadl.
Spring tm pllJttl
STABILIZER SAA· TO-FRAME CUSHION
Ag. '1 .3
front ItablUzer bar componenll - exploded view (Sec 21
Fig. 11 .4 early model (pra-19571Ihreaded bu.hing-type .pring ,hackle ISec 41
Chapter 11
4 Instail the bushings in the shock absorber eyes, place the shock absorber In position, install the mounting nuts and tighten them to the specified torque. 5 Install the wheels. lower the vehicle and remove the jack.
4
Front spring -
remova! and'instellatlon
Removal Rai se the !ront of the vehicle. support It securely on jackstands and remove the wheels. 2 Aai se the ule with a jack Just enough to relieve the weight from the spring. 3 Oisconnect the stabilizer bar link lif equippedl and remove the Ubolts, nuts and tie plates. 4 Remove the spring shackle and reM spring hanger bolt, then remove the spring. On early models (prior to early 19571. the spring shackles have threaded inStead of rubber bushings. These bushings may heve either right or left-hand threads. Right-hand thread bushings hove plain hell: heads and left-hand thread bushings have a groove around the heads or a small forged boss on the lower shank of the shackle.
Installation 5 Place the spring rear eye in the hanger bracket and install the bolt and nut loosely. 6 On later model rubber bushed shackles, place the fear spring eye in the shackle and install the sheckle in the hanger with the nuts linger tight. 7 On early models with threaded bushing shackles. instllil the grellse seal over the threeded end 01 the sheckle up to the shoulder. Insen the sheckle through the frame brecket end the spring eye. Hold the U· sheckle tightly against the freme end lion the upper bushing in the sheckle. taking cere not to cross threed It. Screw' tho bushing in about hall-way and repeat the procedure on the lower bushing. Turn the upper and lower bushings in alternately until the head Is snug against the Irame bracket and the spring eye Is 1132·lnch away from the inside 01 the hell head. Lubricate the bushing with oit and meke sure the shackle can move freely with no binding. B Inllall the U-bolts and the tie plate, tightening the nuts to the specified torque. Connect the stabilizer bar. 9 Install the wheels. lower the vehicle weight onto the suspension and tighten the spring front and rear mounting bolts and nuts to the specified torque.
5
11-3
Suspension and steering syst ems
Front hub - removal and instellation
Removal Remove the hub cap or hub assembly cover and loosen the wheel lug nuts. Raise the front of the vehicle, support it securely on jacltstands and remove the wheel s. 2 Remove the drive lIange or all:leshalt snap-ring. On drum brake models, remove the ade flange bolts and the lIange as described in Chapter B. 3 On disc brake-equipped models, remove the caliper IChapter 91. 4 Straighten the lip of the outer locknut washer and remove the outer locknut and wa5her, lollowed by the inner locknut and washer. 5 Grasp the hub and brake drum or disc assembly securely and withdraw It from the sprndle.
remove the wheels. 2 Use a jack to raise the vehicle weight off the spring. 3 Remove the U-boits, nuts and tie plates. 4 Remove the boit attaching the rear spring eye to the shackl e. On very early models (prior to early 1957) whiCh use threaded rother than rubber bushed shackles. the bushings may have either right or left-hand threads. The right-hand threaded bushings have plain heK heads. while the lelt-hand bushings hove a groove around the heads or a small forged boss on the lower shank of the shackle. 5 Remove the Iront spring-to-Irame fail hanger bolt. 6 Remove the spring from the vehicle.
Installation 7 Piece the spring in position and Install the front 5pring -to· hanger bolt with the nut finger tight. S On vehicles with rubber bushed shackles, install the spring in the shackle with the nuts and bolu finger tight. 9 On early models with threaded bushing shackles, install the shackle ss described in Section 4. 10 Install the U-boh and tie plate. tightening the nuts to the apecified torque. 11 Install the wheels, lower the vehicle weight onto the suspension and tighten the spring front and rear bolllirubber bushed shackle) to the specified torque.
7
Spring bushing - check and raplac.ment
Check All later models are equipped With silent block type rubber bushing. which are pressed into the spring eyes. The bushings should be Inspected for cracks, damage and loo.enesslndicating excessive wear. To check lor wear, jack up the 'rame until the weight is removed from the spring bushing. Pry the spring eye up-and-down to check for movement. II there is considerable movement, the bushing is worn and should be replaced .
Replacement 2 Remove the spring (Section 4 or 61. 3 The bushiogs are of two dillerent siles and tools can be fabricated from threaded rod for pressing them out. For small diameter bushings. cut an eight 181 inch length of 3l B·inch diameter threaded rod and, l or the large diameter bushings. cut en It ·inch length of 1 /2 ~inch diemeter threaded rod. 4 Insert the threaded rod half-way through the bushing . 5 Place a socket over one end of the rod with the open end toward the bushing to serve as a driver. The socket must be 18rge engough to baar egainat the bushing outer sleeve and small enough to pass through the spring eye. 6 Install a flat washer and hex nut on the rod behind the socket. 7 On the opposite end of the threaded rod , install e 2-inch long (small bushing) or 3-inch long lIarge bushing) piece of pipe to serve 8S a receiver as shown in the illustrations. The inside diameter of the pipe 318 HEX NU T
Z INCH LONG PIP E SECT ION
SPRING FL AT WA SHER - __ JY
/
Installation 6
InSlall the hub on the spindle. 7 Install the inner locknut and washer and adjust the wheel bearings as described in Section 9 . a Install the disc brake caliper, outer locknut and washer, snap-ring. gasket end drive llange or hub assembly and hub cap. 9 Install the wheels and lower Ihe veh icle.
6
1
Raise the reer of the vehicle. support it securely on jackstands end
/ 11 , 311 HEX NUT
Rear .prlng - removal and inltallallon
Removal
,n
FLAT WASHER
Fig. ".5
8 INCH LE NGTH OF 318 INCH THREADED
ROO
Small diameter .prlng eye bushing replacement ISec 7 1
11-4
Chapter 11 Suspension and steering systems
muSt be large enough to accommodate the buahinO while still $eating against Ihe .pring eye surface.
8
DEEP SOCKET FOR REMOVAL SHALLOW SOCKET FOR INSTALLATION
Secure tha pipe section on the rod with. lI,t washer and helt nut
8' shown in the illustrations. The walher must be large enough to properly suppa" tha pipe section alignment. 9 Tighten the hex nuts finger tight to align Ihe components. The socket must be positioned in the spring eye and aligned with the bushing and the pipe mUll butt against the eye surface 80 the bushing can pass through It. 10 Pre.. the bushing out of the spring eye by tightening Ihe nut 8t the socket end of the rod. '1 Remove the bushing and tool from the apring eve. 12 Install the new bushing on the thre.cled rod end IIssembkt and aijgn
3-INCH PIPE SECTION \
"'TW~.
8
St••rlng knuckle -
remoyal and Inltallatlon
The steering knuckle on 1949 through 1971 models can only be removed or installed using special toola, so the job should be left to your daaler or a properly equipped shop. 2 To remo .... the knuckle on lal81 modela, raise the front of the vehi· cle. aupper! it securely on jac:utands and remove the front wheela. 3 Remove the front hub (Section 51 and axleshaft {Chapler 81. 4 Remove tile brake 88sembly from the steering knuckle and hang it out of the way with wire. 5 Disconnect the tie-rod end from the ateering knuckle arm. 6 Remove the lower ball-81ud jam nut I I shown In the Illustration. 7 Remove the coner pin from the upper ball-stud and loosen the nut until il8 top edge ia flush with the top of the atud. 8 Usa a lead hammer to unseat tha upper and lower ball-studs. 9 Remove Ihe upper ball-stud nut and aaparate the steering knuckle
~
H<X NUT
the tools 8. previously described. 13 Una up the bushing with the spring eye and press the new bushing into position. 14 !.Dosen the nuts end cneck to meka sure the bushing is cantered in the apring eya with the ends of the buahing lIush with or slightly below the sides of tha eye. II neeesaery. reinllall the tools and adjust tha bushing poaition.
\
1(2 INCH THREADED ROO
It INCH LONG
fig . 11 .6
large diameter spring IIY11 bu.ning replacement ISec 71
from the exla. 10 Replacement of the ball-studs requires special tools and seryice techniques. Consequently, If the ball-studs require replacerT\llnt. the job should be left to a dealer or properly equipped shop. 11 Instell the upper ball-stud split ring seet in the exle yoke with the top of the seat flush with tha top of the yoke. 12 Install the steering knuckle on tile axle yoke and instill the lowar bali -aNd nut finger tight. 13 Use e jack t o raise the knuckle into position so the lower bell-stud il held firmly in its seat and tighten the jam nut to the specified torque. 14 Use a split ring nut wrench tluch es AMC tool J-251581 to tighten the upper ball-stud aplit ring leat to the specified torque IS sn.own In the illustration. This will set the preload for the upper ball-stud. 15 Install the upper ball -stud nut. lighten it to the specified torque and instell a new cotter pin. If the cotter pin holes do no! line up, tighten the nut just enough t o allow insertion of the pin. Do not loosen the nut to align the cotter pin holes. 18 Connect the steering rod end Instell the brake assembly. 17 Install the axleshaf! end hub. 18 Install the wheels end lower the Yehicla.
~TTEIIPIJrl
~-:: _ _ lIf'I'EII BALl
~_ ~STUO NUT
ST EEIIING KJrlUC KLE
Ag. 11 .7 1972 through 1986 model steertng knuckle compo nents - exploded yiew (Sec 8)
Chapter 11
11-5
Suspension and steering systems remove the flange with 8 tool (Chaptet 8).
9
Wh ••1 bearinga - adjustment
4
The front wheel bearings on all mod!!ls and the rBBf wheel baar· ings on early CJ·2A models with fuil-lloating axles (Chapter 8) should De adjusted at the specified intervals. Also, the baMlngs should be ad· jUlled if the check (Chapter 11 indicates excessive drag Of play. 2 Raise the vehicle and support it securely on jackstands.
Straighten the outer loc knut tabbed washer lip and remove the
washer and locknut. S Loosen the inner locknut. 6 Rotate the wheel and tighten Ihe locknut until the bearings bind. Alternately, if 8 torque wrench is available, tighten the locknut while rotating Ihe wheel uOIi! 8 torque of 50 II·fbl is achiEl'l/ed.
Front wheel bearings 3 Remove the hub cap. snap-ring, drive flange and gasket and the outer locknut (Section 51. On some models it will be necessary to
Ag. 11.8 Re moving the lower ball-stud Jem nut (Sec 8 )
Flg. 11 .10
I Huo cap 2 SnlJp -,ing 3 Drive fllmgll GlJsket 5 Locknur Tabbed washer
•
•
Fig. 11 .9 Tlglrtenlng the upper bal·atud split ring with a . pecial nut wrench (Sac 8)
Typical earl y model front hub end bearing assembly - axploded view (Sec 9)
,
Taobed washer 8 BelJring Cup 10 Hub and drum assembly /I SlIlJf
•
11 12 Bl"IJke auembly 13 Spindfll lJnd bushing I. St_ring knucklll 15 Thrust wllshllr I. AKfllshalt
/J Lock washer 18 Boft I. SC/"llW
20 NUl 21 Lock wllshef
22 Bolt
11·6
Chapter 11
Suspension and steering systems
7 While rotating the wheel, bacK OtT me inner locknut approximately 1/6 of a tum. The wheel should tu rn freelv with no looseness or lateral
movement. S
Install the washer and locknut and tighten the nut to the specified
12 Install the inner locknut and washer and adjust the wheel bear· ings (Section 91. 13 Install the outer locknut and washer and the remainder of Ihe hub assembly.
torque. 9
Insl811 the gasket, drive flange and hub cap.
CJ-2A rear wheel bearings 10 Remove the drive flange screws and the axleshaft (Chapter BI. 11 Bend the lock washer lip back and t8movtl the locknut and washer. 12 Rotate the wheel while adjusting the inner adjusting nul until the
bearing binds. Back the nut off appro)(imalely 1/601 a turn while rotating the wheel until it turns freely with no lateral movement or looseness. 13 Install the outer washer and lOCknut and bend the lip of the washer ovef the nut. 14 Install the a)(leshaft. using a new flange gasket.
10 Wheel bearing. - Inspactlon and lubrication The front wheel bearings on all models and the rear wheel bearings on early CJ-2A models with full-floating ades should be inspected and lubricated at the specified intervals. The bearings should also be inspected and lubricated if leakage is noted. 2 Raise the vehicle and support it sacurely on jackstands.
CJ-2A rear wheel bearings 14 Remove the a)(leshaft and hub IChapter 81. Drive out the inner wheel bearing and seal with a hammer and brass drift. The outer bear· ing should have been dislodged during hub removal. 15 Clean the bearings, hub and axle housing bearing surfacas with solvent. 16 Inspact tha components as described in Stap 7. 17 Pack the wheel bearings with wheel bearing greasa. forcing it bet· ween the rollers, race and cage. 18 Spread a thin (appro)(imately 1116-inch) layer of grease inside the hub to prevent rust. 19 Position the grease-packed inner bearing in Ihe rear of the hub and place a little more greasa outboard of tha bearing. 20 Place a new seal over the inner bearing with the lip toward the bear· ing and tap the seal with a hammer and block of wood until it is flush with the hub. 21 Carefully place the hub assembly onto the spindle and push the grease-packed outar bearing into position. 22 Install the washer and locknut adjust the bearings (Section 91 and install the axleshaft. 23 Lower the vehicle.
Front wheel bearings 3 Remove the front hub (Section 51. 4 On the rear side 01 the hub, use a screwdriver to pry out the inner bearing seal. As this is done. note the direction in which the seal is installed. The inner bearing can now ba ramoved from the hub. egain noting how it is installad. 5 Remove the outer bearing Irom the hub if it has not already bean dislodged during hub removal . 6 Use solvent to clean the bearings, hub and spindle. 7 Allow the parts to air dry and Inspect the bearings for cracks. heat discoloration, bent rolle~. score marks and wear. Check the bearing races inside the hub for cracks. score marks and uneven surfaces. If the bearing racas are defective. have them replaced by a repair shop which can press the new races squarely into position. S Use wheel bearing grease to pack the bearings. Work the grease comple tel y into the beerings, forcing it between the rollers. race and cage. 9 Place the grease-packed inner baaring into the rear of the hub and put a little more grease outboard of the bearing. 10 Place a new seal over the inner bearing and tap on the seal with a hammer and block of wood until it is flush with the hub. II Carefully place the hub assambly onto the spindle and push the grease-packed outer bearing into position.
II
Drag link - removal and installation
Removal I Raise the front of the vehicle. support it securely on jackstands and remove the front wheels. 2 Remove the coner pins from the ends of the drag link. 3 Use a screwdriver to unscrew the adjusting plugs and remove the ball seat, springs and spring plugs. 4 Remove the clragJink. dust covern and dust shield from the vehicle.
Installation 5 Place the drag link, dust covers and dust shields in position on the bellcrank and steering gear arm. 6 Install the ball seats. springs and spring plugs. as shown in the illustration. 7 Install the adjusting plugs and tighten them to 20 ft -Ibs, then back them off one full turn. This will adjust the balljoints so they will be tight enough to prevent end play and still allow free movement. Install a new cotler pin in each end of the link. 8 Install the wheels and lower the vehicle.
HUB CAP
HUB AND DISC
Fig. 11 .11
WASHER
SNAP RING
Typical l ate model front hub and bearing a!lsembly ~ exploded view {Sec 9 1
11-7 Fig. 11.12 Typicel early model steering IInkege components (Sec 11' 1 2 3 4
5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Frame cross tube (CJ·38) Steering belfcrank bracket (CJ-3BJ Steering belfcrank Front axle assembly Drag link Steering gear arm Steering gear Left steering knuckle and arm Left shaft and universal ioint Left tie-rod socket Left steering tie -rod Left tie-rod socket Right tie-rod socket Bellcrank nut Washer Bolt Bellcrank bearing Bearing spacer (early model) Washer Bellcrank shaft Bearing seal Nut Lock washer Right steering tie-rod Right shaft and universal ioint Right steering knuckle and arm
(#__ 7
6
3 .. .5
a
Fig. 11-13 Drag link componentl - exploded view (Sec '1) 1 2 3 4 5 6 7 8 9 10
Corter pin Large adjusting plug Ball seat Ball seat spring Spring plug Oust CO'ller Oust shield Small adiusting plug wbrication fitting Drag link
"-lUltNG I(NUCXLf
11
Fig. 11.14 Typical later model steering linkage component. (Sec 12)
11-8
Chapter 11
Fig. 1'.15
,
Early model tle-wd componenu - exploded view lIata model almilar) (Sec 13)
Corte, pin
2 No< 3 Dust cover 4 Tie-rod end
5 Nul 6 Lock washer
,
Suspension and steering systems
Left tie-fod
8 wbrication lifting 9 Tie-rod end 10 Right tie-rod 11 Tie-rod end 12 Bolt '3 Tie-rod clamp
14
Steering belicr.nk
~
ramo vel and installation
Removal 1 Raise the vehicle, suppa" it securely on jeckstands tlnd remove the front wheels. 2 Disconnect the bellcrank arms from the drag link (Section 11) and tie-rod (Section 131. 3 Remove the clamp bolt and locknut. 4 Remove the bellcrank shaft locknut and the shaft, followed by the bellcrank. 5 Replace eny worn or damaged bellcrenk assembly components.
12
5188rl09 connecting rod - removal and Inl lallatlon
Removal Raise the vehicle. support it securely on jackstands and remove the front wheels. Place the steering wheel "in the straight ahead posi tion with the steering arms paratiel to the vehicle centerline. 2 Remove the cotter pins and nuts and disconnect the ends of Ihe connecting rod from the Pitman arm and knuckle with II puller.
Installation 3 4 ing 5 6
13
Verify that the steering 8rm is parallel to the vehicle centerline. Place the connecting rod in position on the Pitman erm and steer· knuckle and install the retaining nuts and new cotter pins. Install the wheels and lower the vehicle. Have the front end alignment checked.
Tie-rod - removal and Inltallation
InstaJlat;on 6 When assembUng'the bellcrank components, make sure that new bearings are positioned lIB-inch below the bellcrank face surface as shown in the illustration. The bearings are a light press fit. which will hold them in place. The chamfer on the washer nut must be installed lacing the bellcrank. 7 Install the clamp bolt and locknut finger tight and adjust the bellcrank shalt locknut until the bellcrank just begins to rotate freely with no binding. S TIghten the clamp nut securely. 9 Connect the drag link and tie-rod to the bellcrank. 10 Install the wheels. lower the vehicle and have the front end alignment checked.
15
Steering demp er
~
removal and installation
The steering damper should be replaced with a new one if it is damaged or leaking.
Removal
Removal
Raise the fronl of Ihe vehicle, suppa" it securely on jackstands and remove Ihe wheels. 2 Remove Ihe cotter pins and retaining nuts at both ends of Ihe lie · rod. On steering damper-equipped models, remove the mounting nut and move the damper aside. 3 Use a puller to disconnect the tie-rod ends and remove the tie·rod assembly. 4 The rod ends can be removed from the tie-rod assembly by loosening the clamp bolts and unscrewing the ends.
2 With the front wheels in the straight-ahead position. raise the vehicle and support it securely on jackstands. 3 Remove the damper-to-spring tie plate locknut and lift the damper from the stud. 4 Remove the damper push rod end -to- tie·rod bracket locknut and separate the damper from the vehicle.
InstaJlat;on 5 Place the tie-rod in position, install the nuts, tighten them to the specified torque and install new cotter pins. 6 Connect the demper (if equippedlto the tie-rod. 7 Install the wheels and lower the vehicle. S Have the front end elignment checked.
Installation 5 Attach the rubber bushings to Ihe damper eyes and the pushrod. 6 Place the pushrod on the tie·rod bracket stud and install the remaining components. 7 Install the bushings in the damper mounting eye. B Pull back on the damper body to eKtend the piston and attach the mounting eye to the tie plate bracket stud. 9 Install the locknuts. 10 Lower the vehicle.
Chapter 11
11-9
Suspension and steering systems STEER ING DAMI'E R· TO. TIE ROD
IRACKET
I
STEERING OAMl"ER
~I lI-80LT
Fig. 11 .17
Fig. 11 .16
Steering bellcrank co mponents - exploded view (Sec 14) Locknut Washer C/emp bolt Locknut 5 Bellcren/< support 6 Wesher 7 S8S/
7 2 3 4
16
Steering demper co mponents - eKploded vie w (Sac 15)
Steering gear -
8 Beering 9 Bel/crank 70 Bel/crank shaft
•
IY- , - --'@
"
Ses/s 72 Bes;,'ogs 73 1lB-inch c/eeranC8
o ~i1(
_____
e ~~
~~i:i. ,
ramoval and inst allation
Removal 1 On power steering-equipped models. disconnect the hoses from the steering gellr housing lind plug them. Remove the clemp bolt lind nut and disconnect the intermediate shah from the stub sheh. 2 Paint elignment marks on the steering gear arm and steering arm (early models) or Pitman arm and steering gear Pitman shaft Hate models) to simplify installation. 3 Remove the steering gear arm or Pitman arm bolt and washer and remove the arm with a puller (AMC tool J-6632). 4 On early models (through 1976), remove the steering gear·to-frame bolts and separate the steering gear from the frame. 5 On 1977lhrough 1986 models. raise the left side of the frame just enough to relieve the pressure on the left front spring and support the frame with a jackstand. Remove the crossmember cover (if equipped). followed by the bolts attaching the steering gear lower bracket to the Irame. Remove the steering gear upper bracket-to-frame rail bolts and separate the gear from the frame . The brackets can be unbolted from the Irame.
Inst8118tion 6 On all models. clean the mounting bolt threads and apply threadlocking compound prior to installation. On 1949 through 1976 models. en9age the steering shaft with the 7 steering gear. Place the steering gear in position on the frame and install the mounting bolts. Tighten them to the specified torque. On 1977 through 1986 models, attach the mounting brackets to 8 the steering gear and tighten the bolts to the specified torque. On all models. tighten the steering shaft coupling bolts and nuts 9 to the specified torque. lOOn all models, install the steering gear arm o r Pi tman arm and tighten the nut to the specified torque. lIOn 1977 through 1986 models. install the crossmember cover (if equipped), remove the jackstand and lower the vehicle. 12 On power steering-equipped models. connect the hoses and bleed the system (Section 18).
Fig. 11 .18 1977 t hroug h 1986 model steering gear mounting b ra c kets (Sec 16)
17
Power st eering pump -
removel end Instailition
RemoV81 Loosen the pump belt adjusting bolts, push the pump toward the engine and remove the belt and (if equipped) the air pump belt. 2 Disconnect tha hoses from the pump Ind plug them and the pump connections to prevent the entry of din. 3 On va engines, remove the front bracket·to·engine bolts and lift the pump and bracket from the engine compartment. 4 On six-cylinder engines, remove the mounting bolts and nuts and lilt the pump away from the engine.
Installa tion 5 On V8 engines, Install the front mounting bracket on the pump. 6 On all models, place the pump in position in the mounting bracket and install the pump-to-brlcket bolts and nuts. 7 Connect the hoses to the pump. Fill the pump reservoir with the specified fluid and rotata tha pulley in a counterclockwise direction unt~ no more bubbles are expelled from the fluid. 8 Install the pump end tif eQuippedl the air pump drlvebelt. 9 Adjust the belt tension (Chapter I) and tighten the bracket adjusting bolts. 10 Tighten all mounting bolts to the specified torque. 11 Fill the reservoir with fluid end bleed the eir from the power steering system (Section 181.
11
11-10 18
Chapter 11
Suspension and steering systems
Power steering syltem - billeding procedure
Bleeding air out of the power steering system Is accomplished in the following manner. Check the fluid level first, with the engine !Ind pump at normal operating temperature, adding fluid as necessary. 2 Raise and support the fronl of the vehicle on jackstands. 3 Turn the steering wheellock-to-Iock (without contacting the stopsl two or three times end recheck the fluid level. It should be at the Cold or Full cold mark. 4 Start the engine l:tnd let it run 81 II fssl idle. Turn the steering wheel lock-la-lock (again, without contacting the slops) and recheck the fluid level to make sure it is above the pump body. Fluid with air in it will be light tan or ten-orange in color. S Continue turning the steering wheellock-to-Iock until all air is bled from the system. 6 After bleeding the air from the system, return the wheels to the straight-ahead position, allow the engine to run for two or three more minutes, shut it off and lower the Yehicle. 7 Road test the vehicle to check the steering action and response and make sure the fluid is at the Hot mark.
•
Fig. 11.19 19
Steering wheel - removal and Installation
Removing the steering wheel with a special puller (Sec 19)
Removal 1 Disconnect the negatiye ballery cable from the battery. 2 Turn the steering wheel until the front wheels are in the straightahead position. 3 Remoye the hom button. This cen be done by grasping it and pulling out or, on some models, roteting the bullon until the tabs align with the notches and then withdrawing it. 4 Remoye the steering wheel nut and washer. S Remove the receiver, bushing and contact plate. 6 Scribe or paint alignment marks on the steering wheel hub and shaft for reference during reassembly. 7 Use a puller to remove the steering wheel from the shaft_
Installation 8 Align the steering wheel and hub marks made during remoyal and install the wheelan the shaft. 9 Install the contact plate. bushing and receiyer assembly. 10 Install the steering wheel washer and nut and tighten the nut to the specified torQUe. 11 Connect the negative battery ca ble.
20
Wheel alignment - general information
Note: Since wheel alignment equipment is generally out of the reach
of the home mechanic, this Section is intended only to familiarize the reader with the basic terms used and procedures followed during a typical wheelalignfTlflnt job. In the lNfInt that your vehicle needs a wheel alignment check or adjustment, we recommend that the work be done by a reputable front end elignment and repair shop. The three basic adjustments made when aligning a Yehicle's front end are toe-in. caster and camber. Toe-in is the amount the front wheels are angled in relationship to the centerline of the yehicle. For e~ample, in a vehicle with zero toe-in. the distance measured between the front edges of the wheels is the same as the distance measured between the rear edges of the wheels_ The wheels are running parallel with the centerline of the vehicle. Toein is adjusted by lengthening or shortening the tie-rods. Incorrect toein will cause tires to wear improperly by making Ihem 'scrub' against the road surface. Camber and caster are the angles at which the wheel and suspension upright are inclined to the vertical. Camber is the angle of the wheel in the lateral (side-to-side) plane. while caster is the angle of the wheel and upright in the longitudinal flore-and-aft) plane. Camber angle affects the amount of tire tread which contacts the road and compensates for changes in the suspension geometry when the vehicle is tr8Y8ling around curves or over an undulating surface. Caster angle affects the self-centering action of the Sleering. which governs straight-line stability.
12-1
Chapter 12
Body
Content. Body and frame ropalrs - major damage Body repair - minor damage Bumpers - removal and installation Front fender - replacement General information Hood - removal and Installation Instrument panel crash pad - ,emoyal and installation Maintenance - body and frame . . ..•....
5
Maintenance - hinges and fatches . . Maintenance - upholstery and carpels .... . Aadialor grille - removal and Installation ... . Seat belts - removal and inslallallon .. .
4 11 7 1
Seals - removal lind installation . . . ..
9 15 2
. . . ..
Tailgate - removal and installation . . . •. •• ..•••• • Windshield and frame assembly - removal lind inSlallation
, 6
10 14
" 12 8
Specifications
Torque specifications Seat belt anchor bolts
Ft-Ib 25 to 35
General Information All models heve a separate frame and body. The hood. front fenders, radiator grill&, Windshield and frame assembly and tailgate can be un· bohed and removed in the event of damage.
2
M aintenance - body and frame
The condition of your vehicle'l body ill very important, because it is on this that the second -hand value will mainly depend. It is much more difficult to repair a neglected or damaged body than it is to repair mechanical components. The hidden areas of the body, such as the fender wells. the frame. and the engine compartment. are equally important, although obviously do not requite aa frequent attention as the rest of the body. 2 Onca a year, or every 12000 milel. it III a good idea to hava tha undersida of tha body and the frame lteam cleaned. All traces of dirt and oil will be removed and the underside can then be inspected carefully for rust, damaged brake lines, frayed electrical wiring. damaged cables. and other problems. The flont suapension components should be greased after completion of this job. 3 At the same time. clean the engine and the engine compartment
Nm 34 to 47
using either a steam cleaner or a water soluble degreaser. 4 The fender wells should be given particular attention. as undercoating can peel away and ltOoal and drrt thrown up by the tires can cause the paint to chip and flak&, alloWing rust to let in. If rust .. lound. clean down to the bare metal end apply an entl-rust paint. 5 The body should be washed once a week {or when ditty). Wat the vehicle thoroughly to soften the dirt. then wash it down with a soft sponge and plenty of clean soapy water. If the surplus dirt is not washed off very carefully, it will in time wear down the peint. 6 Spots of tar or asphalt coating thrown up from the roed should be removed with e cloth loaked In lolvent. 7 Once every six months. give the body end chrome trim a thorough wax job. " a chrome cleaner ill used to remove ruSI from any of Ihe vehicle's plated parts, remember that the claaner also removes patt of tha chrome. so use it sparingly.
3
Mainte nance - upholstery end cerpetl
Every three months, remove the cerpetl or mets and clean the Interior of the vehicle {more frequently if necessary). Vacuum the upholstery and carpets to remove loose dirt and dust. 2 If the upholstery is soiled, apply upholstery cleaner with a damp sponge and wipe it off with a clean. dry cloth.
12
12-2
Ch apter 12 Body
See COIOf photo sequence
Repair of minor scratches If the scratch is '1BIY superficial and does not penetrate to the metal of the body. repai, is Villy simple. Ughtly rub the scratched area with a fine fubblng compound to remove loose paint and built-up wax , Rmse
the area with clean waler. Apply touch-up paint to the scratch, using 8 small brush. Continue to apply thin lavers of paint until the .urface of the paint in the scratch Is level with the surrounding paint. Allow the new paint &t least two weeks to harden, then blend it Into the surrounding paint by rubbing with a vefy fine rubbing compound. Finally. apply 8 coat 01 wax to Ihe
scratch .rel. II the Icrltch 1'111 penetrated the paint and exposed the metal 01 the body, cluling the metal to lust, 8 different repeir technique is required. Remove ell loose rust from the bottom 01 the scratch with e pocket knife. then epplv rUII -lnhibiting paint to prevent the lorm8lion of rust in the future. Using e rubber or nylon epplicator, coat the scratchad aree with glale-type filler. If required, the filler can be mixed With thinner to provide a very thin paste, which is ideal for filling naHOW scratches. Before the glue filler in the scratch hardans, wrilp a piece of smooth cotton Cloth around the tip 01 e linger. Dip the cloth in thinner and then Quickly wipa it along the aurface of the scratch. This will ensure Ihat the surface of the filter I, slightly hollow. The scratch can now be painted over as described earlier in this section.
Repair of dents Whan repeiring dents, the first job i, to pull the dent out unlil the affected area is as close as potsibla to its original shape. Thera is no point in trying to restore Ihe original shape completely as the metal in the damaged area will have stretched on impact and cannot be restored to its original contours. It il better 10 bring the level of tha dent up to a point which Is about 118-lnch below the level 01 the surrounding matal. In cases where the dent is very shallow, it ;s not worth trying to pull it OUI et all. II the back side of the dent is accessible. il can be hammared out gentiv from behind using e soft-faced hammer. While doing this, hold a block of wood firmly egainst the opposile lide of the metal to ebsorb the hemmar biowl and prevent the metel from being stretched out. If the dent is In election of the body which hes double leyers, or some other factor that makes it inaccessible from behind. a different technique is required . Drill several small holes through the metal in· side Ihe damaged area, PBrticulerty in the deeper sections. Screw long, self-tapping screws into the holes JUBt enough for them to gila good grip in the metal. Now tha dent can ba pullad out by pulling on the protruding heads of the screws with locking pliers. The next Itege 01 repair is Ihe removal of paint from the demaged erea end from an inch or so of the IUHounding mall!. This is easily done with a wire brush Of sanding disk in a drill motor, although it can be done just as effecllvelv by hand with sandpaper. To complete the preparation for filling, score the lurface of the bere metal with a screwdriver or the ling of a file tor drill small holes in the affected area). This will provida a very good grip lor the filler material. To complete the repai r, see the Section on fitting and painting.
Repair of rust holes or gashes Ramove all paint from the affected aree end from an inch or so of the surrounding matal using a sanding disk or wire brush mounted in a drill mOtor. If these ara not available, a few sheets of sandpaper will do the job just as affectively. With the paint removed, you will be able to determine tha severity of the corrosion and decida whether to replace the whole panel, if pouible. or repair the affectad area. New body panals are not as expensive as most peopla think and it is ohen Quicker to install a new panel Ihan to repair large areas 01 rust. Remove all trim pieces from the affected erea (except those which will act as a guide to the original shepe of the damaged body, i.e. headlight &hells, etc.). Then, using metal snips or e hacksaw blade, remove all loose metal and eny olher metal that II badly affected by rust. Hammer the edges of the hole In to creale a Ilight depression lor the filler material. Wire brush the affected erea to remove the powdery rust from the surface of the metal. II the back of the rustad area Is accessible, treat
It WIth rust ' lnhibiting paint Sefore filling is done, block the hole In lome way. ThiS can be done with sheet metal riveted or screwed into place. or by stulling the hole With wire mesh. Once the hole is blocked off, the affacted area can be filled and paintad (see the following section on filling and painting) .
Filling and painting Many types of body fillers are available, but generally speaking, body repair kits which contain filler pasta end a tube of rasin hardener Bre best for this type of repair work. A wide, flexible plastiC or nylon ap· plicator Will be necessary lor Imparting a smooth and contoured finish to Ihe surface of the filler material. Mix up a small "mount of filter on a clean piece of wood or card boerd (usa tha herdener spannglyl . Follow the manufacturer' s instructions on the packege, otharwise the filler will set incorrectly. Using the applicator, apply the filler paste to the prepared area . Draw the applicator across the sur lace of the filler to achieve the desired Contour and to level the filler surface. As soon as a contour th81 ap· proxim8las the original one is achieved, stop working the paste. If YOll continue, the paste will begin to stick to the applicator. Continue to add thih layerl of tiller paste at 20-mlnute Intervals until the level of the hllar is just above the surrounding metal. Once the tiller has hardened, Ihe excess can be removed with a body file. from then on, progreSSIVely finar grades of silndpaper should be used, starting with 8 laO-grit paper and finishing wllh 6oo·grit wet or' dry paper. Always wrap the sandpaper around a flat rubber or wuoden block, otherwise the surface of the filler will not be completely flat . Dunng the sanding of the filler surlace. Ihe wet-or-drv paper should be periodicallv rinsed in water ThtS will ensure that a very smooth finish is producad In the final stage. At this point, the repair area should be surrounded by e ring of bare metal, which In turn should be encircled by the finely feathered edge of good paint. Rinse the repair alea wllh clean wat er until aU of the dust produced by the sanding operation is gone. Spray the entire erea wllh a light coat of primer. ThiS will reveal any imperfections in the surface 01 the liller. Repair the imperfections With fresh filler paste or gll1:e filler and once more smooth the surface with sandpap8f. Repeat ttllS spray-"nd -repalr procedul8 unt,l you are satlslied 11'181 Ihe surface of the filler and the feathered edge of the paml are perfect. Rinse the area With clean water and allow i t to dry completely. The repair araa is now ready for peinting. Spray peintlng must be carried out in e warm , dry. windless and dust-free etmosphere. Thase conditions can ba created If you have acce ss to a Illge indoor work area, but If you ere forced to work in the open, you will hava to pick Ihe day very carefully. II you are working Indoors, dOUSing Ihe floor In the work area With water will help settle the dust wh,ch would other· Wtse be in the air. II the repelr erea is confined to one body panel. mask off the surrounding panels. Thtl will help minimize tha effects of a slight mismatch in paint color. Trim pieces such as chrome strips, door handles, etc., will also need to be masked 011 or removed . Use masking tape and several thicknesses of newspaper for the masking operations. Belore spraying, sheke the paint cen thoroughly, then spray a tell area until the sprey painting teChnique is mestered. Cover the repen aree with a thick coat of promer. The Ihickness should be bUilt up UIing several thin layers 01 primer rather than one th,ck one. USing 600-grit wet -or -dry sendpaper, rub down the surfece of the primer until il is vary smooth. While doing this, the work area should be thoroughly nnled wtth water and the wet -or·dry sandpaper periodicallv nnsed as well. Allow the prtmer to dry before spraying additional COliS Sprav on the top coat, &gain building up the thickness by using several thin layers of peint. Begin spraying in the center of the rapair erea and than, using a circular mOlion, work out until the whole repeir areil and about two inches of tha surrounding original paint is covered . Remove alt masking material 10 to 15 minutes after sprilying on the final coat of peint. Allow the new paint at least two weeks to harden. then use a very fine rubbing compound to blend the edges of the new palnl into the existing paint. Finellv, apply a coat of wax.
5
Body and frame repal" -
maior demege
Major damage must be lepaired by an auto body/lrame rapair shop with the requtred welding and hydraulic straightening equipment.
12·3
Chapter 12 Body 2 If Ihe damage is serious. have the frame checked for correct alignment. as the handling characteristics of the vehicle will be affected. Other problems, such 8S excessive tire weer end weer in the transmission and steering m8Y 81so occur.
6
Maintenance -
hinges and latches
Every 3000 miles or three months, the hood, windshield, tailgate and 910vebox hinges, 85 well as the hood letches. should be lubricated with 8 lew drops of oil. Also. the hood lelch mechanism should be given
8 thin coal of grease to reduce wear and ensure free movement.
shield hinge to the frame. Remove the hold-down knobs and separate the windshield from the vehicle. 4 To install the windshield on early models, slide it onto the pins. swing it to the upright position and latch the clamps. 5 On later modell. place the windshield in position and install the Torx-head screws and hold-down knobs. 6 Connect the windshield wiper motor harness or vacuum hose.
9
Hood - removel and In.lallellon
Release the hood latches and safety catch. Mark the position of the hinges on the hood with tapa or e waxtypa pencil. 3 Remove the bolts attaching the hinges to the hood and, with the help of an assistant, separate the hood from the vehicle. 4 Place the hood in position, align the hinges with the marks made during removal and install the bolts. 1
2
7
Front fender -
re placement
Remove or disconnect all components and wire connectors attached to the fender and apron. 2 Remove Ihe rocker penel molding !if equippedl and remOWl the bolts and washers attaching the fender and brace to the dash panel. 3 Remove the fender-to -radiator grille bolts, nuts and washers. 4 Pull the fender out and separate it from the vehicle. 5 To install the fender. place it in position and install the bolts, washers and nuts attaching it to the radiator grille and daSh panel. 6 Instail the brace-to-dash and fender attaching bolts and washers. 7 Connect the side marker light and install the components which were previously removed.
8
Windshield and frame assembly - removal and Installation
Disconnect the windshield wiper motor electrical or vacuum hose connector. 2 On early models (through 1975). unlatch the two clamps and fold the windshield forward until the slot tines up with the flat side of the pin in the body hinges. Slide the windshield off the pins and separate it from the vehicle. 3 On later models. remove the Torx-head screws attaching the wind -
10
Radiator grille -
removal and Inlftellation
On
.....
Fig. 12.1
/
Hood hinge lubrication points (Sec 6)
, rt"-l
~_ _ . IMo.......ftl ~tot.
~",,·/""'.,fj\,1
..
...•
~~"'Cotch
Fig. 12 .2
Hood latch lubrication point {Sec 6)
Fig. 12.3
Typlcal hood com ponents {Sec 9)
12
These photos illustrate a method of repairing simple dents. They are intended to supplement Body repair - minor damage In this Chapter and should not be used as the sale instructions for body repair on these vehicles.
1
"you can't access the backside of the body panel to hammer
out the dent, pull It out with a sllde-hammer-type dent puller. In the deepest portion of the dent or along the crease line, drill or punch !"Iole{s) at least one Inch apart .. .
... then screw the slide-hammer Into the hole and operate It. Tap with a hammer near the edge of the dent to help 'pop' the metal back to its original shape. When you're finished, the dent area should be close to Its orlgir\81 contour and about. lI8-lnch below the sur1ace of the sulTounding metal
2
3 Using coarse-grit sandpaper, remo"e the paint down to the bare metaL Hand sanding works fine, but the disc sander shown here makes the Job faster. Use flner (about 320-grit) sandpaper to feather-edge the paint at least one Inch around the dent area
4 When the paint Is removed, touch will probably be more helpful than sight for telling If the metal is straight. Hammer down the high spots or raise the low spots as necessary. Clean the repair area with wax/silicone remover
5 Following label Instructions, mix up a batch of ptastic filler and hardener. The ratio of filler to hardener Is critical, and, if you mix It IncolTectly, It will either not cure property or cure too quickly (you won 't ha"e time to file and sand It Into shape)
6 Working quickly so the filler doesn't harden, use a plastic applicator to press the body filler firmly Into the metal, assuring It bonds completely. Work the filler until It matches the original contour and Is slightly above the sUlTounding metal
7 Let the filler harden until you can just dent It with your fingernail . Use a body file or Surlorm tool (shown here) to roughshape the filler
9 You shouldn't be able to feel any ridge at the transition from the filler to the bare metal or from the bare metal to the old paint. As soon as the repair is flat and uniform, remove the dust and mask off the adjacent panels or trim pieces
8 Usa coarse-grit sandpaper and a sanding board or block to work the filler down until It's smooth and even. Wont down to finer grits of sandpaper - always using a board or block - ending up with 360 or 400 grit
10 Apply saverallayers of primer to the area. Oon't spray the primer on too heavy, so it sags or runs, and make sure each coat Is dry befora you spray on the Mlxt one. A professional-type spray gun Is being used here, but aerosol spray primer Is avaUable InexpensNely from auto parts stores
12 11 The primer will help reveallmperlectlons or scratches. Fill these with gladng compound. Follow the label instructions and sand it with 360 or 4OO-grit sandpaper until It's smooth. Repeat the glazing, sanding and respraylng untit the primer reveals a perfectly smooth surlace
12 Finish sand the primer with very fine sandpaper (400 or 600grit) to remove the primer overspray. Clean the area with water and allow It to dry. Use a tack rag to remove any dust, then apply the finish coat. Don't attempt to rub out or wax the repair area until the paint has dried compietiWy (at least two weeks)
12-6
Chapter 12 Body
AWHT" CROSSMEM8Ef1
COVER
FRONT aUMPER RAil Fig. 12.4
Radiator gril le and hold-down
Fig. 12.5
."emb ly - ex ploded vie w {Sec 101
9 Saperate the grilie from the vehicle. 10 To Install the grille, place il In position and connect the wires. 11 Remove the plugs end connect the air-conditioning hoses. 12 Place the radiator support rods in position in the grille support brackets and install the mounting hardware. 13 Attech Ihe grille to the crossmember hold-down assembly. 14 Align 1M grilie panel with the fendEifs end install the retaining bolts end washers. 15 Install the screws and washers retaining the radi8tor shroud. 16 Instllil the crossmember cover (if equipped), 17 Take the vehicle to a properly equipped shop to have the eirconditioning system recherged and checked for leaks.
Front bumper and c rossmember cove r (Sec '1 ,
•••
~ '1'"
AHTI-SUP
,."
~~ .
"
Bumper. -
"
removal and Installation
Disconnect all components wnicn could interfere witn removal (sucn as fog lignts and license plate lights). 2 On front bumpers, remove tne lront crossmember cover (if equippedl from tne frame extensions. 3 Remove tne mounting bolts and nuts end separate me bumper from tne venicle. 4 To install tne bumper, place it in position and installtne mounting nuts and bolts. S Install or connect all components wnicn were removed.
Fig. 12.6
13
.r
..
SOC KiET
.~ BULB
'N D W
Ty pical later model ltep rear bumper compo nentl (Sec 11 )
Seetl - remova l end Inl1ellalion
Remove the bo lts atteching the seal assembly brace or suppon to Ihe floor pan and lift the seat out of Ihe vehicle. 2 Place the saat assembly in position and install the mounting bolts.
12 Tailgate - re moval and install ation 14 On most models tne tailgate is neld in tna closed position by nooks wnich pass tnrough tne slotted brackets on tne tailgate and body. To remove the tailgate, rotate it approximately 45 degrees from tne full up position, disengage tne right hinge and tnen rotate it a few degrees funner 10 disengage tne left ninge. Separate t ne tailgate Irom Ine venicle. 2 On late model CJ-7 and Scrambler models, the tailgate is held in place by Torx-head screws and suppa ned by two cables. R.emove the screws and washers retaining the cables and, with the tailgate closed, remove the Torx-head screws and separate tne tailgate from the vehicle. 3 To instell the slotted brecket-type tailgales, hold the tailgate at approximately 45 degrees from the full up position and engage Ihe rlghl hinge. ROlate the tailgate a few degrees lunher and engage the left hinge. 4 On lete model CJ-7 and Scrambler models, piece the tailgate in position and inslall the Torx-head screws. Install the support cables on the tailgate.
Saat behs - removal and Installal ion
Remove the anchor bolts and the seat belts. On later models a Torxhead bolt, requiring a speciel tool for removal, is used to enchor the seat bolts. 2 Plale the seat belt in position, install the anchor bolts end tighten them to tne specified torque.
15
Instrument panel crash pad - removal and inst alletlon
1 Fold the windshield forward for access. 2 Remove the retaining screws and separate the crash pad from instrument panel. On earlier models it will be necessary to use a blade tool, such as a putty knife. inserted batween the frame and pad to pry tha four clips loose. 3 Place the pad in position and snap the clips Of equipped) into retaining holes. Inslall the retaining screws.
the flat the the
Conversion factors Length (distance) X 25.4 = Millimetres (mml X 0.305 = Metres 1m) X 1.609 "" Kilometres (km)
Inches lin) F~t
(ttl
Milas
= Inches (in)
X X X
0.0394 3.281 0 .621
= Miles
X X X X X X X X
0 .061
0 .264
= = = = = = = =
= Ounces (01) .. Pounds Ubi
=
Feet (ft)
Volume (capacity) Cubic inches leu in: in') Imperial pints Ump pd Imperial quarts (Imp qt) Imperial quarts (Imp ql)
US qua"s (US qt) Imperial gallons (Imp gail Imperial gallons (Imp gall us galions (US gal)
X X X X X X X X
16.387 = Cubic centimetres (cc: em')
0.568
=
Litres (II
1.137 = litres (If 1.201 "" US quarts (US qd 0.946 = litre! m 4.546 = litres (I) 1.201 = US gallons (US gal) 3.785 = litres (I)
1.76 0.88 0 .833
1.057 0.22 0.833
Cubic inches leu in; in') Imperial pints (Imp pi)
Imperial quarts limp qd Imperial quarts (Imp qt)
US querts (US ql) Imperial gallons (Imp gall Imperial gallons (Imp gal\ US gallons (US gaif
Mass (weight) Ouncas (all Pounds (lb)
X 28.35 = Grams (gl X 0.454 = Kilograms (kg)
X X
0.035 2 .205
X 0.278 = Newtons (NI X 4.448 .. Newlons (NI 0 .1 = Kilograms -force (kgf; kg) X
X X X
0.225 9.81
X
14.223
inch
X 0.070 .. Kilograms-force per square centimetre (kgl/cm'; kg/cm') X 0.068 _ Atmospheres (aIm)
X
14.696
inch
X 0 .069 = 8ars
X
14.5
inch
X 6.895 = Kllopascals (kPal
X
0. 145
X
98.1
X
0 .868
inches
1.152 = Kilogrems-forca cantimetre (kgf cm: kg cm) X 0 .113 = Newton metres (Nm)
X
8.85
inches
X 0.083 = Pounds-force feet (lbf It; Ib It)
X
12
feet (Ibf It; Ib It)
X 0.138 - Kilograms-force metres (kgf m; kg m) X 1.356 = Newton metres (Nm) X 0.102 = KILograms-force metres (kgf m; kg m)
X
7.233
= Pounds-force (lbf in; Ib in) = Pounds-force (lbf in; Ib in) '" Pounds·force (lbf in; Ib In) = Pounds-force
X X
0.738 9.B04
= Pounds-force feet {Ibf It ; Ib hi = Newton metres (Nm)
X 745.7 =Watts (W)
X
0.0013
Force Ounces-force (olf: Ol) Pounds-force (lbf: Ibl Newtons (N)
3 .•
= Ounces-force (ozf; all = Pounds-force Ubf; Ib) = Newtons IN)
Pressure Pounds-force per square (psi; Ibf/in'; Ib/in') Pounds-force per squilre (psi; IblAn'; Iblin') Pounds-force per square (psi; Ibf/in'; Ib/in') Pound s-force per square (psi; Ibf/in'; Iblin'l Kilopasc&ls (kPa)
Inch
X
0.01
= Kilograms-force per square
= Pounds·force per square (psi; Ibflin'; Ib/in') = Pounds-force per square (psi; Ibflln'; Ib/in') = Pounds-force per square (psi; Ibf/ln'; tblin') :z Pounds-force per square (psi; Ibf/ in'; Iblin') = Kllopascals (kPa)
inch Inch inch inch
centimetre (kgf/cm': kg/cm')
Torque (moment of force) Pounds-force Ubi in; Ib in) Pounds-force (lbf in; Ib in) Pounds-force IIbf in; Ib in) Pounds-force
inches
X
Pounds-force feet (Ibl It: II> It) Newton metres (Nm)
Inches inches inches feet (lbf It: Ib It)
Power Horsepower (hp)
.. HOr1lepower (hp)
Velocity (speed) Miles per hour (mil es/hr; mph)
X
1.609 = Kilometres pflr hour (km/hr: kph) X
0.621
= Miles per hour (mlles/hr; mph)
2.825 2.352
.. Miles per gallon, Imperial (mpg) = Miles per gaHon. US (mpg)
Fuel consumptionMiles per gallon, Imperial (mpg) Miles per gallon, US (mpg)
X 0.354 = Kilometres per litre (km/1) X 0.425 = Kilometres per litre (km/1)
X X
T empersture Oegrees Fahrenheit
= loe)l , .B) ... 32
Degrees Celsius (Degrees Centigrade; °e)
Wlf Is common practicll to convert (rom miflls per gllflon (mpgl to litres/IOO ki/omll fres (f/100kmJ. where mpg (Imperilll) x 1/100 km = 282 and mpg (US) x 1/100 km = 235
= (OF _ 32)
)I
0.56
IND-1
Index A About this manual, 0-2 Air filter and PCV fitter replacement, 1-22 Air cleaner service, 011 bath-type, 1- 22 Air conditioning system check. 3-6 components. removal and installation, 3-9 Air injection (AI) systems, 6-5 Alternator, 5- 4 Antifreeze, general information, 3-7 Automatic transmission, fluid change, 1-25 Automotive chemicals and lubricants, 0-16 Axl. front. 8-8 rear. 8-11. 8-13 Axleshaft front, 8-8 rear, 8-10
V6 engine, 2E-8 150 cu In four-cylinder and alt In-line six-cylinder engines, 2e-11 151 cu In four-cylinder, 2B-l1
Carburetor application. 4-5 choke check (late models only), 1-23 feedback cartJtJr&lor, 6-'2
mounting torque check, 1-24 ovemaul and adjustment, 4-6, 4-8, 4-13, 4-14, 4-18, 4-22. 4-31 removal and installation, 4-5 servicing, 4-5
Catalytic converter, 6-2 Charging system, check, 5-2 Chassis electrical system, 10-0 through 10-37 Chassis lubrication, '-18 Clutch hydraulic release system, removal, installation and bleeding. 8-3 removal, inspection, Installation and adjustment, 8-2 Clutch pedal free play check, 1-25
removal and Installation, 8-2
B Battery booster battery fjump) starting. 0- IS cables, check and replacement, 5-2 check and maintenance, 1-34 removal and installation, 5-2 Body, 12-1 through 12-6 hinges and latches, 12-3 maintenance. 12-1 repair, 12-2 Brakes, 9-0 through 9-13 bleeding procedure. 9-1 cahpef.9-5 check, 1-27 diSC. 9-2, 9-3 drum. 9-6 hoses and lines. inspection and replacement, 9-1 master cylinder. 9-11 parIong brake. adjustment, 9-10 vacuum booster, 9- 1. 9-2 Bulb replacement, 10- 3 Bumpers, removal and installation, 12-6 Buying parts, 0-8
c Cable, replacement, battery, 5-2 Camshaft L- and F-head four-cylinder, 2F-9 V8 engine, 20-7. 20-8
Connecting rods aod pistons assembly, 2A-5, 2A-8 Contact points and condenser, '-29 Coolant, temperature sending unit, 3-7 Cooling system antifreeze, general information, 3-7 check. 1-19 geoeral information, 3-2 servicing (draining, flushing end refilling), 1-36 Cooling, heating and air conditioning systems, 3-1 through 3-11 Crankshaft inspection, 2A-8 L- and F-head four-cylinder engines, 2F-5, 2F-l0 150 cu In four-cylinder and all in-line six-cylinder engines, 2C-14 151 cu In four-cylinder, 28-12 V6 engine. 2E-1O V8 engine, 20-9 removal, 2A-6 Crankshaft pulley hub and front seal, 151 cu in fOUf-cylinder, 28-7 Crankshaft rear main oIlaeal l- and F-head lour-cylinder, 2F-8 150 cu in lour-cylinder and allin-line six-cylinder engines, 2C-12 151 cu In lour-cylinder, 28-10 V6engl09,2E-l0 V8 englJ'IEI, 20-7 Cylinder head cleaning and inspection, 2A-3, 2F-7 disassembly,2A-3 150 cu In four-cylinder and all in-line six-cylinder engines, 2C-8 151 cu In four-cylinder, 28-6, 28-7 L- and F-head four-cylinder. 2F-5, 2F-7, 2F-l1 reassembly,2A-5 V6 engine, 2E-7 V8 engine, 20-5. 20-9
IND
INO-2
Index
D Diagnosis, 0-18 Diff&rentiallubricant change, 1-27 Distributor, 5-10, 5-13 Dnvebelt c heck and adjustment, '-20 Drivetine, 8-1 throug h 8-13 Oriveshatts and universal Joints, 8-4
E Electrical syst ems, 5-1 directional switch, check and replacemeot, 10-7 fuses and fusible links, general information. 10-2 headlight. 10-3, 10-5 ignition switch, removal and Installation, 10-4 instrument cluster, removal and installation. 10-7 troubleshooting, general Information, 10-, windshield wiper molor, removal and installation, 10-5 Emissions control systems, 6-0 through 6-13 Engine 150 cu in four-cylinder and all in-line six-cylinder engines,
2C-l throogh 2C-18 151 cu in four-cylinder engine, 28-, through 28-14 block.2A-7 block valve seats and guides, servicing. L- and F-head four-cylinder, 2F-7 crankshaft, 2A-6, 2A-S cylinder head, 2A-3 through 2A-5 disassembly and reassembly sequence L- and F-head four-cylinder, 2F-3 V6 engine, 2E-4 VS engine, 20-4 disassembly, general information, 2A-3 external components, installation, 2E-tl 150 cu in four-cylinder and allin-line six-cylinder engines, 2C-IS external components, removal ISO cu in four-cylinder and allin-line six-cylinder engines, 2C-6 L- and F-head four-cylinder, 2F-3 V6 engine, 2E-6 front plate, installation, L- and F-head four-cylinder, 2F-l 1 general ovemaul procedures, 2A-l identification numbers, 0-7 Idle speed adjustment, 1-24 Initial start-up and break-in after ovemaul, 2A-12 installation, 2E-tl ISO cu in lour-cylinder and allin-line six-cylinder engines,2C-IS 151 cu in four-cylinder, 28-13 L- and F-head four-cylinder, 2F-12 VS englna, 20-10 V6 engine, 2E-l1 L- and F-head lour-cylinder engines, 2F-O through 2F-12 main and connecting rod bearings, inspection, 2A-a mount flexible cushions, replacement, 150 cu In four-cylinder and allin-line six-cylinder engines, 2C-6 mounts, replacement, va engine, 20-4 oil and filter change, 1-16 oil,levai check, 1-13 overhaul, general Inlormation, 2A-2 piston rings, instatlation, 2A-9 Piston/connecting rod assembly, installation and bearing oil clearance check, 2A-l a pistons and connecting rods assembly, 2A-5, 2A-S rebuilding alternatives, 2A-2 removal, 2A-2 150 cu In four-cylinder and aJi in-line six-cylinder engines, 2C-6
151 cu in four-cylinder, 28-4 L- and F-head lour-cylinder, 2F-2 V6 engine, 2E-3 va engine, 20-4 repair operations possible with the engine in the vehicle, 2A-l V6 engine, 2E-l th rough 2E-l1 VB engine, 20-1 th rough 20-10 valves, servicing, 2A-5 Engine electrical systems, 5-1 through 5-13 Evaporative Control System (ECSI, I -34, 6-1 Exhaust Gas Recirculation (EGR) system, 1- 24, 6-6 Exhaust heat valve chec k, 1-24 Exhaust manifold, removal and installation, 151 cu in four- cylinder, 28-6 Exhaust system , 1-19, 4-36 EJrtemal voltage regulator, removal and Installation, 5-4
F Fault finding , 0- 18 Fencler, front, r eplacement, 12-3 Filter replac ement, engine 011, 1-16 Floating oil intake, L- and F-head four-cylinder, 2F- 5 Fluid level checks, 1-13 FJywhool 151 cu in four-cylinder, 28-10 150 cu in four-cylinder and all in-line six-cylinder engines, 2C-ll, 2C-12,2C-15 V6 engine, 2E-9 Front wheel, drive hub, 6-13 Fuel and exhaust system s, 4-0 th rough 4-36 check and filter replacement , 1-21 general Information, 4-4 lines and hoses, check and replacement, 4-5 pump, 4-4 tank,4-35
G General engine overhaul procedures, Generator, 5-5
lA-'
H Heater system, 3-7 Hood, 12-3 Hom, 10-7 Hoses, underhood, 1-20 Hub, rear, removal and installation , 6- 11 Hydraulic lifters 151 cu in lour-cylinder, 28-5 150 cu in lour-cylinder and all inline six-cylinder engines, 2C-9, 2C-ll,2C-16 L- and F-head four cylinder engines, 2F-7, 2F-9
I Ignition system coil, removal and installation, 5-9 conventional, check, 5-7 electronic check. 5-8 electronic module, removal and installation, 5-10 electronic, pick-up coli, removal and installation, 5-12 timing, check and adjustment, 1-31
Index Instrumen t c luster, removal and installation, 10-7 Instrument panel crash pad, removal and installation, 12-6 Intake manifold, va engine, 20-5, 20-9 151 cu In four-cylinder, 28-5 Introduction to routine m
J
IND-3
Piston/connecting rod assembly installation and bearing 011 clearance check, 2A-l0 removal, L- and F-head four-cylinder, 2F-5 removal and inspection, 2A-5, 2A-8 POSitive Crankcase Ventilation (PCV) system, 1-21, 6-1 Power steering system bleeding procedure, 11-10 pump, removal and installation, 1t-9 Pushrod cover, 151 cu in four-cylinder, 28-4 Pushrods and valve lifters.. V6 engine, 2E-8
Jacking, 0-15
L Lubric ation system, 150 cu in four-cylinder and all in-line sixcylinder engines, 2C-l1
M Main and connecting rod bearings, 2A-S Inspection, 2A-a selection 150 cu in four-cylinder and all in-line six-cylinder engines, 2C-14 va engine, 20-10 Maintenance techniques, 0-9 Manual transmission, lubricant change, 1-26
N Neutral safety switch, check, adjustment and replacement , 78-3
o Oil bath-type air c leaner service, 1-22 Oil pan 150 cu in four-cylinder and all in-line six-cylinder engines, 2C-l1, 2C-15 V6 engines, 2E-9 va engine, 20-5, 20-9 151 cu in four-cylinder, 28-9 L- and F-head four-cylinder, 2F-5 Oil pump 151 cu in four-cylinder engines, 28-9, 28-10 150 cu in four-cylinder and ali in-line six-cylinder engines, 2C-12, 2C-15 L- and F-head lour-cylinder, 2F-3, 2F-a, 2F-l 1 va engine, 20-7 V6 engines, 2E-6, 2E-l a Oil pump driveshaft, 151 cu in four-cylinder, 28-8 OU seal, 2C-12, 2D-7, 7C-3, S-8 Oversize and undersize component designation 150 cu In four-cylinder and all in-line six-cylinder engines, 2C-6 L- and F-head four-cylinder, 2F-2 va engine, 20-3
p Pinion oit seal, replacement, 8-12 Piston ring s, installation, 2A-9
R Radiator, 3-2, 3-7 Radiator grille, removal and Installation, 12-3 Recommended lubricants and fluids, 1-' Rocker arms, covers, pushrods and valve springs, 151 cu in four-cylinder, 28-4 Rocker gear, 150 cu in four-cylinder and all in-line slx-cyllnder engines, 2C-8, 2C-l1 Routine maintenance schedule, 1-6
5 Safety lirst, 0-17 Scheduled maintenance, 1-6 Seat belt, 12-6 Spark control system, 8-3 Spark plug, 1-28 Speedometer, 10-6 Stabilizer bar, front, removal and installation, 11-1 Starting system, 5-5 through 5-7 Steering system, 11-4 through 11-10 Suspension and steering check, 1-20 Suspension and Steering systems, 11-0 through 11-10 hub, removal and installation, 11-3 shock absorber, removal and installation, 11-1 springs, 11-3
T Tailgate, removal and installation, 12-6 Temperature sending unit, coolant, check and replacement, 3-7 Thermo-controlled Air Cleaner (TAC), 1·23, 6-10 Thermostat, removal and installation, 3-5 Throttle linkage, check and adjustment, 4--4 Timing chain va engine, 20-5, 20-8 V6 engine, 2E-6 150 cu In four-cylinder and all in-line six-cylinder engines, 2C-ll 150 cu in four-cylinder and all in-line six-cylinder engines, 2C-9 Timing gear 151 cu in four-cylinder, 28-7 L- and F-head four-cylinder, 2F-5, 2F-ll Timing gears or chain and sprockets, l - and F-head lour-cylinder, 2F-5,2F-l1 Tire and tire pressure cheeks, 1-17 Tire rotation, 1-25 Tools, 0-12 Towing, 0-15
IND
INO-4
Index
Transfer Case, 7C-O through 7e·tO disassembly, Inspection and reassembly, 7C-3, 7e-S, 7C-6 lubricant change, 1-26 mounted drum-type parking brake, shoe replacement, 9- " oil seal replacement, 7C-3 Quadra-Trac, stick-slip condition diagnosis and correction, 7e-1 removal and Installation, le-1 shift linkage, lubrication, check and adjustment, 7C-2
Transmission automatic, 7B-l through 78-5 band, adjustment, 78-4 diagnosis, 78-2 fluid change, 1-25 neutral safety switch, check. adjustment and replacement. 78-3 removal and installation, 78-4 shift linkage, adjustment, 78-2 throttle linkage, adjustmen t, 78-2 manual, 7A-O through 7A-24 disassembly. inspection and reassembly, 7A-5, 7A-9, 7A-12,
7A-17, 7A-IS, 7A-21 external shift linkage, adjustment, 7A-3 lubricant change, 1-26 planning major transmission work, 7A-3 removal and Installation, 7A-l, 7A-2 shift assembly, removal and Installation, 7A-2 Troubl eshooting, 0-18 Tune-up and routine maintenance, 1-1 through 1-36 Tune-up sequenc e, 1-6
u Undersize/oversize c omponent designation V6 engine, 2£-3 Universal joints, 8-6 Upholstery and carpets maintenance, 12-1
v Valve clearance adjustment (F- and L-head engines only), 1-36 lifters L- and F-head fou r-cylinder, 2F-7, 2F-9 150 cu in four-cylinder and all in-line six-cylinder engines, 2C-9, 2C-l 1,2C-16 15 1 cu in four-cylinder engine, 28-5 Valves and springs (In block), installation, 2F-5, 2F- 9 Valves, S8fVicing, 2A-5 Vehicle Identification numbers, 0-7
w Water pump, removal and Installation, 3-5 Wheel bearings adjustment, 11-5 check,I-25 inspection and lubrication, 11-6 Wheel cylinder, 9-9 Windshield and frame assembly, 12-3 Windshield wipers, inspection and blade replacement, '-36 WIring diagrams, 10-6
Automotive Manuals NOTE: New manusls are added /0 (his list on a periodic basis. If you do not 588 alisling for your vehicle, consull your local Haynes dealef for the lalest product informa tion. ACURA ' 12020 Int-e.. '86 th'" '89 .. Legend '86 IhN '90
AMC J _ CJ - Me JEEP (50020) 14020 NlId • mod.... Concord, Homet, Gremlin .. Spil'll '70 thru '83 14025 (ReneuItlAm.nce" Encon '83 thN '87
.u:.
AUDI 15020 4000 all model, 'SO thru '87 1602.5 5000 all models '77 Ihru '83 15028 5000 all model. '&4 thru '68
AUSTIN·HEALEY Sprite · see MG Midget (660 15)
BMW ' 18020 311 Series roollnctuding diesel 01' 11M-wheel dnvto models '82 II'IN '92 "18021 3 s.n.. e~cep t l25iX models '92 thru '97 18025 3201 all .. eyl models '75 tlvu '83 18036 11281 & 530i l1li models '75 thN '80 18050 1&00 ttl'" 2002 ucop! TUIbo '59 thN '77
BUICK Century (front ....... .. drhle) • _ GM (829) ' 1!i102O 8ulck, Olclamobl.... Pontiac: Full-" . (front wheel dmre) all model. '65 IhN . . IkridI EIiI<:tr1l, LeSabnI ...:I Pan. ...........; Oldsmobile o.tt. 88 Roy., Ninety Eight and Regency: PontltIC BonlleVilie t8025 Sule k Oldamobllto .. Pontiac Full-ek. (tkar whHI 1It'Iw) Bu6cII e-. 70 thru '90, Ellctra70 IIwu '&4. LeSabre '70 thru '85 Limiliod '7. thru 79 OIdINnOblI. CIA,""'; C~ '70 Itwu '9(1, Oehl!. 88 '70 thn.l '85,Ninety •• lght '70 thru '84 Ponu.e BoorMvilie '10 Ihtu C.taIina '10 Ihtu 'S" GrandltlIIe 70 Ihru 75. P~ '83lhru '86 l D030 MkI-.u:. ~I & C ... f'Nr-drive models willi V8, vallrld TUI'bo '14 Ihru '81 Aev-I • we GENERAL MOTORS (38OIO) Alvieno .... GENEFIAL MOTORS (38030) ANd ..... t ....... CHEVROtET (2400f6) 5qNwk · ... GENERAL MOTORS (38( 15) SkyIaort< ' 80 thru ' 85 · ... GM (38020) SlI~rt< 'M! on · ... GM (38025) Som....t · ... GEN ERAL MOTORS (38025)
·S'.
tu..,. "
CADILLAC '21030 Cadll..., A. .r Wheel D..... "I gasoline model. '70 thru '93 CI....rTOn ' . . . GENERAL MOTORS (38O IS) Eldorado · ... GENERAL MOTORS (38030) SevlIIe'SO thru '&5 .... GM (38l3D)
CHEVROLET ' 24010 Astra & GMC Set. ri Mlnl. ... n. ·85 Ihru '93 24015 C ..... rova .. modeI.'701tvu·81 24018 C~ 811 modeII'821htu 't2 C.... IIM· ... GENERAL MOTORS (38OIS) C.\ebrttr · ... GENERAL MOTORS (38005) 24011 C.....ro & Flreblrd '931hru '91 24020 C ...... IIe , Malibu & EI C .... 1no '69 thru 'S7 24024 c .......... a Pont..., Tlooo 761hru '87 Cltstlon· see GENERAL MOTORS (38020) ' 24032 ~ .. model. '81 thru'96 24040 Co .... tt .... V8 model. '68 Ihru '82 '2404' Corv. tt. all models '64 Ihru '96 103015 C..... ro .. t Engine Overfl..,1 M......, 24045 Full-slze s.un. Capric;:., ~~, Bel AM & W~ '691hru '90 24048 Impels ss a c.prk. Mel 8u1c11 ANdm. ."" '9' Ihru'96 Lumina · see GENERAL MOTORS (38010)
24048 .......... Mont. carlo '95 Ihru '116 LumI... APY • _ OM (38035) 24050 Lu .. Pkk. up all 2WO & 4WO '12 thru'82 ' 240155 Monte c."., .. modIIIs '70 thru '88 Monte Car10 "951twu '911 • _ LUMINA (2«)48j 2 4059 Mov• .at va rn<>sns. BIaz_ & JImmys '67 IhN '9' '240&5 Pick .... '88 thru ' N · Chevrolet & GMC, .. 1uII·1i" picI<-ups. '68 thru '98; 81a1:... & Jimmy '92 Itvu '94: Suburban '921hru '118: Tahoe & YukOll '96 24070 5-10' 5- 15 Plck-upe '62 tIwu '93, Blazer & Jimmy '8311vu '94, ' 240 71 5-'0.5· 15 Plck-<194 '$( IIvu '96 BIaz., • Jimmy '95 thru '96 ' 240715 $print & Qeo Metro '85 Ihru '94 ' 24080 Vane _ Chsvrolst a GMC, va & In-lins 6 cyI/ndSr models '68 ttwu '96
CHRYSLER 250' 5 Chrpl.r Clm,I. , Dodge SlJ'stus, PIymoU'th Breeu '95 thru '96 25025 Chov-ler Conconle, N_ YOf'ker' utS, Dodge intrepid, EsoIe VIsIon, '93 Ihru 'i7 10310 Chrp .... En-gine 0ve0tIsu1 ......... '28020 Full •.u:. Front_~ Drive '881twu '93 K-C... , _ OOOGE Aries (30008} Le. ., - ... DODGE DaytOOIi (30030) ' 25030 Ch..,..,.r' ptymouth MId-, 1n fronI....tMsI drive '621hn1 '95 Aur_'IIIfMeI Drive • see Dodge (30050)
DATSUN 280011 200SX all models '60 thru '8J 28007 8-210 all models '13 Ihru '76 28009 210 .. models '19 IhN '62 28012 24OZ,:ze.oz & 2.IIOZ Coups '70 Itwu 78 280,4280ZlI Coups&2.2'79IhN'8J 300Zll _ ' " NISSAN (72010) 280111 310 all models '711 1hru '82 28018 510 & PU21 PIck-up '1I6IhN '73 28020 510 811 modeIs'78 IhN '81 28022 520 SeriH PIck_.... all modeII '731twu '19 120 $eri. . PIck, up -,.. NlSSAN (72030) 28025 810JMp1.... aUguoiIne modeIl. 'n Ihru 's.
DOOGE
~ & aoo -,.. CHRYSLER (2SO:JO) ' 30008 """ & Plymouth Aetlsnt '81 IhnI '69 30010 C......n & Plrmouth Voy-es' M1n1_V.... all modeIs·S. ttvu '95 ' 3001' C........ a Plymouth Voyager Mini-V.", all models '96 thru '98 300 t 2 ChsllenferlPtymouth Ssporno 76 Itwu '83 30015 Colt & ~ ct..np (fnInt ............... all models '781hru '87 ' 3002 0 D.!tobo Plck_upe all models '87 tlv\l '96 300211 D..... OeInon, P'Iymovth BsITKIICIs, Dust..... Vellant 5 cyi models '87 IhnI '7tI ' 30030 Daytonl & Ch..,..... ~ 's. ttwu '89 Intrepid - _ CHRYSLER (2502S) ' 30034 Neon all model. '1I51hru '97 ' 300315 Omnl a Plymouth Horizon '76 tlv\l '90 ' 30040 PIck_u ... .. tuI·~. modsIs '7. 1twu '93 '30041 PIck_upe all lui,,, models '$( IhnI '98 '30045 A.... 5OID50 PIck' upe a "-'cIef'MeI Plymouth 4rTow Plck-upe 79 1hru'93 300150 DoOge/PIyrnouthIChrp", rear w'-I drive '7' ttwu '89 ' 300&5 Shadow & ~ . . . . . . - - 'Vltvu '94 '30050 SpIrit & ptymouth Acelelm '891hn1 '9S ' 3OOe5 V.n. - Dodoe' PI)'movth 71 Itwu '96
EAGLE T. . . _,.. MitSI.J/JhhI Eclipse (68030) Vblon - _ CHRYSLER (2502S)
fORD 103155 Ford AutOff'st1c T,."smIssIon o...m..,1 ' 35004 MI'04W' M.......". .. mods!I'861twu '08 ' 38008 Con'- & ~ Mystlqus '9S thru '98 38008 Couriet' PIck... .. rnodeII72 thru '62 3801 2 Crown Vlctorbl' Mereu..,. 0.....:1 Marqul. '88 Itwu '96 10320 Ford Engine OOIemsul Manu.1 38018 ~ L~ " rnodeiII '6' ttwu '110 '38020 &cortIMsn:ury T,..,... '9' IhnI '96 ' 38024 ~ .......ct. IhnI '9S 30028 Felrmont' Mereu..,. Zephyr '78 Ihtu '83 :MJ03O F. .t .... & upl ... '86 ttvu '111 3&032 F". ts 411 model, 'n thru '80 3&030 Ford & Mercvty FuIt"llz., Ford LTO & Mercury ~ thru '82): Ford Custom 5OO,Coootl'y Squh, ero.n Victolill & Msrcu-y Colony Pn IhN '611: Ford LTO Crown Victorll & Mercury GnIn MsrquiI f831hN '87) 3$040 GnonM.. iIIIeI'cury Monwdo '7111hn1 '80 35044 Ford. Mercwy Mld-liu. Ford T1u1dsotWd & t.4erewy Cougw nllltwu '62); Ford LTO & Msreury "'-
"'"* '.,
nil nil
nil
""'*"
GENERAL MOTORS '10300 OM AutomatIc TrsnsmiMkotI 0w0rtIau1 °380015 BuIck Century, a-..o..t c.Iebrtty, 0IdIi. Ibl a ~ Clan a PorotiIic 8000 811 rnodIII5 '62 thru '96 '38010 Buick Aepl. Chewolet Lu-m1..., Oldslnobl.. CIItlaI Supremto a PontlK O.-.nd Prbc lront-wtlNI dr1Ys modeIIo '88 Itwu '9S '38015 Buick ~ c.dtl..., CImsrTon, Chewolet c.-Iler. Oldsmobile Flrenu • PorrtlllC J-2000 a aunbird '821hn1 '94 ' 38018 CMvroIet CSV.cier. PontIsc ~ '9S Ihru '96 38020 llulck ~ C ........... Citstlon. 0kIs Omep, I"ontlIlC Phoenbt '80 Ihru '85 3&02.15 Ikolck Sky\atk • Some.Mt, Oldsmoblla Achleva a Cabo1. and PonUIlC Gnnd Am .. modsl& '85 ttwu '95 38030 CsdII..., EIdoor-..Io '71 Ihru '85, ........ '80 tIwu '88, Il'demotol.. TOf'OIIedo 7' Ihru '85 & Sulck A....... 7& thno '85 ' 38035 CHwoIst Lumlnsl4fl'V, DIds SlII>oo>ette & .--u.c T, . . Sport • ~ '$0 Itwu 'M ~MolonFuIHA.
fIN,......... Ortve - _
BUtCI< (19025)
fiAT 34010 124 Sport Coupe' Splde, '68 thru '78 34025 X1/9 all models '7. Ihtu '60
(Continued on other .Ide)
'LJs/lllgS showrI wt//! an IIstensk (') Indicalfl model COVfIfa{18I1S oIlhil1 prirwng. These btItJs Mf be ~Iy t¢af8d 10 ItocIudtJ IBteI" modeI)'9IItS - consvII)'OIH' Hayne' deal8r for more informa/Jon.
Haynes North America, Inc., 861 Lawrence Drive, Newbury Park, CA 91320-1514· (805) 498-6703
Haynes Automotive Manuals (continued) NOTE: New manuals are added to this list on a periodic basis. If you do not see a listing for your vehicle, consult your local Haynes dealer for the latest product information.
a,o rMtro - see CHEVROLET Sprint (24075) Prizm _ '85 thru '92 see CHEW (2J/060). '93 thIlJ '96 "" TOYOTA Coro/Ift (92036) ' 40030 Storm all modeIs ' 90 Ihru '93 Track ... - see SUZUKI SllmURI (IIOOfO)
Sat.rI · see CHEVROI..ET ASTRO (24010) Van...
Plck-u~
-_
CHEVROLET
HONDA
42022 42023
'42024 '42040
TRIUMPH
'118020 Cordia, Tredl., Galant, P...c:I. & MI ... ge '83 thlU '93 '158030 Eellpee, E41I'. Taloll & Ply, L.ooH' '9(1 thlU '94 '118040 Pick-up '83 thlU '96 & Mont.ro '83 thlU '93
04007 Spitfire all models 'S2 thlU '81 94010 TR7 all models '75 thlU '81
NISSAN
aMC
42010 42011 42012 42013 42020 42021
MITSUBISHI
Accord CVCC all models '16 thru'83 Accord all modeIs'8
HYUNDAI
72010 '72015 '72020 '72030 72040 '7201SO '72051 '72080
300ZX all models including Turbo '841hru '89 Altlmil all models '93 thlU '97 M.,.I .... all models '85 thlU '91 PIclt-u~ thru '96 PettotInder '81 thnJ '95 Pulsar all models '83 thtu '86 Sentno all models '82 thlU '94 Senlnl & 2OO5X all models '95 thlU 'gs Slanu all models '82thIU '90
'eo
' 730111 Cutl_. VS &
va gas models '74 thlU '88
For other OLDSMOBILE tlf/. ., .... SUlCK, CHEVROLET 01' GENERAl. MOTORS IIsllllg.
JAGUAR
' 41M1tO )US all 6 cyI models 'sa thru ' 86 'slMlff XJe all mode'- ' 88 thlU '$4 '4110111 XJ12 & XJS all 12 cyI models '72 thlU '85
T ECHBOOK MANUALS 7i008 FI.ro.1l models '84 thIU '88 711018 R ... blrd VB models a~cepl Turbo 70 tIvu '81 711019 Rrablrd all model s '82 tllru '92 For 0,,",' PONTIAC tltlel, H. BUICK, CHEVROLET 01' GENERAl. MOTORS lI.tlng,
PORSCHE '80020 80025 80030 '80035
911 9 14 924 944
except Turbo & C.rrera' '65 thlU'~ all 4 eyI models '69 thlU ' 76 all model, including Turbo '76 thlU '82 all models Including Turlx> 'I!3thlU '89
RENAULT
'Il0010 ctMorvk... Comanchoeoi. W~UmIt.cI all fTIO(IeIs '114 thnJ '96 Il0020 c.J aH model. '49 thnJ '88 ' Il00211 O... fICI C"-rok. . all models '93 thlU '98 1IOO2G O...nd WagonH' & Pick-up '72 thnJ '91 Grand Wagoneer '114 thIU '91, Cherok. . & W~ '72 thnJ '83, Plck-up ' 72 thlU '88 ' Il0030 WI1IPIgIM all models '97 thnJ '95
SUB
LINCOLN
87010 S.tum all models '91 thlU '96
- see FOR~ Pick-up (36059) 1111010 Re.r Wh. .1 Ortv. all models '70 thnJ '96
SUBARU
MAZDA
80002 1100,1300,1400 & 1Il00 '71 thlU '79 '89003 11500 & 1800 2WO ,\ 4WO '80 thlU '94
AlII.ne. & Eneo ... - see AMC (l4020)
'64010 900 all models including Turbo '79 thlU '88
SATURN
N.~or
111030 81035 -81038 81040 -81041
OLC HatchbKII (IWIr wtIHI d"") TI thru '83 aLC!front wt.. .1 dnv.) '81 thnJ '85 323 & pr0t0g6 '9(1 thIU '97 MX-II MIN '9(1 thIU '97 MPV all modttIs '89 thlU '94 Nav.qo - see Ford Explorer (,)6024) Plck-u~ ' 72 thlU '93 PIck-111M '94 thIU '96 - _FOI'I1 fW>get {3607I/ RX_7 all models '79 thlU '85 RX_7 all modeIs'86 thlU '91 828 (rear wheel drivII) all models '79 thlU '82 8281MX-8 !front wheoel driv.) '83 thnJ ' 91
MERCEDES·BENZ 113012 '83015 113020 830211 Il303O
123 Serl.. DI_1 76thnJ '85 11M) Serl•• Iour-cyl gas models. '/14 thlU '86 2301250/280 S cyI sohc models '88 thlU '72 280 123 $eriq gasoline models 'n thnJ '81 350 & 41SO all models '71 thnJ '80
MERCURY 5H FORO Ultlnfl.
MG 88010 MOB Roadster & GT Coupe '62 thnJ '80 88015 MG Midget, AI.mIn Healey Sprite '56 tIYu '80
120, 130 Seria. & 1800 &porno 'SI thru 73 140 Serl.s all models '66 thlU '14 240 Serle. all models '76 thru '93 280 Serl•• all model s '75 thlU '82 740 & 780 Sarle. all mod!tls '82 thlU '88
For PI..YMOUTH title...... DOOOE listing.
JEEP
111010 111011 '81018 '1110111 ' 81020
97010 970111 "9 7020 97025 ·97040
PLYMOUTH
PONTIAC
Homb", - see CHEVROlET 50 lO(241)71) 'aTOn Rodeo '01 Ihru '97: AmIgo '89 thru '9<1: Konda Pauport ' 95 thru '97 '47020 Trooper .. Plclr. ..... p , all ~I"" models Pil;k-up, ' 61 thru '93: Trooper. '84 thru '01
aflOOS Beetl. & K....... lln GhLe '54 thlU '19 afl012 D.lh.r .1I o-asoline models '74 thru '81 'gooll1 R.bblt, J . W , Sc:lrocco, & Plck-up gas models '74 thlU '91 & Convertible '80 thlU '92 9&017 Oolf & Jett. all models '93 thlU '97 "020 R.bblt, Jelt. & Plck' lIp diesel '71 thlU '84 96030 Tr1IInlporte r 1800 all models '68thlU '79 96035 T... nlport.r 1700, 1800 & 2000 '72 thn; '79 96040 TYIHI 3 1500 & 11100 all models'63 IhIU '73 !MI045 V.n.gon all ...·cooled models '80 thlU '83
VOLVO OLDSMOBILE
'430HI Exeat all models '86 thl'\l '94
ISUZU
vw
SUZ UK I 'OOC)10 Samu.. VSldeltlck & Gao T..ck•• '86lhru '96
T OYOTA 920011 92008 92015 "92020 920211 92030 112032 9203S '9203& 92040 92045 1120lI0 920115 92058 ·920115 92010 '92075 '92078
C.mry all models '83 thlU '91 C.mry all models ' 92 thlU '96 C.lt.c. A. . r W ...., Driv. ' 71 thlU '85 C.IICIO Frollt Wheel Driv. '66thlU ' 93 Celt.c. S u p ... all models '79 thnJ '92 Coroll. all models '75 IhlU ' 79 Coral" aI I'I,IW wheel driV'8 models '80 thtu '87 eoroa. aI fnJnt wheel modeI:s '8411wu '92 Corolla & G40 PNm '93 IIwu '97 COI'oli. Terc:el all model. ' 80 thlU '82 Corona all models ' 74 thlU '82 C ..... ld. all models '78 thlU '82 Lelld Crul... FJ40, 43, 45, 55 '68lhlU '82 LInd Crul. .r FJ60, 62, 80, FZJ80 '80 thlU '96 MA2.all models '85 thru '87 Pick-up all models '69thIU '78 Plek-up.1I models '79 Ihru '95 Tecoma '95 thlU ' gs, 4Runner '96 thlU 'gs, & T l00 '931h1U '98 '92080 Pr.vl. all models '91 thlU '95 920811 Terc.1 all models '87 IhlU '94
cm-e
10205 10210 102tll 10220 10225 10230 10240 10305 10310 10320 10330 10340 103411 103511 103110 10405 10410 10415 10420 1042S 10430 10435 10440 10445 104110
Automotlv. Computer Codes Automotive Emluions Control Manual F..... Injection Manual, 1978 Ihru 19811 F..... Injection Ma ..... I, 1988lhru 1998 Holley Cerbu ... tor Manual Rochester Cerbu ... tor M.nuaI WeborlZenithlStrombeorglSU C.rburetor1o Chevrol.t Ellllill e o...rto.ul M.nu.' Chry.ler Enoine Ovem.ul M.nual Ford En9111. Ovem.ul Man .. OM...cI Ford 0 ....' Engine Repair MiIn.... 5 ....11 En9ln. R.~lt Manll.1 Su.p.nslon , Steerln9 & Drivelill. Ml llual Ford Automatic Tr.lIsmlu lon Overto.ul OM Autom.tic T... nsmi •• loll o...erto...1 Automotiv. Body A.p.l. & P.lntlllg Alltomotlv. 8r.ke M.nu.1 Automotive Detellll9 M.nu.1 Automotive EeleciriCIOI Menu.' Automotlv. He.tllIg & Air COlldlllonl1l9 Automothl. Reference M.llual & OIclioruo'Y Automotive Tools M.nu.1 Used C •• Buyillll Guide Weldlllll Me llu.' ATV S •• ics
e'
SPANISH MANUALS 98903 989011 981110 98915 lIlW40 99041 99042 99055 911075 lIlW77 99083 H08B 9'9091 9'9095 99100 99110 99118 99125
Repar&ci6n de Carrocerl. & Plnlur. C6dlgos Aulomotrlce. de I. Comput.ldorl Frenos Automolri:r. Iny.cel6n d. Combu. tlble 1988.11994 Chevrolet & GMC C.mlon.ta. '67 aI '87 Incluye Suburtlan, Blaze. & Jlmmv '67 al '91 Ch.vrolet & OMC C.mlonet • • '88 aI '95 InclllYe Suburban '92 "I '95, Blazer & Jlmm~ '92 al '94, Tahoe V Yukon '95 Chevrol.t & GMC Camloll"" ee...dsl '68 aI '95 Dodge C.....an ... Plymouth YOYlger '84 at '95 Fo.d C.mlon.t. . Y Bronco 'SO aI '94 Ford C.mlon.tal C....da. '69 al '91 Ford Modelos d. T.malio Orand. '75 at '87 Ford ModelOI d. Tamalio MedllllO '75 at '86 Ford T.urus & Mercury Sabl. '86 at '95 OM Mod.los d. T.m ...... Orende '7081 '90 OM Mod.lol d. Tam. fio Medlano ',0 "'88 NI""n C.mlon.W 'SO al'96, P. thfi ..... ' '87 81'95 Ni...n Selltr. '82 aI '94 Toyola Camlanel" Y 4Rllnll. r '79 aI'95
...
• LlSlings shown MIft 8n as/erisk (') indica/e model coverage as of this prin~ng, These Iitles will be penodically updated to Include laler mod6I years - consult your Haynes deale. lor more Inlonna/ion
Haynes North America , Inc., 861 Lawrence Drive, Newbury Park, CA
91320~ 1514
e
(805) 498-6703
Common spark plug conditions NORMAL Symptoms: Brown to graYIsh-tan color and slight electrode wear. Correct heat range for engine and operating condit ions. Recommendation: When new spark plugs are installed , replace w ith plugs of the same heat range.
TOO HOT
WORN Symploms; RounOOCl ~l!(;lrodes w,t/l a small amounT of depoMS on
the 1'''"9 end Normal color. Causes hard starling In damp Of cold weather and poor fuel ecOflOfTlY
Recommenda llon; Plugs have been lett III the eng.ne too long Replace wtllt new plugs 01 Ihe same heal rnngfl Fol low the ree:· ommended maintenance schedu le
SymplO/n1S: Dry sooty depoMs "ld,eate a neh ml~lu re Of weak tgmlIOn Causes m ,sl" H19. hard s tarling and hIt$olalKlll.
Recommendalion; Make sore the plug has the CO(rfIC! heal .ange >:I"
0f\SU-
lator,
etoded ele<; trode and absence 01 depos,ts Results Irl $hOr\ened plug lile Recommendation: Check for lhe corract plug heat range. Olreradvanced IQI"IIIKlII Iomong. IMt1 fuel rT... ture Irltake man,loId vacuum leaks. stlCk'ng yalves and 'nsufficient engine cooling,
PREIGNITION
CARBON DEPOSITS
CheCk lor a cIogge
Symptoms; Bhstl!Ald. white
filter or
problem ,n Ihe fuel system o r eng lP'\ll management system. AlSO
Symp l oms; Metted el~trodes InsulatOfS are wh,le, but may be d,rty due to mlsflm'g or Ilying debris 'rl lhe combusl!On chamber Can Iuad 10 eng.r.e damage Recom~tion; Check for the correct plug heat range. o~er advanced '9f11hon liming. ~ 100 ml~ture, ,rlSUflictenl engine COOling and lack o f tubncah()!1
check lor '9'"T'on system problems
ASH DEPOSITS Symptoms.: light
I)tOwtl
oep<:lSJIs
8(l(:rtlsled on the SlOe or centl!'l
electrodes or bam Derived from Oi l and/or luel additives. ExceSSive amounts may mask me !Wark causing rrusf"'ng and hesilatKlll d\Mlng lICCeIefatoon
Recommendal,on:
If excess,ye deposits accum ulate ever a short f>me Ct low mileage. ,,,stall new Yalve gUIde seats te prevenl se&p. age of Oil Into the combust.o" chambefs Also try cnanglng gaso· line t>rands
HIGH SPEED GLAZING Symptoms: Insulator has yellowISO. glazed appearance. IndICates that combustoon chamber tempe
Causes rmsf'nrIg a\
hlQh s.peeds
Recomm .... dstion: In~tall new plugs ConSlder USIng a colder plug 'f driVIng MOlts .... amJI1t
DETONATION Sym p tom,:
OIL DEPOSITS Otly C03ltng caused 1$ leaking pasl wom valve gUIdes or piston nngs IrIIO the combustlOO chamber Causes hard slanong, mlsf'rlng and
Symptoms:
by poor 011 conlrol OIl
hesotal lOfl
Recommendation: CO~I Ihe mechanocal CO!\d,lron ..."th rl8Cesury repa,rs aod InStall new plugs
Insulat()l"!l may be cracked Of crupped Improper gap setting tecMlques can also resutt III a kaclured Irlsutator t,p. Can lead to PISton damage Recom~tion: Make $Ute the fuel anti-knock values meet engine requl remet"lts. Use care .... hen set· \lng the gaps on new plugs A_Old lugg.ng the engone
MECHANICAL DAMAGE Symp toms: May be cal.l$6d by a
Symptoms: Combustooo deposits lodge bel .... een Ihe elOCl rodti, Heavy deposil S accumulate and ondge the eloctrode gap. The plug to IQ, rnullmg Of) • ~
c_
R Kom~.tlon:
oo,ect In the combustoon chambel" or the poston stnkng an Incorrect reach Itoo long! plug Causes 8 dead cyhroder and could result In Piston damage Recommenda tion: Repair the mechaoIcaI damage Rerr"ll:Ne the tDrelgn object from the engine and/or mst~U the COl'l1lCt <each
10II!I9r1
GAP BRIDGING
Locate the
lMAry plug and rerroove the deposits from ~ !he -.ctrodes
....
_.......
__.. .... - .---...::------------ -_ ---
':".....
...
:::::- .:..::.:-_.,
"0-
~-
.....
-=-..:: ::-..:.-:.-=..:. =- -. ..=::::-;:;::--= -=::....:::=..:---= - .. .;::'::.=
::.," :::=..
., .=..... -.--= -- _._.::---
::.:..':"" =::::..- -' ..,:--':'::'.,;..~ ........ :.::-'=-:"- - --" -.=-"-
--= _-.. ... ....:'" .. ---...~~!-:.:: _-_ ... _-.. "---_ .. _c =-..-_-:...-::._.-'" ::--..:::: -- ----=-:..:::
:::.. ==:.. _::': _ -. ""::"'" "'",..:.:-..:
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