Download GROUP 9 CONTENTS ENGINE APPLICATION SERVICE

GROUP 9
A.
E N G I N E
CONTENTS
Page
Page
G E N E R A L INFORMATION
S E R V I C E DIAGNOSIS
SERVICE PROCEDURES
CRANKCASE VENTILATION S Y S T E M . . .
ENGINE OILING
1
1
4
25
22
ENGINE
Model
Application
No. Cyl.
REPAIR OF DAMAGED OR WORN
THREADS
SPECIFICATIONS
TIGHTENING R E F E R E N C E
APPLICATION
Engine Type
& Displacement
Compression
latio
Newport a n d Town
a n d Country (Std.)
8
" L B " 383 C u b i c Inch
8.7 to 1
2 B B L Carb., S t d . C a m . , S i n g l e E x h a u s t
(Opt.)
8
" L B " 383 C u b i c Inch
9.5 to 1
4 B B L Carb., S t d . C a m . , Dual E x h a u s t
(Opt.)*
8
" R B " 440 C u b i c Inch
9.7 to 1
4 B B L Carb., S p e c . C a m . , Dual E x h a u s t
(Std.)
8
" L B " 440 C u b i c Inch
9.7 to 1
4 B B L Carb., S t d . C a m . , S i n g e E x h a u s t
(Opt.)
8
" R B " 440 C u b i c Inch
9.7 to 1
4 B B L Carb., S p e c . C a m . , Dual E x h a u s t
(Std.)
8
" R B " 440 C u b i c Inch
9.7 to 1
4 B B L Carb., S t d . C a m . , S i n g e E x h a u s t
(Opt)
8
" R B " 440 C u b i c Inch
9.7 to 1
4 B B L Carb., S p e c . C a m . , Dual E x h a u s t
8
" R B " 440 C u b i c Inch
9.7 to 1
4 B B L Carb., S t d . C a m . , S i n g e E x h a u s t
300
New Yorker
Imperial
25
26
30
* T o w n a n d C o u n t r y — S t a n d a r d C a m Only
GENERAL INFORMATION
The standard N E W P O R T E N G I N E w i t h t w o bore
carburetor, 8.7 to 1 compression r a t i o uses regular
fuel.
The V 8 engines f o r the 1970 Chrysler and I m p e r i a l
Models are a l l t h e valve-in-head t y p e w i t h h y d r a u l i c
tappets. The engines vary i n compression r a t i o , piston
displacement,
manifold
camshaft,
valve
springs,
A l l other engines w i t h a 4 bore carburetor; use
p r e m i u m fuel.
carburetor,
arrangement.
SERVICE
Possible Cause
Condition
ENGINE WILL NOT
START
DIAGNOSIS
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
Correction
(a) T e s t battery s p e c i f i c gravity. R e Weak Battery.
charge or r e p l a c e a s n e c e s s a r y .
Corroded or loose battery c o n n e c - (b) C l e a n a n d tighten battery c o n n e c tions. Apply a c o a t of petrolatum to
tions
terminals.
(c) Refer to "Starting Motor."*
Faulty starting motor.
Moisture on ignition w i r e s a n d distri- (d) Wipe w i r e s a n d c a p c l e a n a n d dry.
butor c a p .
(e) R e p l a c e any c r a c k e d or shorted
Faulty ignition c a b l e s .
cables.
(f) T e s t a n d r e p l a c e a s n e c e s s a r y . *
Faulty coil or c o n d e n s e r .
Dirty or corroded distributor c o n t a c t s . (g) C l e a n or r e p l a c e a s n e c e s a s r y .
Incorrect s p a r k plug gap.
(h) S e t g a p a t .035".
Incorrect ignition timing.
(i) Refer to "Ignition T i m i n g . " *
Dirt or water in fuel line o r carburetor, (j) C l e a n l i n e s a n d c a r b u r e t o r . * *
Carburetor flooded.
(k) A d j u s t float l e v e l — c h e c k s e a t s * *
Condition
Possible Cause
Correction
(I)
(I) Incorrect carburetor float setting.
(m)
(m) Faulty fuel pump,
(n) Carburetor percolating. No fuel in the (n)
carburetor.
ENGINE S T A L L S
Idle s p e e d s e t too low.
Incorrect c h o k e a d j u s t m e n t .
Idle mixture too lean or too r i c h .
Incorrect carburetor float setting.
L e a k in intake manifold.
(a)
(b)
(c)
(d)
(e)
Dirty, burned or incorrectly gapped
distributor c o n t a c t s .
(g) Worn or burned distributor rotor.
(h) Incorrect ignition wiring.
(i) Faulty coil or c o n d e n s e r .
(f)
(a)
(b)
(c)
(d)
(a)
(b)
(c)
(d)
(a)
(b)
(c)
(d)
(e)
(f)
ENGINE LOSS OF
POWER
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(I)
(m)
Incorrect ignition timing.
Worn or burned distributor rotor.
Worn distributor shaft or c a m .
Dirty or incorrectly gapped spark
plugs.
Dirt or water in fuel line, carburetor
or filter.
Incorrect carburetor float setting.
Faulty fuel pump.
Incorrect valve timing.
Blown c y l i n d e r head gasket,
Low c o m p r e s s i o n .
B u r n e d , warped, pitted v a l v e s .
Plugged or restricted e x h a u s t s y s t e m .
Faulty ignition c a b l e s .
(n) Faulty coil or c o n d e n s e r .
E N G I N E M I S S E S ON
ACCELERATION
A d j u s t float l e v e l — c h e c k s e a t s . * *
Install new fuel p u m p . * *
M e a s u r e float level. A d j u s t
bowl
v e n t . * * I n s p e c t operation of manifold
control valve.
Adjust carburetor.**
Adjust choke.**
Adjust c a r b u r e t o r . * *
Adjust float s e t t i n g . * *
I n s p e c t intake manifold g a s k e t
replace if n e c e s s a r y . * * *
R e p l a c e c o n t a c t s and a d j u s t . *
(g) Install new rotor.
(h) Install new wiring.
(i) T e s t and replace if n e c e s s a r y . *
Refer to "Ignition T i m i n g . " *
Install new rotor.
Remove and repair distributor.*
C l e a n plugs and set gap at .035".
(e) C l e a n lines, carburetor and replace
filter.**
(f) Adjust float l e v e l . * *
(g) Install a new pump.
(h) Refer to " C h e c k i n g Valve T i m i n g . " * * *
(i) Install new head g a s k e t . * * *
(j) T e s t c o m p r e s s i o n of e a c h c y l i n d e r . *
(k) Install new valves or r e g r i n d . * * *
(I) Install new parts a s n e c e s s a r y .
shorted
(m: R e p l a c e any c r a c k e d or
cables.
(n) T e s t and replace a s n e c e s s a r y . *
(a) Dirty, burned, or incorrectly gapped (a) R e p l a c e c o n t a c t s and a d j u s t *
distributor c o n t a c t s .
(b) Dirty, or gap too wide in s p a r k plugs. (b) C l e a n spark plugs and s e t gap
.035".
(c)
(d)
(e)
(f)
(g)
E N G I N E M I S S E S AT
HIGH S P E E D
Incorrect ignition timing.
Dirt in carburetor.
A c c e l e r a t i o n pump in carburetor.
B u r n e d , warped or pitted v a l v e s .
Faulty coil or c o n d e n s e r .
(c)
(d)
(e)
(f)
(g)
at
Refer to "Ignition T i m i n g . " *
Clean carburetor.**
Install new p u m p . * *
Install new v a l v e s or r e g r i n d . * * *
T e s t and replace if n e c e s s a r y . *
(a) Dirty or incorrectly g a p p e d distributor (a) C l e a n or replace a s n e c e s s a r y . *
contacts.
(b) Dirty or gap s e t too w i d e in s p a r k plug. (b) C l e a n spark plugs a n d s e t gap
.035".
NOISY V A L V E S
and
at
(c)
(d)
(e)
(f)
(g)
(h)
Worn distributor s h a f t c a m .
Worn or burned distributor rotor.
Faulty coil or c o n d e n s e r .
Incorrect ignition timing.
Dirty j e t s in carburetor.
Dirt or water in fuel line, carburetor
or filter.
(c)
(d)
(e)
(f)
(g)
(h)
R e m o v e and repair distributor.*
Install new rotor.
T e s t and replace if n e c e s s a r y . *
R e f e r to "Ignition T i m i n g . " *
Clean jets.**
C l e a n lines, carburetor a n d r e p l a c e
filter.**
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
High or low oil level in c r a n k c a s e .
T h i n or diluted oil.
Low oil p r e s s u r e .
Dirt in tappets.
B e n t p u s h rods.
Worn rocker a r m s .
Worn tappets.
Worn valve g u i d e s .
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
C h e c k for correct oil l e v e l . * * *
Change oil.***
C h e c k engine oil l e v e l . * * *
Clean tappets.***
Install new p u s h r o d s . * * *
I n s p e c t oil supply to r o c k e r s . * *
Install new t a p p e t s . * * *
R e a m a n d install new v a l v e s with
oversize s t e m s . * * *
A
A
ENGINE
Condition
Possible Cause
(i)
CONNECTING ROD
NOISE
E x c e s s i v e run-out
valve f a c e s .
Correction
of valve s e a t s or (i) G r i n d valve s e a t s a n d valves.*
(a) Insufficient oil supply.
(b) L o w oil p r e s s u r e .
(c) T h i n or diluted oil.
(d) E x c e s s i v e bearing c l e a r a n c e .
(e) C o n n e c t i n g rod j o u r n a l s out-of-round.
MAIN B E A R I N G N O I S E
9-3
(a) C h e c k engine oil l e v e l . * * *
(b) C h e c k engine oil level. I n s p e c t oil
p u m p relief valve a n d s p r i n g . * * *
(c) C h a n g e oil to correct viscosity.
(d) M e a s u r e bearings for correct c l e a r ance.***
(e) R e p l a c e c r a n k s h a f t or regrind journals.***
(f) R e p l a c e bent c o n n e c t i n g r o d s . * * *
(f) Misaligned c o n n e c t i n g rods.
(a) Insufficient oil supply.
(b) L o w oil p r e s s u r e .
(c)
(d)
(e)
(f)
(g)
(a) C h e c k engine oil l e v e l . * * *
(b) C h e c k engine oil level. I n s p e c t oil
p u m p relief valve a n d s p r i n g . * * *
(c) C h a n g e oil to c o r r e c t v i s c o s i t y . * * *
T h i n or diluted oil.
(d) C h e c k bearings for correct c l e a r a n E x c e s s i v e bearing c l e a r a n c e .
ces.***
(e) C h e c k No. 3 main bearings for w e a r
E x c e s s i v e e n d play.
on f l a n g e s . * * *
C r a n k s h a f t j o u r n a l s out-of-round or (f) R e p l a c e c r a n k s h a f t or regrind journals.***
worn.
(g) Tighten to c o r r e c t torque.
L o o s e flywheel or torque converter.
(a) Hone cylinder bores if n e c e s s a r y a n d
install new r i n g s . * *
(b) C a r b o n in piston ring grooves a n d oil (b) R e m o v e rings. C l e a n grooves. C h e c k
ring s l o t s .
groove width. Install new r i n g s . * * *
(c) R e m o v e
rings. C h e c k grooves. If
(c) R i n g s fitted too tight in grooves.
groove i s not proper width, r e p l a c e
pistons.***
OIL PUMPING AT
RINGS
(a) Worn, scuffed, or broken rings.
OIL P R E S S U R E DROP
(a)
(b)
(c)
(d)
(e)
(f)
L o w oil level.
Faulty oil p r e s s u r e s e n d i n g unit.
Clogged oil filter.
Worn parts in oil pump.
T h i n or diluted o i l .
E x c e s s i v e bearing c l e a r a n c e .
(a)
(b)
(c)
(d)
(e)
(f)
C h e c k engine oil level.
Install new s e n d i n g unit.
Install new oil filter.
R e p l a c e worn parts or pump.
C h a n g e oil to correct viscosity.
M e a s u r e bearings for correct c l e a r ance.
(g) R e m o v e valve a n d inspect, c l e a n , a n d
(g) Oil p u m p relief valve s t u c k .
reinstall.
(h) Oil p u m p suction tube loose, bent or (h) R e m o v e oil p a n a n d install new tube
cracked.
if n e c e s s a r y .
* Refer to t h e " E l e c t r i c a l a n d Instrument" Group 8 for s e r v i c e p r o c e d u r e s .
* * Refer to the " F u e l S y s t e m " G r o u p 14 for s e r v i c e p r o c e d u r e s .
* * * Refer to the " E n g i n e " Group 9 for s e r v i c e p r o c e d u r e s .
383-440 C U B I C INCH
ENGINES
INDEX
Camshaft
Camshaft Bearings
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C r a n k c a s e Ventilation S y s t e m . . . . . . .
C r a n k s h a f t Identification
C r a n k s h a f t Main B e a r i n g s
C r a n k s h a f t Main J o u r n a l s
Cylinder Block
Cylinder Heads
Distributor Drive S h a f t B u s h i n g
Engine Assembly
E n g i n e Mounts . . . .
.....
E n g i n e Oiling S y s t e m
Hydraulic T a p p e t s
Installing Piston a n d C o n n e c t i n g R o d A s s e m b l y
Page
14
15
20
25
19
20
20
16
6
15
5
4
22
10
20
M e a s u r i n g C o n n e c t i n g Rod B e a r i n g C l e a r a n c e . . .
M e a s u r i n g Main B e a r i n g C l e a r a n c e
Oil Filter
Oil P a n
Oil P u m p
Pistons, Pins and Rings
R e a r Main B e a r i n g Oil S e a l
R e p a i r of D a m a g e d or Worn T h r e a d s
Rocker Arms and Shaft Assembly
Specifications
T i m i n g C h a i n Cover, Oil S e a l a n d C h a i n
Tune-Up
..
V a l v e s a n d Valve S p r i n g s
Valve T i m i n g
Page
20
21
24
22
22
17
22
25
6
26
12
4
7
11
1-4
ENGINE-
SERWICE PROCEDURES
TUNE-UP
(1) Test battery specific gravity, add water i f necessary, clean and t i g h t e n battery connections.
(2) Test c r a n k i n g voltage. See " S t a r t i n g Motor
C r a n k i n g V o l t a g e " Electrical Section o f this manual.
(3) T i g h t e n the Intake m a n i f o l d bolts t o 50 footpounds.
(4) P e r f o r m cylinder compression test. Compression should not be less than 100 pounds f o r 383 Cubic
I n c h Engine w i t h two b a r r e l carburetor and not vary
more than 40 pounds. 110 pounds for 383, 440 Cubic
I n c h Engine w i t h f o u r b a r r e l carburetor and should
not vary more than 40 pounds. The recommended
pressures are to be used only as a guide to diagnosing
engine problems. A n engine i n good condition may
exhibit higher pressures. Many conditions w h i c h are
difficult t o c o n t r o l cause variations i n compression
readings. A n engine should not be disassembled t o
determine the cause of low compression unless some
other malfunction is present.
(5) Clean o r replace spark plugs as necessary and
adjust gap t o .035 inch. T i g h t e n t o 30 foot-pounds
using new gaskets.
(6) Test resistance of spark p l u g cables. Refer t o
" I g n i t i o n System Secondary Circuit I n s p e c t i o n " Elect r i c a l Section.
(7) Inspect the breaker plate contacts, p r i m a r y w i r e
and vacuum advance operation. Test coil output voltage, p r i m a r y a n d secondary resistance. Test Condenser. Replace parts as necessary. Refer t o I g n i t i o n
System and make necessary adjustments.
(8) Reset the i g n i t i o n t i m i n g w i t h the vacuum advance l i n e disconnected. T h e i g n i t i o n t i m i n g should
be set t o compensate f o r altitudes and/or gasoline
grades.
(9) Set carburetor idle m i x t u r e adjustment. A d j u s t
t h r o t t l e stop screw t o specifications. P e r f o r m a com-
bustion analysis.
(10) Test the f u e l p u m p f o r pressure and vacuum.
Refer to " F u e l System" Group 14, Specifications.
(11) Inspect the m a n i f o l d heat c o n t r o l valve i n the
r i g h t exhaust m a n i f o l d f o r proper operation a n d
apply M a n i f o l d Heat C o n t r o l Valve Solvent N u m b e r
2525054 o r equivalent t o the bushing and shafts.
(12) Every 6 months, remove filter element a n d
blow out d i r t gently w i t h air hose. Direct air f r o m
inside out, and keep nozzle 2 inches away f r o m element t o avoid damaging (Fig. 1). Clean t h e m e t a l
housing and replace t h e element. Every t w o years
install a new factory recommended filter element.
Service the u n i t more frequently w h e n d r i v i n g under
severe conditions, such as i n dusty areas.
(13) Inspect crankcase ventilation system as outl i n e d on page 25.
(14) Inspect and adjust the accessory belt drives
r e f e r r i n g t o "Cooling System" Group 7 f o r proper
adjustments.
(15) Road test vehicle as a final check.
FRONT ENGINE MOUNTS (Fig. 2)
Removal
(1) Disconnect t h r o t t l e linkage at transmission and
at carburetor.
(2) Raise hood and position fan t o clear radiator
hose and radiator top tank.
(3) Remove torque nuts f r o m insulator studs.
(4) Raise engine just enough t o remove f r o n t engine m o u n t assembly.
Installation
(1) Install insulator t o engine bracket and t i g h t e n
to specified torque.
(2) Lower the engine and install washers and prev a i l i n g torque nuts t o insulator studs; t i g h t e n nuts t o
specified torque.
(3) Connect t h r o t t l e at transmission a n d carburetor.
REAR ENGINE MOUNT (Fig. 3)
Removal
(1) Raise vehicle on hoist.
(2) Install transmission jack.
(3) Remove rear engine crossmember f r o m frame
and remove rear mount.
Fig. 1—Cleaning Filter
Element
Installation
(1) Install rear engine m o u n t t o crossmember and
t i g h t e n n u t to specified torque.
(2) Install rear crossmember t o frame and t i g h t e n
bolts to specified torque.
ENGINE
VIEW A
/ / ' S i '
/<?7'fY'
RIGHT SIDE A//)m/w^%*
»y
TIGHTENING
TORQUE
N
4
V
-J<;
,
/
VIEW P
LEFT SIDE
'
<A> 50 FT. LB.
55 FT. LB.
<£> 75 FT. LB.
NR42A
Fig. 2—Engine Front
Mounts
ENGINE A S S E M B L Y
Removal
(1) Scribe the outline of hinge brackets on hood to
assure proper adjustments w h e n installing.
(2) Remove hood.
(3) D r a i n cooling system and remove battery.
(4) Remove a l l hoses, f a n shroud, disconnect o i l
cooler lines and remove radiator.
(5) Disconnect f u e l lines and wires attached to engine units. Remove a i r cleaner and carburetor.
(6) A t t a c h engine l i f t i n g fixture t o carburetor
flange studs on intake m a n i f o l d .
(7) Raise vehicle on a hoist and i n s t a l l engine supp o r t fixture Tool C-3487-A to support rear of engine.
TRANSMISSION
EXTENSION
SPACER (2)
STUD(2)F
^
|CAST IRON <^>
LUM,NUM<
50 FT. LB.
<i>
<&
20 FT. LB.
15 FT. LB.
CROSS MEMBER
Fig. 3—Engine Remr Support
PY434
9-5
(8) D r a i n transmission and torque converter.
(9) Disconnect exhaust pipes at manifolds, propeller shaft, wires, linkage, cable, and o i l cooler lines at
the transmission.
(10) Remove engine rear support crossmember and
remove transmission f r o m vehicle.
(11) L o w e r vehicle and attach chain hoist t o fixture
eyebolt.
(12) Remove engine f r o n t m o u n t i n g bolts. Raise
engine w i t h a chain hoist and w o r k engine out of
chassis.
(13) Place engine i n repair stand T o o l C-3167 and
adapter C-3662 for disassembly, using transmission
m o u n t i n g bolts.
Installation
(1) A t t a c h engine l i f t i n g fixture to carburetor flange
studs on i n t a k e manifold.
(2) A t t a c h chain hoist to fixture eyebolt.
(3) Remove engine f r o m repair stand and l o w e r engine carefully u n t i l engine is positioned i n vehicle.
(4) Install engine support fixture Tool C-3487A and
adjust to support rear of engine.
(5) Remove chain hoist f r o m fixture eyebolt.
(6) Raise vehicle on hoist, install and t i g h t e n engine f r o n t support m o u n t i n g bolts.
(7) I n s t a l l transmission and engine rear support
crossmember.
(8) L o w e r engine i n t o position and i n s t a l l engine
rear support crossmember bolts. Remove engine supp o r t fixture T o o l C-3487A.
(9) Connect propeller shaft, wires, linkage, cable,
oil cooler lines at the transmission, connect exhaust
pipes to m a n i f o l d using new gaskets. I n s t a l l transmission filler tube.
(10) L o w e r vehicle and install radiator, fan shroud,
hoses, o i l cooler lines and connect a l l wires and l i n k age.
(11) Remove engine l i f t i n g fixture f r o m intake
manifolds and install carburetor and f u e l lines. Connect t h r o t t l e linkage.
(12) I n s t a l l hood, using scribe marks f o r proper
alignment.
(13) Close a l l d r a i n cocks and fill cooling system.
(14) F i l l engine crankcase and tranmission. Refer
to " L u b r i c a t i o n " Group 0 for quantities and l u b r i cants to use and check entire system for leaks and
correct as necessary.
Whenever an engine has been rebuilt and/or a
new camshaft and/or tappets are installed, one quart
of engine supplement, Chrysler Part Number 1879406
or equivalent should be added to the engine oil to aid
in break-in. The oil mixture should be left in the engine for a minimum of 500 miles. Drain the oil mixture at the next normal oil change.
(15) Start engine and r u n engine u n t i l n o r m a l
operating temperature is reached.
9-8
ENGINE
A
•
(16) Inspect I g n i t i o n t i m i n g a n d adjust carburetor
as necessary.
(17) A d j u s t accelerator and transmission linkages.
Road test vehicle.
ROCKER ARMS AND SHAFT
ASSEMBLY
The rocker arms are of stamped steel and are arranged o n one rocker a r m shaft, p e r c y l i n d e r head.
The push r o d angularity tends t o force the pairs of
rocker arms t o w a r d each other where oilite spacers
carry t h e side t h r u s t at each rocker a r m . The rocker
shaft is h e l d i n place b y bolts and stamped steel r e tainers attached to the five brackets on the c y l i n d e r
head.
Removal
(1) Remove cylinder head cover and gasket.
(2) Remove rocker shaft bolts a n d retainers and
remove rocker arms and shaft assembly.
(3) I f rocker a r m assemblies have been disassembled f o r cleaning, inspection, or replacement, refer t o
F i g u r e 4 f o r proper reassembly.
Installation
(1) I n s t a l l rocker arms and shaft assembly m a k i n g
sure to install the l o n g stamped steel retainers i n t h e
n u m b e r t w o and f o u r positions.
(2) Install rocker shafts so that 3/16 i n c h diameter
rocker a r m l u b r i c a t i o n holes p o i n t d o w n w a r d i n t o t h e
r o c k e r a r m , so that the 15° angle of these holes
p o i n t o u t w a r d towards the valve e n d of t h e rocker
arms, (Fig. 5). This is necessary t o provide proper
l u b r i c a t i o n to t h e rocker assemblies.
The 15° angle of the rocker arm lubrication holes
is determined from the center line of the bolt holes
through the shaft which are used to attach the shaft
assembly to the cylinder head.
(3) T i g h t e n r o c k e r shaft bolts to 25 foot-pounds.
(4) Inspect cylinder cover f o r distortion. Straighten
i f necessary.
(5) Place new cylinder head cover gaskets i n posit i o n a n d install c y l i n d e r head covers. T i g h t e n nuts t o
40 i n c h pounds.
Fig. 4—Rocker Arm Assemblies
Installed
LUBRICATION HOLES
RIGHT BANK
LEFT BANK
ND23
Fig. 5—Rocker Arm Lubrication
Holes
(6) Install crankcase ventilation system and evaporative c o n t r o l system (if so equipped).
CYLINDER
HEADS
The chrome alloy cast i r o n cylinder heads are h e l d
i n place b y 17 bolts. The spark plugs enter the cylinder head horizontally a n d are located at the wedge
of the combustion chambers.
Removal
(1) D r a i n cooling system.
(2) Remove alternator, carburetor, a i r cleaner and
f u e l line.
(3) Disconnect accelerator linkage.
(4) Remove closed v e n t i l a t i o n system and evaporative c o n t r o l system (if so equipped).
(5) Remove vacuum c o n t r o l tube at carburetor a n d
distributor.
(6) Disconnect d i s t r i b u t o r cap, coil wires and heater hose.
(7) Disconnect heat indicator sending u n i t w i r e .
(8) Remove spark plugs.
(9) Remove intake manifold, i g n i t i o n coil and carb u r e t o r as an assembly.
(10) Remove tappet chamber cover.
(11) Remove cylinder head covers and gaskets.
(12) Remove exhaust manifolds.
(13) Remove rocker a r m and shaft assemblies. Remove push rods a n d identify to insure installation in
original location.
(14) Remove the 17 head bolts f r o m each cylinder
head and remove cylinder heads.
(15) Place cylinder head i n h o l d i n g fixture t o o l
C-3626.
-ENGINE
KR137A
Fig. 6—Cylinder Head Tightening Sequence
Installation
(1) Clean gasket surfaces o f the cylinder block and
cylinder head. Remove a l l b u r r s f r o m edges of cylinder heads.
(2) Inspect a l l surfaces w i t h a straightedge I f there
Is any reason t o suspect leakage. I f out of flatness
exceeds .00075 times the span length I n any direction;
either replace head or l i g h t l y machine the head gasket
surface. A s an example, I f a 12 i n c h span is .004" out
of flat, allowable is 12 x .00075 = .009". Head Is O K .
The cylinder head surface finish should be 70-180
micro-Inches.
(3) Coat new gaskets l i g h t l y w i t h a suitable sealer,
Chrysler N u m b e r 1057794 o r equivalent. Install gaskets and c y l i n d e r heads.
(4) Install cylinder head bolts. S t a r t i n g at top center, t i g h t e n a l l cylinder head bolts t o 40 foot-pounds
i n sequence (Fig. 6). Repeat the procedure, t i g h t e n i n g
all head bolts to 70 foot-pounds.
(5) Inspect push rods and replace any w o r n or bent
rods.
(6) Install push rods I n t h e tappets maintaining
alignment, using r o d (Fig. 7).
(7) Install rocker a r m and shaft assembly starting
each push r o d i n t o its respective rocker a r m socket
(Fig. 4) m a k i n g sure to install the l o n g stamped steel
retainers I n t h e n u m b e r t w o a n d f o u r positions.
Tighten bolts to 25 foot-pounds.
(8) Place new cylinder head gasket i n position and
install cylinder head covers. T i g h t e n n u t s t o 40 Inch
pounds.
(9) Install exhaust manifolds and t i g h t e n nuts to 30
foot-pounds.
(10) A d j u s t spark plugs to .035 I n c h gap and install
plugs, t i g h t e n plugs t o 30 foot-pounds.
(11) Install a new tappet chamber cover and t i g h t e n
end bolts to 9 foot-pounds.
(12) Install Intake manifold, carburetor and ignit i o n coil as an assembly and t i g h t e n m a n i f o l d bolts t o
40 foot-pounds.
(13) Install d i s t r i b u t o r cap. Connect the coil w i r e ,
heat indicator sending u n i t w i r e , accelerator linkage,
spark p l u g cables and insulators.
(14) Install vacuum hose at carburetor and distributor.
(15) Install closed ventilation system and evaporative control system (if so equipped).
(16) Install alternator and drive belts. Tighten alternator adjusting strap bolt to 200 inch-pounds, and
alternator m o u n t i n g bolt to 30 foot-pounds.
(17) Install fuel line and carburetor a i r cleaner.
(18) F i l l cooling system. A d j u s t belt tensions as outlined i n "Cooling System" Group 7.
VALVES AND VALVE SPRINGS
Valves are arranged in-line i n the cylinder heads
and inclined 30 degrees o u t w a r d f r o m vertical. T h e
intake and exhaust valves operate i n guides that are
cast i n t e g r a l w i t h the heads.
TOOL
CYLINDER H E A D
ASSEMBLIES
.
INTAKE PUSH
A
—
-
RODS
INSTALLING
ROD
CYLINDER
HFAD
ASSEMBLY
-
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1
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HAUST
PUSH
fig. 7-Push Rods
RODS
Installed
9-7
(IOOL)
MH65?
I'RHJA
Fig. 8—Compressing Vsive
Sprang
9-8
A
ENGINE
Removal
(1) W i t h cylinder head removed, compress valve
springs, using Tool C-3422A, (Fig. 8).
(2) Remove valve r e t a i n i n g locks, valve s p r i n g retainers, valve stem cup seals and valve springs.
(3) Before r e m o v i n g valves, remove any b u r r s f r o m
valve stem lock grooves to prevent damage t o t h e
valve guide. Identify valves to insure installation in
original location.
TOOL
VALVE
Valve
Inspection
(1) Clean valves thoroughly, and discard any
burned, warped or cracked valves.
(2) Measure valve stems f o r wear. Refer t o specifications f o r proper size. I f wear exceeds .002 inch,
replace the valve.
(3) Remove carbon and varnish deposits f r o m i n side of valve guides w i t h a reliable guide cleaner.
(4) Measure valve stem guide clearance as follows:
Install sleeve Tool C-3973 over valve stem (Fig. 9)
and install valve.
(5) The special sleeve places the valve at the correct height f o r measuring w i t h a d i a l indicator. A t tach d i a l indicator T o o l C-3339 to the cylinder head
and set i t at a r i g h t angle t o the valve stem b e i n g
measured (Fig. 10).
(6) Move valve to and f r o m t h e indicator. T o t a l d i a l
indicator reading should not exceed .017 i n c h . I f the
d i a l indicator reading is excessive or i f the stems are
scored or w o r n excessively, r e a m the guides f o r new
valves w i t h oversize stems.
(7) Service valves w i t h oversize stems are available
i n .005, .015 and .030 inch oversizes. Reamers to accommodate the oversize valve stem are as follows:
Reamer
Valve Guide
Reamer
Tool Number
Size
Oversize
.379-.380 in.
.005 in.
C-3433
.389-.390 in.
C-3430
.015 in.
.404-.405 in.
.030 in.
C-3427
KR143
Fig. 10—Measuring
Valve Guide
Wear
(8) Slowly t u r n reamer by hand and clean guide
thoroughly before installing new valve. Do not attempt to ream the valve guides from standard directly
to .030 inch. Use step procedure of .005, .015 and .030
inch so the valve guides may be reamed true in relation to the valve seat.
Refacing
Valves
and Valve
Seats
The intake and exhaust valve faces have a 45 degree angle. Always inspect the r e m a i n i n g valve marg i n after t h e valves are refaced (Fig. 11). Valves w i t h
less than 3/64 i n c h m a r g i n should be discarded.
(1) The angle of both the valve and seat should be
identical. W h e n refacing valve seats, i t is i m p o r t a n t
that the correct size valve guide p i l o t be used f o r
reseating stones. A t r u e and complete valve seat
surface must be obtained.
(2) Inspect valve seat w i t h Prussian blue to determine where valve contacts seat. To do this, coat valve
seat l i g h t l y w i t h Prussian blue, then set valve i n
place. Rotate valve w i t h l i g h t pressure. I f the blue is
transferred to the center of the valve face, the contact
is satisfactory. I f the blue is transferred t o the top
edge of the valve face, lower the valve seat w i t h a 30°
FACE
TOOL
INTAKE VALVE
EXHAUST VALVE
VALVE SPRING
RETAINER LOCK GROOVES
PY600
Fig. 9—Installing Valve and Tool C-3973
Fig. 11—Intake and Exhaust
Valves
ENGINE
94
stone. I f the blue is transferred t o the bottom edge o f
the valve face raise the valve seat w i t h a 60° stone.
(3) When the seat Is p r o p e r l y positioned the w i d t h
;- .0 y
of the intake seats should be 1/16 t o 3/32 Inch. T h e
w i d t h of the exhaust seats should be 3/64 to 1/16
inch. (4) Measure the concentricity o f the valve seat usi n g d i a l indicator No. 13725. The t o t a l r u n o u t should
not exceed .003 i n c h (total indicator reading).
(5) When valves and seats are reground, the posit i o n of the valve i n t h e cylinder head Is changed,
shortening the operating l e n g t h o f the hydraulic tappet. This means that the p l u n g e r is operating closer to
its " b o t t o m e d " position, and less clearance is available
H P
for t h e r m a l expansion of the valve mechanism d u r i n g
m
high speed d r i v i n g .
(6) The design of the valve mechanism includes a
safety factor to allow f o r a l i m i t e d amount of wear,
KH333A
and the refacing of the valves and seats.
Fig. 13-Testing Valve Springs
(7) To insure that l i m i t s have not been exceeded,
the dimension f r o m valve s p r i n g seat i n the head t o
instant. M u l t i p l y this reading b y two. This w i l l give
the valve t i p should be measured w i t h gauge, Tool
the s p r i n g load a t the test length. Fractional measC-3648 (Fig. 12).
urements are indicated on the table for finer adjust(8) The end of the c y l i n d r i c a l gauge and the bottom
ments. Refer t o specifications t o obtain specified
of slotted area represent the m a x i m u m and m i n i m u m
height and allowable tension. Discard t h e springs
allowable extension of the valve stem t i p beyond the
that do n o t meet specifications.
spring seat.
(2) Inspect each valve spring for squareness at b o t h
(9) I f the t i p exceeds the m a x i m u m , g r i n d stem t i p
ends w i t h a steel square and surface plate (Fig. 14).
to w i t h i n gauge l i m i t s . Clean tappets i f t i p g r i n d i n g is
(3) I f the s p r i n g is more than 1/16 i n c h out of
required.
square, install a new spring.
v
Testing
the Valve Springs (Fig. 13) •
(1) Whenever valves are removed for inspection, reconditioning or replacement, the valve springs should
be tested. As a n example, t h e compressed l e n g t h
of the spring t o be tested is 1-15/32 inches. T u r n
the table of Tool C-647 u n t i l the surface is i n l i n e
w i t h the 1-15/32 i n c h m a r k on the threaded stud and
the zero m a r k to the f r o n t . Place the spring over the
stud on the table and l i f t the compressing lever to set
the tone device. P u l l on the torque wrench u n t i l a p i n g
is heard. Take the reading on torque wrench at this
VALV:
Installation
(1) Coat valve stems w i t h l u b r i c a t i n g o i l and insert
t h e m i n position i n cylinder head.
(2) Install new cup seals on the intake and exhaust
valve stems and over valve guides (Fig. 15 and 16) and
install valve springs and retainers.
(3) Compress valve springs w i t h Tool C-3422A. I n stall locks and release tool. I f valves and/or seats are
reground, measure installed height of the springs.
^RING
TOOL
4^ ^ :
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i
f
ml
^ ^ ^ ^ ^ ^ ^ ^
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MINIMUM
jzjg.
,
r
MEASUREMENT
MEASUREMENT
Fig. 12—Measuring V&IVQ
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$ig. 14—ln§pe<sltimg ^©Ihf© Spiri®^ §qfw®reness
9-10
ENGINERETAINER
7,\17' ~
Oil Level Too High
(3) I f o i l level is above the " f u l l " m a r k on dipstick,
i t is possible f o r the connecting rods to dip i n t o the o i l
while engine is r u n n i n g and create foam. Foam i n o i l
pan w o u l d be f e d t o t h e hydraulic tappets by the o i l
p u m p causing t h e m t o lose l e n g t h and allow valves t o
seat noisily.
!
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"
O I L s-c/-;.
?!NG
„ EXHAUST
VALVE
PY601
Fig. 15—Valve Assembly
(Disassembled
View)
Make sure measurement is taken f r o m t h e bottom o f
spring seat i n cylinder head t o bottom surface of
spring retainer. I f t h e height is greater than 1-57/64
inches, install a 1/16 inch spacer in t h e head counterbore t o b r i n g t h e spring height back t o normal
1-53/64 t o 1-57/64 inch. (If spacers a r e installed,
measure f r o m the top of the spacer.)
HYDRAULIC T A P P E T S
Preliminary
to Cheeking
the
Hydraulic
Tappets
(1) Before disassembling any p a r t of the engine t o
correct tappet noise, read t h e o i l pressure at t h e
gauge (Install a reliable gauge at pressure sending u n i t
If vehicle has n o o i l pressure gauge.) a n d check t h e
oil level I n t h e o i l pan. T h e pressure should be between 45 and 65 pounds at 1000 R.P.M.
(2) H i e o i l level i n t h e pan should never be above
the " f u l l " m a r k o n dipstick, o r below t h e " a d d o i l "
m a r k . E i t h e r o f these t w o conditions could be responsible f o r noisy tappets.
RETAINER--.,
SPRING-...
INTAKE
Fig.
VALVE
Installing Valve, Sprim§
and Retainer
ff
Cup Seal
O i l Level Too Low
(4) L o w o i l level may allow o i l p u m p to take i n a i r
which, when f e d t o t h e tappets, causes t h e m t o lose
length and allows valves t o seat noisily. A n y leaks o n
intake side of p u m p t h r o u g h w h i c h a i r can be d r a w n
w i l l create the same tappet action. W h e n tappet noise
is due to aeration, i t may be i n t e r m i t t e n t o r constant,
and usually more than one tappet w i l l be noisy. W h e n
oil level and leaks have been corrected, engine should
be operated at fast idle f o r sufficient t i m e t o allow a l l
of the air inside of the tappets t o be bled out.
Tappet Noise
Diagnosis
(1) To determine source of tappet noise, operate
engine at idle w i t h cylinder head covers removed.
(2) Feel each valve s p r i n g o r rocker a r m t o detect
noisy tappet. The noisy tappet w i l l cause t h e affected
spring and/or rocker a r m t o vibrate or feel r o u g h i n
operation. Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is the
case, noise may be dampened by applying side thrust
on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet.
Inspect the rocker arm push rod sockets and push rod
ends for wear.
(3) Valve tappet noise ranges f r o m l i g h t noise t o
a heavy click. A l i g h t noise is usually caused b y excessive leakdown around t h e u n i t plunger w h i c h w i l l
necessitate replacing t h e tappet, or b y t h e plunger
p a r t i a l l y sticking i n the tappet body cylinder. A heavy
click is caused either b y a tappet check valve n o t
seating, o r b y foreign particles becoming wedged between t h e plunger and t h e tappet body, causing t h e
plunger t o stick i n the down position. This heavy click
w i l l be accompanied b y excessive clearance between
the valve stem a n d rocker a r m as valve closes. I n
either case, tappet assembly should be removed f o r
inspection and cleaning.
Tappet
Removal
(1) T h e tappet can be removed w i t h o u t removing
intake manifold o r cylinder heads b y following this
recommended procedure: Remove cylinder head covers.
(2) Remove rocker arms and shaft assembly.
(3) Remove push rods a n d identify to insure installation in original location.
(4) Slide a magnetic p i c k u p tool t h r o u g h push r o d
opening i n cylinder head and seat tool firmly i n t h e
head o f tappet.
A
9-11
ENGINE
(5) P u l l tappet out of bore w i t h a t w i s t i n g motion.
I f a l l tappets are to be removed, identify tappets to
insure installation in original location.
A diamond shaped marking stamped on the engine
numbering pad indicates that some tappet bodies are
.008 inch oversize.
C A U T I O N : The plunger and tappet bodies are not
interchangeable. The plunger and valve must always
be fitted to the original body. It is advisable to work
on one tappet at a time to avoid mixing of parts.
Mixed parts are not compatible. Do not disassemble a
tappet on a dirty work bench.
Disassembly
(Fig. 17)
(1) P r y out plunger retainer spring clip.
(2) Clean varnish deposits f r o m inside of tappet
body above plunger cap.
(3) I n v e r t tappet body and remove plunger cap,
plunger, flat check valve, check valve spring, check
valve retainer and plunger spring.
Cleaning
and
Assembly
(1) Clean a l l tappet parts i n a solvent that w i l l remove all varnish and carbon.
(2) Replace tappets that are unfit f o r f u r t h e r service w i t h new assemblies.
(3) I f plunger shows signs of scoring or wear and
valve is p i t t e d , or i f valve seat on end of plunger
indicates any condition that w o u l d prevent valve f r o m
seating, install a new tappet assembly.
(4) Assemble tappets (Fig. 17).
Testing
(1) F i l l a pan w i t h clean kerosene.
(2) Remove cap f r o m plunger and plunger f r o m
tappet body.
(3) F i l l tappet body w i t h kerosene and install
plunger.
(4) Unseat check valve w i t h a brass r o d to p e r m i t
complete installation of plunger. Replace cap.
(5) H o l d tappet i n an u p r i g h t position and insert
lower j a w of pliers, Tool C-3160, i n t h e groove of
tappet body (Fig. 18).
(6) Engage j a w of pliers w i t h top of tappet plunger.
Test leakdown b y compressing the pliers. I f plunger
RETAINER
CHECK VALVE
SPRING
PLUNGER
RETAINER
SPRING CLIP
TAPPET BODY
PLUNGER SPRING
CHECK V A L V E '
PLUNGER
PLUNGER CAP
Fig. 17-Hydraulic Tappet Assembly
(Disassembled
View)
NR65
TOOL
CLE AM
KEROSENE
\
NR66
Fig. 18—Testing Tappet Using Tool C-3160
collapses almost instantly as pressure is applied, disassemble tappet, clean and test again (Fig. 18).
(7) I f tappet s t i l l does n o t operate satisfactorily
after cleaning, install a new tappet assembly. If the
tappet or bore in cylinder block is scored, scuffed, or
shows signs of sticking, ream the bore to next oversize.
Installation
(1) Lubricate tappets.
(2) Install tappets and push rods i n t h e i r o r i g i n a l
positions.
(3) Install rocker a r m and shaft assembly.
(4) Start and operate engine. W a r m u p t o n o r m a l
operating temperature.
C A U T I O N : To prevent damage to valve mechanism,
engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become
quiet.
VALVE TIMING
(All
Models)
(1) T u r n crankshaft u n t i l NO. 6 exhaust valve is
closing and NO. 6 intake valve is opening.
(2) Insert a 1/4 i n c h spacer between r o c k e r a r m
pad and stem t i p of No. 1 intake valve (second valve
on t h e l e f t bank).
(3) Install a d i a l indicator so plunger contacts valve
s p r i n g retainer as nearly perpendicular as possible.
(4) A l l o w s p r i n g load t o bleed tappet down giving
i n effect a solid tappet. Zero the indicator.
(5) T u r n the crankshaft clockwise (normal r u n n i n g
direction) u n t i l intake valve has l i f t e d .025 i n c h w i t h
256-260° camshaft and .033 i n c h w i t h 268-284° camshaft. See specifications f o r engine application. The
t i m i n g o n t h e t i m i n g indicator, located on the chain
case cover, should read f r o m 10 degrees B T D C t o 2
degrees ATDC. I f the reading is n o t w i t h i n specified
l i m i t s : Inspect t i m i n g sprocket index marks, inspect
t i m i n g chain f o r wear, and determine accuracy of
ENGINE-
9-12
TORQUE WRENCH-
the DC m a r k o n t i m i n g indicator. T u r n crankshaft
counterclockwise u n t i l valve Is closed a n d remove
the indicator and spacer.
C A U T I O N : Do n o t t u r n crankshaft any f u r t h e r clockwise, as the valve spring m i g h t bottom and result i n
serious damage.
•H h~-3/s6 INCH
TIMING CHAIN COVER, OIL S E A L AND
CHAIN
Cower
Removal
(1) D r a i n cooling system and remove radiator and
water p u m p assembly.
(2) Remove crankshaft v i b r a t i o n damper attaching
bolt.
(3) Remove t w o o f the p u l l e y bolts, i n s t a l l T o o l C3688, a n d p u l l damper assembly off end o f crankshaft
(Fig. 19).
(4) Remove chain cover and gasket. I t is n o r m a l t o
find particles of neoprene collected between seal retainer and crankshaft o i l slinger after seal has been
in operation.
(5) Slide crankshaft o i l slinger off end of crankshaft.
Measuring
Timing Chain for
Stretch
(1) Place a scale next t o t h e t i m i n g chain so a n y
movement of t h e chain may be measured.
(2) Place a torque w r e n c h a n d socket over camshaft sprocket attaching bolt and apply torque i n t h e
d i r e c t i o n of crankshaft r o t a t i o n t o take u p slack; 30
foot-pound ( w i t h cylinder heads installed) o r 15 footpounds (cylinder heads removed). With torque applied to the camshaft sprocket bolt, crankshaft should
not be permitted to move. It may be necessary to
block crankshaft to prevent rotation.
(3) H o l d i n g a scale w i t h dimensional reading even
w i t h edge of a chain l i n k , apply torque i n t h e reverse
direction 30 foot-pounds ( w i t h cylinder heads i n stalled) o r 15 foot-pounds (cylinder heads removed),
and note amount of chain movement (Fig. 20).
(4) I n s t a l l a new t i m i n g chain, i f i t s movement exceeds 3/16 inch.
'
Fig. lO—Lvie&T'&ring timing
Chain
KR151A
Stretch
(5) I f chain is satisfactory, slide crankshaft o i l
slinger over shaft a n d u p against sprocket (flange
away f r o m sprocket).
(6) I f chain is n o t satisfactory, remove camshaft
sprocket attaching bolt a n d remove ' t i m i n g chain
w i t h crankshaft a n d camshaft sprockets. When installing timing chain, use Tool C-3509 to prevent camshaft from contacting the welch plug in the rear of
engine block. Remove distributor and oil pump-distributor drive gear. Locate tool against rear side of
cam gear and attach tool with distributor retainer
plate bolt (Fig. 21).
(7) Place camshaft sprocket and crankshaft sprocket on the bench w i t h t i m i n g marks on exact imaginary
center l i n e t h r o u g h b o t h camshaft a n d crankshaft
sprocket bores.
(8) Place t i m i n g chain around b o t h sprockets.
(9) T u r n crankshaft and camshaft t o l i n e u p w i t h
keyway location o n crankshaft sprocket a n d dowel
hole i n camshaft sprocket.
(10) L i f t sprockets and chain (keep sprockets t i g h t
against chain i n position as described).
TOOL
ARM (TOOL)
-'MAIN CASE COVER
— TIMING INDICATOR
mm
— C Y L I N D E R BLOCK
^
TIMING MARK
V . 3 RATI O N DAMPED
.TOOL
^ ^ ^ ^ ^ ^ ^ ^
KR149A
Fig. f 9—Removing Vibration
Damper
Assembly
\ ^f^lRlSUTOR
GEAi?
(CAMSHAFT)
"
KR162
ENGINE
H O O V E R
S C R ^ W
R5JV\0\' NG
(TOOL)
AN ;
:
R
I N S F A . J N G
PU..E
CHAIN
CASE
C O V E R
X
4^
•
9-13
HIHHii
KR153B
£i@/ %$—&&m®w!]Ddg Oil
0
4 ; - -4-
•'
1
F i g . 22—Alignment of Timing
NN358
Marks
(11) Slide both sprockets evenly over t h e i r respective shafts.
(12) Use a straight edge to measure alignment of
t i m i n g marks (Fig. 22).
(13) Install washer and camshaft sprocket bolt,
tighten t o 35 foot-pounds. Check t o be sure that rear
face of a l u m i n u m camshaft sprocket Is flush w i t h e n d
of camshaft. Slide the crankshaft o i l slinger over shaft
and u p against sprocket (flange away f r o m sprocket).
O i l Seal Replacement
(Cower
Removed)
(1) Position remover screw of Tool C-3506 t h r o u g h
case cover, inside of case cover u p . Position remover
blocks d i r e c t l y opposite each other, a n d force t h e
angular l i p between the neoprene and flange of seal
retainer.
(2) Place washer and n u t on remover screw.
Tighten nut, forcing the blocks into the gap to a point
REMOVER BLOCKS
CHAIN CASE
(TOO*)
COVER
^ .4.-.^.
of distorting the seal retainer l i p (Fig. 23). This is i m portant, remover is only positioned at this point.
(3) Place sleeve over retainer a n d place removing
and installing plate i n t o the sleeve.
(4) Place flat washer a n d n u t on t h e remover
screw. H o l d center screw and t i g h t e n remover n u t t o
remove the seal (Fig. 24).
(5) Insert remover screw t h r o u g h the r e m o v i n g and
installing plate so t h i n shoulder w i l l be facing u p .
(6) Insert remover screw w i t h t h e plate t h r o u g h
seal opening (inside of chain case cover facing up).
(7) Place seal i n cover opening, w i t h neoprene
down. Place seal installing plate i n t o t h e new seal,
w i t h protective recess t o w a r d l i p of seal retainer (Fig.
25). The lip of the neoprene seal must be toward
source of oil.
(8) Install flat washer a n d n u t on remover screw,
hold screw and tighten n u t (Fig. 26).
(9) The seal is p r o p e r l y installed w h e n t h e neoprene is t i g h t against face of cover. T r y t o insert a
.0015 inch feeler gauge between t h e neoprene a n d
the cover (Fig. 27). I f t h e seal is installed properly,
feeler gauge cannot be inserted. Do not over compress
neoprene.
INSTALLING
PLATE
l\r OF SEAL
RETAINER
(TOOL)
•J
-r
4-
-f
REMOVER
'V*"*
s
:
!
KR152B
Fig. 23—Remover Blocks Expanded to Puller Position
•
^
S C R E W
.<T
SEAL-""
ASSEMBLY
1
(TOOL)
CHAIN
CASE
Fig. 25—Positioning Installer
C O V E R
KR154B
Plate
9-14
ENGINE-
REMOVER SCREW
(TOOL)
^
i\^§f\^
CHAIN CASE COVER
INDICATOR
CYLINDER BLOCK
T
i
M
I
N
G
TIMING MARK
VIBRATION DAMPER
^J-'^INSYALLING
(TOOL)
SEAL
PLATE
Fig. 28—installing Vibration Damper
CHAIN CASE COVER
RETAINER
KR155B
Fig. 26—Installing New
Seal
Cover
Installation
(1) Be sure m a t i n g surfaces of chain case cover and
cylinder block are clean and free f r o m burrs.
(2) Using a new gasket slide chain case cover over
locating dowels. I n s t a l l a n d t i g h t e n bolts 15 footpounds.
(3) Lubricate seal l i p w i t h L u b r i p l a t e , place damper
hub slot on k e y i n crankshaft, and slide v i b r a t i o n
damper on crankshaft.
(4) Place i n s t a l l i n g tool, p a r t of T o o l C-3688 i n
position and press damper on the crankshaft (Fig. 28).
(5) Install damper retainer washer and bolt. Tighten t o 135 foot-pounds.
(6) Slide belt p u l l e y over shaft a n d attach w i t h
bolts and lockwashers. Tighten bolts to 200 inchpounds.
CAMSHAFT
The camshaft has an i n t e g r a l o i l p u m p a n d distribu t o r drive gear and f u e l p u m p eccentric (Fig. 29).
The r e a r w a r d camshaft t h r u s t is taken b y t h e rear
face o f t h e a l u m i n u m camshaft sprocket h u b , bearing
directly o n t h e f r o n t of cylinder block, e l i m i n a t i n g
FEELER G A U G E
~_
^
SEAL
mm
IS
KR157A
HflHH • l
1
Assembly
need f o r a t h r u s t plate. The h e l i x o f the o i l p u m p and
distributor d r i v e gear and camshaft lobe taper b o t h
tend to provide a rearward thrust.
Removal
(1) W i t h tappets and the t i m i n g chain and sprockets
removed, remove d i s t r i b u t o r and l i f t o u t o i l p u m p
and d i s t r i b u t o r drive shaft.
(2) Remove f u e l p u m p t o allow f u e l p u m p push r o d
to drop away f r o m cam eccentric.
(3) Remove camshaft, being careful n o t t o damage
camshaft bearings w i t h the cam lobes.
Installation
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert camshaft t o w i t h i n 2 inches of its
final position i n cylinder block.
(2) Modify Tool C-3509 b y g r i n d i n g off index l u g
h o l d i n g the upper a r m on the tool and rotate a r m 180
degrees.
(3) Install Tool C-3509 i n place of d i s t r i b u t o r drive
gear and shaft, as shown i n Figure 2 1 .
(4) H o l d tool i n position w i t h d i s t r i b u t o r lock plate
screw. This t o o l w i l l restrict camshaft f r o m being
pushed i n too f a r and prevent k n o c k i n g out the welch
p l u g i n t h e rear of cylinder block. T h e tool should
remain installed u n t i l camshaft and crankshaft sprockets and t i m i n g chain have been installed.
Whenever an engine has been rebuilt and/or a new
camshaft and/or tappets are installed, one quart of
engine supplement, Chrysler Part Number 1879406 o r
CAMSHAFT SPROCKET
BOLT
WASHER
CAMSHAFT
Ifiij
HBjjjH • H H H
A .
'
,
'
CHAIN CASE COVER
Fig. 27—inspecting Seal f o r Proper
_ _ _ _ _
9
t^^\^^
1
t
r
DISTRIBUTOR DRIVE GEAR
(CAMSHAFT)
FUEL PUMP ECCENTRIC (CAMSHAFT)
LOCATING DOWEL
K
R
]
KRI56A
Seating
Fig. 29—Camshaft and Sprocket
(Disassembled
View)
Assembly
5
8
A
_
_
_
,
equivalent should be added to the engine o i l t o aid in
break-in. The o i l mixture should be left i n the engine
for a minimum of 500 miles. Drain t h e oil mixture at
the next normal oil change.
Whenever camshaft is replaced, a l l tappet faces
must be inspected f o r crown w i t h a straight edge. I f
any contact surface is dished or worn, tappet must be
replaced.
CAMSHAFT BEARINGS
(Engine
R e m o v e d from
Vehicle)
Removal
(1) W i t h engine completely disassembled drive out
camshaft rear bearing welch p l u g .
(2) Install proper size adapters a n d horse shoe
washers (part of Tool C-3132A) at t h e back of each
bearing t o be removed and drive o u t bearings (Fig.
30).
Installation
(1) Install new camshaft bearings w i t h Tool C3132A. Place new camshaft bearing over proper
adapter.
(2) Position bearing I n the tool. I n s t a l l the horse
shoe lock and b y reversing removal procedure, caref u l l y drive bearing i n t o place.
(3) Install r e m a i n i n g bearings i n l i k e manner. I n stall the NO. 1 camshaft bearing 1/32 inward from
the front face of cylinder block.
The o i l holes i n camshaft bearings and the cylinder
block must be i n exact register to insure proper l u b r i cation (Fig. 30).
The camshaft bearing index can be inspected after
installation by i n s e r t i n g a pencil flashlight i n the
bearing. The camshaft bearing o i l hole should be perfectly aligned w i t h the d r i l l e d o i l passage f r o m the
m a i n bearing. Other o i l holes i n the camshaft bearings should be visible by looking d o w n on the left
bank o i l hole above and between N O . 6 and NO. 8
cylinders to NO. 4 camshaft bearing and on the r i g h t
bank above and between NO. 5 and 7 cylinders t o N O .
• ^^^^^^^^^^^^^^^^^
l
—-
^—^
^
-ENGINE
9-15
4 camshaft bearings. I f camshaft bearing o i l holes are
not i n exact register, remove and r e i n s t a l l t h e m correctly. Install a new welch p l u g at rear of camshaft.
Be sure this plug does not leak.
DISTRIBUTOR DRIVE SHAFT BUSHING
Removal
(1) Insert Tool C-3052 into the old bushing and
thread down u n t i l a t i g h t fit is obtained.
(2) H o l d remover screw and t i g h t e n n u t u n t i l bushi n g is removed, (Fig. 31).
Installation
(1) Slide a new b u s h i n g over b u r n i s h i n g end of
Tool C-3053 and insert t o o l bushing i n t o the bore.
(2) D r i v e bushing and t o o l i n t o position, using a
soft hammer, (Fig. 32).
(3) A s the b u r n i s h e r is p u l l e d t h r o u g h the bushing
by t i g h t e n i n g remover n u t , the bushing is expanded
t i g h t i n the block and burnished t o correct size (Fig.
33). DO NOT R E A M THIS BUSHING.
Distributor
Timing
Before i n s t a l l i n g d i s t r i b u t o r and o i l p u m p drive
shaft, t i m e the engine as follows:
(1) Rotate crankshaft u n t i l N O . 1 cylinder is at top
dead center o n the firing stroke.
(2) W h e n i n this position, the straight line on the
vibration damper should be under " 0 " on t i m i n g i n d i cator.
(3) Coat shaft and drive gear w i t h engine oil. Install
the shaft so that after gear spirals i n t o place, i t w i l l
index w i t h the o i l p u m p shaft, so slot i n top of drive
gear w i l l be parallel w i t h center l i n e of crankshaft
(Fig. 34).
Installation
of
Distributor
(1) H o l d d i s t r i b u t o r over m o u n t i n g p a d on cylinder
block w i t h vacuum chamber p o i n t i n g t o w a r d center of
engine.
BUSHING
/
TOOL
1 CRANKSHAFT MAIN BEARING OIL HOLE
4CAMSHAFT BEARING OIL HOLE
?
'
. *
t
KR164
Fig. 3©—Removing €@m§Um$Q Bowing
Fog* D U —R®m@vkdg distributor
Drive Shaft
Bushing
Fig. 32—Installing Distributor Drive Shaft Bushing
(2) T u r n r o t o r u n t i l i t points f o r w a r d and to approximate location of No. 1 tower t e r m i n a l i n the dist r i b u t o r cap.
(3) Place d i s t r i b u t o r gastet i n position.
(4) Lower the d i s t r i b u t o r a n d engage t h e shaft i n
the slot of d i s t r i b u t o r drive shaft gear.
(5) T u r n d i s t r i b u t o r clockwise u n t i l breaker contacts are j u s t separating, install and t i g h t e n h o l d
down clamp.
CYLINDER "BLOCK "
T h e cylinder Mock is of the deep block design
w h i c h eliminates the need f o r a torque converter
housing adapter plate. Its sides extend three inches
below the crankshaft center l i n e .
Piston
Removal
(1) Remove top ridge of cylinder bores w i t h a r e l i able ridge reamer before r e m o v i n g pistons f r o m cylinder block. Be sure to keep tops of pistons covered
during this operation.
The pistons and connecting rods must be removed
from the top of the cylinder block. When removing
piston and connecting rod assemblies from the enBUSHING
TOOL
KR161
Fig. 33—Burnishing Dlstrtbost©F
©FOV©
§h®§$ Bushing
CENTER LINE CP
KR163A
CRANKSHAFT'
Fig. 34—Distributor Drive Gear
Installed
gine, rotate the crankshaft so each connecting rod is
centered in cylinder bore.
(2) Inspect connecting rods and connecting r o d caps
for cylinder identification. Identify t h e m i f necessary.
(3) Remove connecting r o d cap. Install connecting
rod bolt guide set on connecting r o d bolts. Push each
piston and r o d assembly out of cylinder bore. Be careful not to nick crankshaft journals.
(4) Install bearing caps on m a t i n g rods.
Cleaning
and
Inspection
(1) Clean cylinder block thoroughly and inspect a l l
core hole plugs f o r evidence of leaking.
(2) I f new core plugs are installed, coat edges of
p l u g and core hole w i t h N u m b e r 1057794 Sealer o r
equivalent. D r i v e the core p l u g i n so that the r i m lies
at least 1/64" below the lead-in chamfer.
(3) Examine block f o r cracks or fractures.
Cylinder
Bore
Inspection
The cylinder walls should be measured f o r out-ofr o u n d and taper w i t h T o o l C-119. I f the cylinder bores
show more than .005" out-of-round, or a taper of more
t h a n . 0 1 0 " or i f the cylinder walls are badly scuffed
or scored, the cylinder block should be rebored and
honed, and new pistons and rings fitted. Whatever
type of b o r i n g equipment is used, b o r i n g and honing
operation should be closely coordinated w i t h the
fitting
of pistons and rings i n order that specified
clearance may be maintained.
H o n i n g Cylinder
Bores
Before honing, stuff plenty of clean rags under the
bores, over the crankshaft to keep the abrasive materials f r o m entering the crankcase area.
(1) Used carefully, the cylinder bore resizing hone
C-823 equipped w i t h 220 g r i t stones and 390 extensions necessary w i t h 383 and 440 cubic i n c h engines
-ENGINE
is the best tool f o r this j o b . I n addition to deglazing, i t
w i l l reduce taper and out-of-round as w e l l as removing
l i g h t scuffing, scoring o r scratches. Usually, a f e w
strokes w i l l clean u p a bore and maintain t h e required limits.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501,
equipped w i t h 280 g r i t stones (3501-3810) i f the cylinder bore is straight and r o u n d . 20 t o 60 strokes depending on the bore condition w i l l be sufficient t o
provide a satisfactory surface. Inspect cylinder walls
after each 20 strokes. Using honing o i l C-3501-3880
or a l i g h t honing o i l available f r o m major o i l distributors. Do not use engine or transmission oil, mineral
oil or kerosene.
(3) Honing should be done b y moving t h e hone u p
and down fast enough t o get a cross-hatch pattern.
When hone marks intersect at 60°, cross hatch angle
is most satisfactory f o r proper seating o f rings (See
Fig. 35).
(4) A f t e r honing, i t is necessary that the block be
cleaned again to remove a l l traces of abrasives. Wash
cylinder block and crankshaft thoroughly.
C A U T I O N : Be sure all abrasives are removed from
the engine parts after honing. It is recommended that
a solution of soap and water be used with a brush and
the parts then thoroughly dried. The bore can be considered clean when it can be wiped clean with a white
cloth and the cloth remains clean. Oil bores after
cleaning to prevent rusting.
PISTONS, PINS and RINGS
Pistons
The pistons are cam g r o u n d so that the diameter at
the p i n boss is less than its diameter across the t h r u s t
face. This allows f o r expansion under n o r m a l operati n g conditions. Under operating temperatures, expanCROSS-HATCM
PATTERN
i-17
sion forces the p i n bosses away f r o m each other, t h u s
causing the piston t o assume a more nearly r o u n d
shape. I t Is i m p o r t a n t that o l d or new pistons be measu r e d f o r taper and elliptical shape before they a r e
fitted i n t o the cylinder bore (See F i g . 36).
Finished
Pistons
A l l pistons are machined t o t h e same weight i n
grams, regardless of oversize so piston balance can be
maintained. F o r cylinder bores w h i c h have been
honed o r rebored, pistons are available i n standard
and the f o l l o w i n g oversizes: .005, .020, and .040 i n c h .
Fitting
Pistons
Piston and cylinder w a l l must be clean and d r y .
Specified clearance between the piston and the cyli n d e r w a l l is .0003 to .0013 inch.
Piston diameter should be measured at the t o p of
s k i r t 90 degrees t o piston p i n axis. Cylinder bores
should be measured halfway down the cylinder bore
and transverse t o the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 70 degrees F.
A l l service pistons include pins, and are available i n
standard and the following oversizes: .005, .020 and
.040 inch.
Fitting
Rings
(1) Measure piston r i n g gap about two inches f r o m
b o t t o m of cylinder bore i n w h i c h i t is t o be fitted.
(An inverted piston can b e used t o push rings d o w n
t o insure positioning rings squarely i n cylinder w a l l
before measuring.)
(2) Insert feeler stock i n the gap. Ring gap should
be between .013 t o .052 i n c h f o r t h e compression
rings and .015 t o .062 i n c h f o r the o i l r i n g steel rails
i n standard size bores. M a x i m u m gap on .005 i n c h
O/S bores should be .060 i n c h f o r compression rings
and .070 i n c h f o r the o i l r i n g steel rails.
. .020 TO .028 IN. LESS
THAN DIAMETER AT (C)
mm
Fig. 35-Cross
Hatch
Pattern
THE ELLIPTICAL SHAPE O F
THE PISTON SKIRT SHOULD
BE .010 T O .012 IN. LESS AT
DIAMETER (A) THAN
ACROSS THE THRUST FACES
AT DIAMETER (B). MEASUREMENT IS MADE Vs IN. BELOW LOWER RING G R O O V E
Fig. 36—Piston
DIAMETERS AT (C) A N D (D)
C A N BE EQUAL OR DIAMETER
AT (D) C A N BE .0015 !N.
GREATER THAN (C)
NU258
Measurements
948
ENGINE-
PISTON
FEELER
RING
G A G E
G R O O V E
PRESS—.„
RING
MAIN
SCREW
(TOOL)
X
i
"
;
k
-PILOT
v
PISTON PIN
- '
(TOOL)
- - PISTON
C -Hf/
— A N V I L (TOOL)
.Jfcr'
KR165 A
Fig„ 37—Measuring
Pistom Pin
Removal
(1) A r r a n g e Tool C-3684 parts f o r removal o f piston
p i n , (Fig. 38).
(2) Install pilot on m a i n screw.
(3) Install m a i n screw t h r o u g h piston p i n .
(4) Install anvil over threaded end of m a i n screw
w i t h small end of anvil against piston boss. Be sure
spring is removed from anvil.
(5) Install n u t loosely on m a i n screw and place assembly on a press, (Fig. 39).
(6) Press piston p i n out of connecting r o d . When
pin falls free from connecting rod, stop press to prevent damage to bottom of anvil.
(7) Remove tool f r o m piston.
Installation
(1) Test piston p i n fit i n the piston. I t should be a
sliding fit i n the piston at 70 degrees F. Piston pins
are supplied i n standard sizes only.
(2) Lubricate piston p i n holes i n t h e piston and
connecting rod.
(3) A r r a n g e Tool C-3684 parts f o r installation of
piston p i n (Fig. 40).
(4) Install spring inside t h e pilot and install spring
and pilot i n the anvil. Install piston p i n over m a i n
screw.
(5) Place piston, w i t h " f r o n t " u p , over the p i l o t so
p i l o t extends t h r o u g h piston p i n hole.
(6) Position connecting r o d over the p i l o t w h i c h extends t h r o u g h piston p i n hole. Assemble rods to pistons of the right cylinder bank (2, 4, 6, and 8) with
indent on piston head opposite to the larger chamfer
NUT (TOOL)
ANVIL (TOOL)
ANVIL
PISTON
PILOT
(TOOL)
(TOOL)
SPRING (TOOL)
• P I L O T (TOOL)
• PISTON
PISTON PIN
MAIN
/SCREW (TOOL)
MAIN
GUIDE-SMALL
(TOOL)
CONNECTING ROD
CONNECTING ROD
KR195B
GUIDE-LARGE (TOOL)
Fig* 38—Tool Arrangement
for Removing Piston Pin
S C R E W
(TOOL)
GUIDE-SMALL
(TOOL)
PISTON PIN
NR808
Fig* -39—Removing Pis$@n Pin
Piston Ring Clearance
(3) Measure side clearance between piston r i n g and
r i n g groove (Fig. 37). Clearance should be .0015 t o
.003 inches f o r the top compression r i n g and intermediate r i n g . Steel r a i l service o i l r i n g should be free
i n groove, b u t should n o t exceed .005 Inch side
clearance.
(4) Install t h e three piece o i l r i n g i n lower r i n g
groove using Instructions I n r i n g package.
(5) Install compression rings I n m i d d l e a n d t o p
groove as shown o n instruction sheet. Be sure t h e
m a r k " t o p " o n each compression r i n g faces t o p o f
piston.
(6) F o r the t w o top rings use r i n g installer Tool
C-3673 f o r 383 cubic i n c h engines and T o o l C-4001
f o r the 440 cubic i n c h engines.
"
KR196B
GUIDE-LARGE (TOOL)
Fig. 40—Tool Arrangement
for Installing Piston Pin
A
ENGINE
9-19
.PRESS
I
-MAIN SCREW (TOOL)
PISTON P I N -PISTON
- A N V I L (TOOL)
NR809
Fig. 41—Installing Piston Pin
on the large bore end of connecting rod. Assemble
rods to pistons of the left cylinder bank ( 1 , 3, 5, and
7) with indent on piston head on the same side as the
large chamfer on the large bore end of the connecting
rod.
(7) Install main screw and piston pin in piston,
(Fig. 40).
(8) Install nut on puller screw to hold assembly
together. Place assembly on a press (Fig. 41).
(9) Press piston pin in until piston pin "bottoms"
on the pilot. This will position pin in connecting rod.
(10) Remove tool and arrange tool parts and piston
assembly in same manner (Fig. 38).
(11) Place assembly in a vise (Fig. 42).
(12) Attach torque wrench to nut and tighten up to
15 foot-pounds. If the connecting rod moves downward on piston pin, reject this connecting rod and
piston pin combination. Obtain a connecting rod with
NUT
(TOOL)
TORQUE WRENCH
KR169
Fig. 43—Showing Location of External
Numbering Pad
Engine
proper small end bore diameter and repeat the installation and tightening procedure.
(13) If connecting rod does not move under 15
foot-pounds, piston pin and connecting rod interference is satisfactory, remove tool.
CRANKSHAFT IDENTIFICATION
IMPORTANT: A Maltese Cross stamped on the engine
numbering pad (Fig. 43) indicates that engine is
equipped with a crankshaft which has one or more
connecting rods and/or main bearing journals finished
.001 inch undersize. The position of the undersize
journal or journals is stamped on a machine surface
of the NO. 3 counterweight (Fig. 44). A Maltese Cross
with an X indicates .010 inch undersize journals.
The connecting rod journals are identified by the
letter "R" and main bearing journals by the letter
" M . " For example " M - l " indicates that NO. 1 main
bearing is .001 inch undersize.
SOCKET
PISTON
R - 1-2^ ROD)
ANVIL (TOOL)
M
"
I—4
MAIN)
LETTERS
PILOT (TOOL)
r\
MAIN SCREW (TOOL)
KK
NRS10
Fig. 42—Testing Fit of Piston Pin in Connecting Rod
162
Fig. 44—Showing Location of Internal Marking of
Counterweight
9-20
ENGINE-
CONNECTING RODS
Installation
of Connecting
A
—
Rod
Bearings
Fit ail rods on one bank u n t i l complete. Do not
alternate f r o m one bank to another, because when
rods are assembled to the piston correctly, they are
not interchangeable from one bank t o another.
Each bearing cap has a small " V " groove across
p a r t i n g face. W h e n Installing the lower bearing shell,
make certain " V " groove i n shell Is i n line w i t h " V "
groove i n cap. This allows l u b r i c a t i o n of the cylinder
wall. The bearings should always be installed so t h a t
the small f o r m e d tang fits into the machined grooves
of the rods. The end clearance should be f r o m .009 to
.017 inch (two rods).
L i m i t s of taper or out-of-round o n any crankshaft
journals should be held to a m a x i m u m of .001 i n c h .
Bearings are available i n .001, .002, .003, .010 and
.012 i n c h undersize. Install the bearings in pairs. Do
not use a new bearing half with an old bearing half.
Do not file the rods or bearing caps.
MEASURING CONNECTING ROD
BEARING C L E A R A N C E
Shim Stock
Method
(1) (a) 383 engine w i t h 2-barrel carburetor, place
an oiled .001 i n c h brass shim stock (1/2 i n c h wide
and 3/4 i n c h long) between the bearing and connecting rod journal.
(b) 383 engine w i t h 4-barrel carburetor and 440
w i t h t r i - m e t a l bearings, use an oiled .002 inch brass
shim stock (1/2 inch wide and 3/4 i n c h long) between
the bearing and connecting r o d j o u r n a l .
(2) I n s t a l l bearing cap and t i g h t e n to 45 footpounds.
(3) T u r n crankshaft 1/4 t u r n i n each direction. A
slight drag should be felt w h i c h indicates clearance
is satisfactory. 383 engine w i t h 2-barrel carburetor,
correct clearance Is f r o m .0005 to .0015 i n c h ; 383
w i t h 4-barrel carburetor and 440 w i t h t r i - m e t a l bearings, correct clearance Is f r o m .001 to .002 inch.
(4) Side play should be f r o m .009 to .017 i n c h (two
rods).
(3) Immerse piston head and rings i n clean engine
oil, slide r i n g compressor, Tool C-385, over the piston
and t i g h t e n w i t h special wrench (part of Tool C-385).
Be sure position of rings does not change during
this operation.
(4) Install connecting r o d bolt protectors on r o d
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting r o d
j o u r n a l is on the center of the cylinder bore. Insert
r o d and piston into cylinder bore and guide r o d over
the crankshaft j o u r n a l (Fig. 45).
(6) Tap piston down i n cylinder bore, using handle
of a hammer. A t the same time, guide connecting r o d
into position on c r a n k p i n j o u r n a l .
(7) The notch or groove on top of piston must be
pointing t o w a r d f r o n t of engine and larger chamfer of
connecting r o d bore must be installed t o w a r d crank
p i n j o u r n a l fillet.
(8) I n s t a l l r o d caps, tighten nuts to 45 foot-pounds.
CRANKSHAFT MAIN JOURNALS
Crankshaft m a i n bearing journals should be i n spected f o r excessive wear, taper and scoring. J o u r n a l
g r i n d i n g should not exceed .012 i n c h under the
standard j o u r n a l diameter. DO N O T g r i n d the t h r u s t
faces of the NO. 3 m a i n bearing. Do n o t n i c k c r a n k p i n
or m a i n bearing fillets. A f t e r r e g r i n d i n g , remove
r o u g h edges f r o m crankshaft o i l holes and clean out
all o i l passages.
CRANKSHAFT MAIN BEARINGS
New lower m a i n bearings halves Numbers 1, 2, 4 5
are interchangeable (Fig. 46). New upper main beari n g halves N u m b e r 2, 4 and 5 are also interchangeable. Upper and lower bearing halves are not interchangeable because upper bearing is grooved and
lower bearing is not.
The NO. 1 upper m a i n bearing IS N O T INTER-
INSTALLING PISTON AND CONNECTING
ROD A S S E M B L Y IN CYLINDER BLOCK
(1) Before i n s t a l l i n g pistons, rods, and r o d assemblies i n the bore, be sure t h a t the compression r i n g
gaps are staggered so t h a t neither are i n line w i t h o i l
r i n g r a i l gaps.
(2) The o i l r i n g expander ends should be positioned
t o w a r d the outside of the " V " of the engine. The o i l
r i n g r a i l gaps should be positioned opposite each
other and above the piston p i n holes.
Fig. 45—Installing Connecting
Rod
-ENGINE
— 1
,
n
2 iW-.-'j 3
...
4
^
TOOL
5
9-21
BEARING
UPPER
4-
W j
r^f.
7
!
LOWER
!
•
;
Fig. 46—Main Bearing
.1
4«
* -V/--
NU256
Identification
C H A N G E A B L E A N D IS CHAMFERED on the tab side
for t i m i n g chain oiling and can be identified b y a r e d
m a r k i n g on edge of bearing.
Upper and lower NO. 3 bearings are flanged t o
carry the crankshaft thrust loads and are not Interchangeable w i t h any other bearings I n t h e engine.
Bearings that are not badly w o r n o r pitted must be
reinstalled i n the same position.
Bearing caps are not interchangeable and should be
marked at removal t o Insure correct assembly. Bearings are available i n standard a n d t h e f o l l o w i n g
undersizes: .001, .002, .003, .010, .011 and .012 inch.
Do not install an undersize bearing that w i l l reduce
clearance below specifications.
Removal
(1) Remove oil pan and identify bearing caps before
removal.
(2) Remove bearing caps one at a time. Remove
upper half of bearing by Inserting Tool C-3059 (Fig.
47) into o i l hole of crankshaft.
(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing.
Installation
Only one main bearing should be selectively fitted
while a l l other main bearing caps are properly
torqued.
When installing a new upper bearing shell, slightly
chamfer the sharp edges f r o m the plain side.
(1) Start bearing i n place, and Insert Tool C-3059
into o i l hole of crankshaft (Fig. 47).
(2) Slowly rotate crankshaft counter-clockwise slidi n g the bearing i n t o position. Remove Tool C-3059.
REMOVING
INSi AILING
Fig. 47—Removing or Installing Upper Main Bearing
(2) Install bearing i n center m a i n bearing cap,
bearing tang i n groove i n cap, lubricate bearing and
position shim stock across t h e bearing, Install cap,
tighten bolts to 85 foot-pounds.
(3) I f a slight drag Is felt as crankshaft is t u r n e d
(moved no more t h a n 1/4 t u r n I n either direction),
clearance is .001 i n c h o r less and Is considered satisfactory.
i f , however, no drag is felt, the bearing Is too large
or crankshaft cannot be rotated, bearing is too small
and should be replaced w i t h the correct size.
(4) Measure crankshaft end play .002 t o .007 Inch.
I f end play Is less t h a n .002 i n c h o r more than .007
inch, install a new number 3 m a i n bearing.
(5) F i t remaining bearings I n same manner.
I t Is permissable t o use one .001 Inch undersize
bearing shell w i t h one standard bearing shell o r one
.002 Inch undersize bearing shell w i t h one .001 i n c h
undersize shell. Always use t h e smaller diameter
bearing half as the upper. Never use an upper bearing half more than . O i l inch smaller t h a n the lower
BRIDGE
• PART OF TOOL)
\
SEALSEAL
M E A S U R I N G MAIN B E A R I N G
CLEARANCE
Shim Stock
Method
(1) Smooth edges of a 1/2 x 3/4 i n c h piece of brass
shim stock, .001 inch thickness.
RETAINER
SIDE SEAL
GROOVES
^
KR237
Fig. 48—Installing Rear Main Bearing Lower Oil Seal
9-22
A
ENGINE
bearing half and never use a new bearing half w i t h a
used bearing half.
REAR MAIN BEARING OIL SEAL
(Crankshaft
Removed)
Upper Rear Main Seal
Installation
(1) Install a new rear m a i n bearing o i l seal i n cylinder block so that b o t h ends protrude.
(2) Tap seal down i n t o position, using Tool C-3625
f o r 383 Cubic I n c h Engines o r T o o l C-3743 f o r 440
Cubic I n c h Engines, w i t h bridge removed u n t i l t o o l is
seated i n bearing bore.
(3) H o l d the t o o l i n this position and c u t off p o r t i o n
of seal that extends above the block on b o t h sides.
L o w e r Rear Main Seal
Installation
(1) Install a new seal i n seal retainer so ends protrude (Fig. 48).
(2) Install bridge o n t o o l and tap the seal down i n t o
position w i t h Tool C-3625 f o r 383 Cubic I n c h E n gines o r Tool C-3743 f o r 440 Cubic I n c h Engines
u n t i l t o o l is seated.
(3) T r i m off that p o r t i o n of the seal that protrudes
above the cap (Fig. 49).
Side Seals
Installation
Perform the following operations as rapidly as pos-
KR238
Fig. 49—Trimming Rear Main Bearing Lower Oil Seal
sible. These side seals are made from a material that
expands quickly when oiled.
(1) A p p l y m i n e r a l spirits o r diesel f u e l t o t h e side
seals.
(2) Install seals immediately i n t h e seal retainer
grooves.
(3) I n s t a l l seal retainer a n d t i g h t e n screws t o 30
foot-pounds.
Failure to pre-oil the seals will result in an oil leak.
E N G I N E OILING S Y S T E M (Fig. 50)
OIL PAN
Removal
(1) Disconnect battery cable and remove dipstick.
(2) Raise vehicle o n a hoist and disconnect steering
linkage f r o m idler a r m a n d steering a r m .
(3) Disconnect exhaust pipe branches f r o m r i g h t
and left manifolds.
(4) Remove clamp attaching exhaust pipe t o extension and remove exhaust pipe.
(5) D r a i n crankcase o i l .
(6) Remove converter dust shield.
(7) Remove o i l p a n bolts. T u r n flywheel u n t i l
counterweight and connecting rods at f r o n t e n d of
crankshaft are at t h e i r highest position t o provide
clearance, a n d lower t h e p a n . T u r n p a n counterclockwise t o clear o i l screen and suction pipe as i t is
lowered.
Installation
(1) Inspect alignment o f o i l strainer. The b o t t o m of
the strainer must be o n a horizontal plane w i t h
machined surface o f cylinder block. T h e b o t t o m of
the strainer must t o u c h t h e b o t t o m of o i l pan.
(2) Install o i l pan.
(3) Install converter dust shield.
(4) Connect exhaust pipe branches t o the manifolds
and t o the exhaust extension.
(5) Connect steering linkage at idler a r m a n d a t
pitman arm.
(6) Connect battery cable, install dipstick.
(7) Install d r a i n p l u g and r e f i l l crankcase w i t h t h e
proper grade and quantity of o i l .
OIL PUMP
Removal
Remove o i l p u m p attaching bolts a n d remove p u m p
and filter assembly f r o m b o t t o m side o f engine.
Disassembly
(1) Remove filter base and o i l seal r i n g .
(2) Remove p u m p r o t o r and shaft and l i f t out outer
p u m p rotor.
(3) Remove t h e o i l pressure relief valve p l u g a n d
l i f t o u t t h e spring and relief valve plunger (Fig. 51).
Inspection
and
Assembly
(1) Clean a l l parts thoroughly. T h e m a t i n g face of
filter base (oil p u m p cover) should be smooth. Replace
filter base i f i t is scratched o r grooved.
(2) L a y a straightedge across o i l p u m p filter base
surface (Fig. 52). I f a .0015 inch feeler gauge can be
fNGlNE
A
9-23
ROCKER A R M
RIGHT BANK
LUBRICATION
| NO. 4 CAMSHAFT
(BEARING
RIGHT MAIN OIL GALLERY
LEFT ROCKER SHAFT
OIL FILTER
OIL PUMP
OIL PRESSURE
RELIEF VALVE
NU257
Fig. 50—Engine Oiling
inserted between t h e base a n d straightedge,
filter
base should be replaced.
(3) I f outer r o t o r length measures less t h a n .943
PLUG
GASKET
\
BOLTS AND
/COVER
^
X
' f t
SPRING
RELIEF VALVE
PLUNGER
WASHERS
/OIL
FILTER
I M.
wML
OUTER ROTOR
System
inch (Fig. 53) a n d diameter less t h a n 2.469 inches,
replace outer r o t o r .
(4) I f i n n e r r o t o r l e n g t h measures less t h a n .942
inch (Fig. 54), a new i n n e r r o t o r should be installed.
(5) I n s t a l l outer r o t o r i n t o p u m p body, pressing to
one side w i t h fingers and measure clearance between
outer r o t o r and p u m p body (Fig. 55). I f measurement
COVER -
INNER ROTOR
AND SHAFT
-—-BODY
DRIVE SHAFT
AND GEAR
SEAL RING
GASKET
"O"
KR173
STRAIGHT
EDGE
4
/
R!NG
/
PIN
Fig. 51—Oil Pump and Filter Assembly
(Disassembled
View)
FEELER GAUGE
Fig. 52—Measuring
KR174
v
Oil Pump Caver
Flatness
9-24
ENGINE- OUTER ROTOR
-PUMP BODY
KR176
Fig. 55—Measuring
Outer Rotor
Clearance
STRAIGHT EDGE *
DIAMETER
KB66B
Fig. 53—Measuring
Outer Rotor
4%
Thickness
is more than .014 inch, replace o i l p u m p body.
(6) Install i n n e r r o t o r Into p u m p body and place a
straightedge across the face between bolt holes (Fig.
56). I f a feeler gauge of more than .004 inch can be
inserted between the rotors and straightedge, replace
p u m p body.
(7) I f the t i p clearance between i n n e r and outer rotors (Fig. 57) is more t h a n .010 inch, replace inner and
outer rotor.
S e r v i c i n g O i l Pressure
Relief
Valve
Inspect o i l p u m p relief valve plunger f o r scoring
and free operation i n its bore. Small scores may be
removed w i t h 400 g r i t w e t o r d r y paper p r o v i d i n g
extreme care is used not t o r o u n d off the sharp edge
p o r t i o n of the valve.
The relief valve s p r i n g has a free l e n g t h o f 2-9/32
to 2-19/64 i n c h a n d should test 14.85 t o 15.85 lbs.
when compressed to 1-19/32 inch. Discard s p r i n g that
fails to meet specifications.
I f the o i l pressure is low, inspect f o r w o r n bearings,
or look f o r other causes o f possible loss o f o i l
pressure. When assembling the oil pump, be sure to
use new oil seal rings between filter base and pump
body.
FEELER G A U G E
Fig. 56—Measuring
^
^^^^^^^^^^^^^^^
Clearance Over
KR175
?
Rotors
Installation
(1) Install a new " O " r i n g seal o n the pilot o f o i l
p u m p before attaching o i l p u m p t o cylinder block.
(2) Install o i l p u m p on engine, using a new gasket
on engine and t i g h t e n attaching bolts t o 30 footpounds. Install o i l filter element.
OIL FILTER R E P L A C E M E N T
The " s p i n o n " o i l filter should be replaced preferably to coincide w i t h every second o i l change.
Removal
Use care so as not to damage transmission oil cooler
lines.
(1) Using Tool C-4065 unscrew the filter f r o m the
base on b o t t o m side of engine and discard (Fig. 58).
(2) Wipe base clean.
OUTER ROTOR
INNER ROTOR
FEELER
GAUGE
KR177
KB67A
Fig. 54—Measuring
Inner Rotor
Thickness
.
4
Fig. 57—Measuring
Clearance
Between
Rotors
ENGINE
9-25
AIR CLEANER HOSE
NN359
Fig? 3&—&®wwk$g Oil Fitter
FLOW CONTROL VALVE
0
[
V-8 E N G I N E S
Installation
(1) Install the " s p i n " o i l filter by hand, finger
tight. Do not use tool.
(2) To obtain an effective seal, tighten filters by
hand the additional n u m b e r of turns Indicated on the
replacement filter. Start engine and inspect for leaks.
Fig. 1—Fully Closed Ventilation
N
p
1 2 7
B
System
CRANKCASE VENTILATION SYSTEM
(1) A f u l l y closed crankcase ventilation system Is
Installed on a l l vehicles. The f u l l y closed ventilation
system operates by air d r a w n into the crankcase f r o m
the air cleaner and t h r o u g h the crankcase Inlet air
cleaner by means of a hose (Fig. 1).
A i r is circulated t h r o u g h the engine and d r a w n out
of the cylinder head cover by manifold vacuum into
the combustion chambers and dispelled w i t h the exhaust gases.
The system consists of a ventilation valve installed
i n the outlet vent of the cylinder head cover, and a
hose. The hose is connected between the outlet vent
and the lower p a r t of the carburetor body. The function of the valve Is to regulate the flow of crankcase
ventilation at various t h r o t t l e positions and w i l l operate effectively as long as n o r m a l maintenance is applied.
The valve and hose are subject to f o u l i n g w i t h
sludge and carbon formation due to the nature of the
material carried by the ventilation system.
A plugged vent system may i n t u r n cause excessive
engine crankcase sludge formation and may also
cause rough and erratic engine idle or excessive o i l
Heli-Coil Insert
Thread
Size
Part
No.
Insert
Length
1/2-20
5/16-18
3/8-16
7/16-14
1/2-13
1185-4
1185-5
1185-6
1185-7
1185-8
3/8"
15/32"
9/16"
21/32"
3/4"
Fig. 2-HeU-Coil
Installation
leakage. The ventilation system should be cleaned
every six months and valve replaced every year i n
average service and more frequently i f the vehicle is
used extensively for short t r i p s — d r i v i n g less than 10
m i l e s — w i t h frequent i d l i n g , such as city traffic.
See the " L u b r i c a t i o n and Maintenance" section,
Group O of this manual for proper service procedures.
REPAIR OF DAMAGED OR WORN
THREADS
Damaged or w o r n threads can be repaired by the
use of Heli-Coils. Essentially, this repair consists of
d r i l l i n g out w o r n or damaged threads, tapping the
hole w i t h a special Heli-Coil Tape, and i n s t a l l i n g a
Heli-Coil Insert i n t o the tapped holes. This brings the
hole back to its original thread size (See Fig. 2).
The f o l l o w i n g chart lists the threaded hole sizes
which are used i n the engine block and the necessary
tools and inserts for the repair of damaged or w o r n
thread. Heli-Coil tools and inserts are readily available
f r o m automotive parts jobbers.
Drill
Tap
Inserting
Tool
Extracting
Tool
Size
Part
No.
Part
No.
Part
No.
528-4N
528-5N
528-6N
528-7N
528-8N
1227-6
1227-6
1227-6
1227-16
1227-16
17/64C266)
Q(.332)
X(.397)
29/64C453)
33/64C516)
4
5
6
7
8
CPB
CPB
CPB
CPB
CPB
-9-26
SPECIFICATIONS-
SPECIFICATIONS
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of C y l i n d e r s . . . . . . . . . . . . . . . . . . . . .
Bore
383 Cubic Inch
440 C u b i c Inch
Stroke
383 Cubic Inch . . . . . . . . . . . . . . . . . . . . . . . . .
440 Cubic Inch
Minimum Compression with Engine Warm,
S p a r k P l u g s R e m o v e d , Wide-Open Throttle
90°V
8
4.25 inch
4.320 i n c h
3.375 inch
3.750 inch
100 psi*
110 p s i * *
40 psi
1-8-4-3-6-5-7-2
TDC±24/2°
2.5°BTC±2-l/2°
5°BTC±:2-l/2
Maximum Variation Between C y l i n d e r s (any one engine)
Firing Order
B a s i c T i m i n g . . . . . . Manual
Automatic 383 a n d 440 H i . P e r i . . . . . . . . . . . . . .
440 S t d . Automatic
C Y L I N D E R N U M B E R I N G (FRONT TO R E A R )
Left B a n k
—
Right Bank
C Y L I N D E R BLOCK
Cylinder Bore (Standard)
383 Cubic Inch
—
440 C u b i c Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Bore out-of-round (Maximum allowable)
Cylinder Bore T a p e r (Maximum allowable) — . . —
Reconditioning Working Limits (for taper and out-of-round)
Maximum Allowable Oversize (cylinder bores) . . . . . . . — . . . . . . .
Tappet Bore D i a m e t e r
....................................
Distributor Lower Drive Shaft Bushing (press fit in cylinder block)
R e a m to
— . — .—
...............
Shaft to B u s h i n g C l e a r a n c e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT
Type
Bearings
—
Journal Diameter 383 Cubic Inch
440 Cubic Inch
C r a n k P i n Diameter
—
M a x i m u m Out-of-Round P e r m i s s i b l e
N u m b e r of Main B e a r i n g s
C l e a r a n c e Desired ( B e a r i n g s Installed I.D. Minus Journal O.D.)
M a x i m u m C l e a r a n c e Allowable
E n d Play
T h r u s t T a k e n by
F i n i s h at R e a r S e a l S u r f a c e
I n t e r c h a n g e a b l y of B e a r i n g s
MAIN B E A R I N G S ( S e r v i c e )
All available in standard a n d t h e following u n d e r s i z e s
CONNECTING RODS AND BEARINGS
Type
Length (Center to C e n t e r ) 383 C u b i c Inch
440 C u b i c Inch
Weight ( L e s s B e a r i n g S h e l l s ) 383 C u b i c Inch
440 C u b i c Inch
B e a r i n g s 383 2 - B B L .
383 4 - B B L . , 440 4 - B B L
Diameter a n d Length
C l e a r a n c e Desired ( B e a r i n g s Installed I.D. Minus Journal O.D.)
383 2 - B B L
383 4 - B B L . , 440 4 - B B L .
Maximum Allowable
—
* 383-2BBL. Carb.
**383-440-4BBL Carb.
A44Q—#3 T i n A l u m i n u m Alloy S t e e l B a c k e d
0
1- 3-5-7
2-4-6-8
4.2495-4.2515"
4.320-4.322"
.005"
.010"
.001"
.040"
.9050-.9058"
.0005-.0040"
.4865-.4880"
.0007-.0027"
Fully C o u n t e r - B a l a n c e d
Steel B a c k e d Babbitt^
2.6245 to 2.6255"
2.7495 to 2.7505"
2.374 to 2.375"
.001"
5
.0005 to .0015"
.0025"
.002 to .007"
No. 3 Main B e a r i n g
Diagonal Knurling
Upper Nos. 2, 4, 5
Lower Nos. 1, 2 , 4 , 5
.001, . 0 ) 2 , .0)3, .010, .011, .012"
—
Drop Forged " I " B e a m
6.356 to 6.360"
6.766 to 6.770"
812 ± 4 G M S .
846 ± 4 G M S .
S t e e l B a c k e d Babbitt
Tri-Metal Steel B a c k e d
2.376 x .927"
.0005 to . 0 ) 1 5 "
.001 to .002"
.0025"
A
SPECIFICATIONS
Side Clearance
Bearings for Service
9-27
.009 to .017"
Standard .001, .002, .003,
.010, .012" Undersize
1.0923 to 1.0928"
Piston Pin Bore Diameter
CAMSHAFT
Chain
Drive
Steel Backed Babbitt
Bearings
5
Number
Cylinder Block
Thrust Taken By
.001 to .003"
Clearance Desired (Bearing Installed I.D. Minus Journal O.D.)
.005"
Maximum Allowable
CAMSHAFT BEARING JOURNALS
Diameter
1.998 to 1.999"
No. 1
1.982
to 1.983"
No. 2
1.967 to 1.968"
No. 3
1.951 to 1.952"
No. 4
1.748 to 1.749"
No. 5
CAMSHAFT BEARINGS
Diameter (after reaming)
2.000 to 2.001"
No. 1
1.984 to 1.985"
No. 2
1.969 to 1.970"
No. 3
1.953 to 1.954"
No. 4
1.750 to 1.751"
No. 5
440 Cubic Inch
383 and 440 Cubic Inch
Hi. Pert
VALVE TIMING
21°
Intake Opens (BTC) . . . .
18°
67°
Intake Closes (ABC) . . . .
58°
79°
Exhaust Opens (BBC) . .
66°
25°
Exhaust Closes (ATC) . .
14°
46°
32°
Valve Overlap
268°
256°
Intake Valve Duration . .
284°
260°
Exhaust Valve Duration
TIMING CHAIN
None
Adjustment
50
Number of Links
.50"
Pitch
.75"
Width
TAPPETS
Hydraulic
Type
.9040 to .9045
Body Diameter
.0005 to .0018 inch
Clearance in Cylinder Block
.001, .008, .030 inch
Oversize Available for Service
.060-.210 inch
Clearance Between Valve Stem and Rocker Arm Pad (Dry Lash)
PISTONS
Type
Land Clearance (diametrical)
440 Cubic Inch
383 Cubic Inch
Clearance at Top of Skirt
Weight (Standard Through .040" Oversize)
383 Cubic Inch
440 Cubic Inch
Piston Length (Overall)
383 Cubic Inch
440 Cubic Inch
Ring Groove Depth
No. 1—
383 Cubic Inch . . .
440 Cubic Inch . . .
No. 2—
383 Cubic Inch
440 Cubic Inch
Autothermic w/Steel Struts
.021" to .029"
.023" to .030"
.0003" to .0013"
770 grms.
857.5 grms.
3.874 in.
3.650 in.
.220 in.
.220 in.
.220 in.
.220 in.
9-28
A
SPECIFICATIONS
n
383 C u b i c I n c h
440 C u b i c I n c h
-20° ! .208 in.
jS!2S?' A
stan
Pistons for S e r v i c e
PISTON PINS
T
v
n
0 0 5
_
_.. .
.
P r e s s F i t in Rod
D
p
Dffietor""::::::::::::::::::::::::::::::::::::::::::::.:
^ f l S '
Leneth
c i e a ^ e Y n Piston':::::::::::::::::::::::::::
Interference in Rod
Piston P i n s for S e r v i c e
Direction Offset in Piston
PISTON RINGS
Number of R i n g s P e r Piston
Compression
Oil
Oil R i n g T y p e
^
6
3.555 to 3.575"
. 0 ^ 5 to0 .00075-
•S?"J J^r,
.^ S"? . L „.
s
0n
y
*
f
_ J
- ' ^f „ .
Chrome-Plated
R a i l s with S t a i n l e s s
Steel Expander-Spacer
3
R i n g Width
Compression
Oil—Steel Rails
p
e
.0775"-.078O"
-025"
Compression
O i l - S t e e l Rails
Ring Side Clearance
Compression
O i l - S t e e l Rails
Service Rings
.013"-.023"
.015"-.055"
.0015"-.0030"
.0000"-.005"
U i J
383-440
2.008"
4.87"
.3723"-.3730"
S t e m to G u i d e C l e a r a n c e
.0010"-.0027"
Maximum Allowable
.017"*
F a c e Angle
45°
Valve for S e r v i c e (Oversize S t e m s Diameter)
S t d . , .005", .015", .030"
Lift (Zero L a s h )
.425"
Valves—Exhaust
Head Diameter
1.75"
Length to (center of valve f a c e )
4.87"
S t e m Diameter
Hot E n d
.3713"-.3720"
Cold E n d ' . . :
.3723"-.3730"
S t e m to G u i d e C l e a r a n c e
Hot E n d
.0020"-.0037"
Cold E n d . . : . . ' .
.0010"-.0027"
Maximum Allowable
.017"*
F a c e Angle
45°
Valve for S e r v i c e '(Oversize S t e m D i a m e t e r ' ) ' S t d . , .005", .015", .030"
Lift (Zero L a s h )
.435"
Valve S p r i n g s
Number
16
F r e e Length
2.58"
L o a d When C o m p r e s s e d to
„
Valve C l o s e d
121-129 @ 1-55/64"
•With T o o l s C-3973 and C-3339 u s i n g wobble method.
n
_
c
M
Toward Right S i d e of E n g i n e
J
Compression
O i l - S t e e l Rails
Ring Side Clearance
Compression
O i l - S t e e l Rails
Valves—Intake
H e a d Diameter
Length to (center of valve f a c e )
S t e m Diameter
0 2 0
"'- - "*
.040", O v e r s i z e
.015"-.062"
„„„„
.0015"-.004"
.0000"-.005"
440 High P e r f o r m a n c e
2 008"
„„f,,„-„„.„
.3718"-.3725"
.0015"-.0032"
.017"*
45°
S t d . , .005", .015", .030"
.450"
1.75
4.87"
.3708"-.3715"
.3718"-.3725"
„„„„„
.0025"-.0042"
.0015"-.0032"
.017"*
45°
S t d . , .005", .015", .030"
.458"
16
2.23"
^ ,
-.„
100-110 @ 1-55/64"
r r i r
SPECIFICATIONS
9-29
Valve Open
.
192-208 @ 1-7/16"
236-256 @ 1-23/64"
Valve Spring I.D.
1.01"-1.Q3"
1.07"-1.09"
Maximum Allowable Out of P l u m b
.060"
.080"
Valve Spring Installed Height (spring s e a t to retainer) .
1-53/64-1-57/64"
l-53/64"-l-57/64"
U s e 1/16" s p a c e r to reduce s p r i n g height w h e n over specifications
VALVE GUIDES
Type
..
..
.
C a s t in Head
G u i d e Bore Diameter
.374-375" std.
C Y L I N D E R HEAD
Number Used
—.....
2
Combustion C h a m b e r
Wedge Type
Valve S e a t Runout (maximum)
.002"
Intake Valve S e a t Angle
45°
Intake S e a t Width
.060 to .085"
E x h a u s t Valve S e a t Angle
<
—
45°
E x h a u s t S e a t Width
.040 to .060"
Cylinder Head G a s k e t C o m p r e s s e d ( t h i c k n e s s )
.021"
ENGINE LUBRICATION
P u m p Type
Rotor Full P r e s s u r e
Capacity (qts.)
4 U . S . or 3-1/4 Imperial Q u a r t s *
P u m p Drive . . . . . . . . .
Camshaft
Operating P r e s s u r e at 1000 R.P.M
45 to 65 lbs.
Oil Filter Type
F u l l Flow
P r e s s u r e Drop R e s u l t i n g from Clogged Filter
7 to 9 lbs.
OIL PUMP INSPECTION LIMITS FOR R E P L A C E M E N T
Oil P u m p Cover (filter b a s e ) . . . .
.0015 i n c h or more
Outer Rotor Length
—
.943 i n c h or l e s s
Outer Rotor Diameter
..
2.469 inch or l e s s
Inner Rotor Length
.942 i n c h or l e s s
C l e a r a n c e Over Rotor—Outer
.004 i n c h or more
Inner
.004 inch or more
Outer Rotor C l e a r a n c e
.014 inch or more
T i p C l e a r a n c e Between Rotors
.010 inch or more
* W h e n filter is r e p l a c e d , add 1 U . S . Quart or 3 / 4 of a n Imperial Quart.
OVERSIZE A N D UNDERSIZE
ENGINE COMPONENT
Engine
Displacement
383 c u . in.
440 c u . in.
Condition
Identification
.001" U / S C r a n k s h a f t
.010" U / S C r a n k s h a f t
MARKINGS
Maltese C r o s s
M-2-3 etc. (indicating
# 2 & 3 main bearing
journal)
and/or
R - l - 4 e t c . (indicating
# 1 & 4 c o n n e c t i n g rod
journals)
Maltese C r o s s a n d X
M-10 (indicate .010"
U / S all main journals)
and/or
R 4 0 (indicates .010" U / S
all rod journals)
Location of
identification
T o p P a d — F r o n t of E n g i n e
C r a n k s h a f t Counterweight
T o p P a d — F r o n t of E n g i n e
C r a n k s h a f t Counterweight
.020" O / S C y l i n d e r B o r e s
A
T o p P a d — F r o n t of E n g i n e
.008" O / S T a p p e t s
Diamond
T o p P a d — F r o n t of E n g i n e
.005" O / S Valve S t e m s
O.S.
S i n g l e Bolt B o s s on E n d of t h e H e a d
9-30
TIGHTENING R E F E R E N C E
TIGHTENING REFERENCE
ENGINE
Foot-Inch
Pounds
A / C C o m p r e s s o r to E n g i n e Bolt
Alternator A d j u s t i n g S t r a p
Mounting Bolt
Alternator Adjusting S t r a p Bolt
Alternator Mounting Bolt
C a m s h a f t L o c k Bolt
Carburetor to Manifold Nut
C o n n e c t i n g Rod Nut
........
C y l i n d e r H e a d Bolt
C h a i n C a s e C o v e r Bolt
C l u t c h H o u s i n g Bolt
;
Crankshaft Rear Bearing S e a l Retainer . .
C r a n k s h a f t Vibration D a m p e r Bolt . . . . . . .
C y l i n d e r H e a d C o v e r S t u d a n d Nut
Distributor C l a m p Bolt
E x h a u s t Manifold Nut
E x h a u s t Pipe F l a n g e Nut
E x h a u s t Pipe C l a m p Nut . . . . . . . . . . . —
E x h a u s t Pipe S u p p o r t C l a m p Bolt
F a n A t t a c h i n g Bolt
F a n B e l t Idler P u l l e y Nut
30
30
200
30
35
200
45
70
200
30
25
135
40
200
30
50
20
20
15-18
45
F a n Belt Idler Pulley B r a c k e t Bolt . . . . . .
F l e x Plate to C r a n k s h a f t
Flex Plate to Converter
Flywheel to C r a n k s h a f t
F u e l P u m p Attaching Bolt
Intake Manifold Bolt
Main B e a r i n g C a p Bolt
Oil P a n Drain P l u g . . . . . . . . . . . . . . . . . . . . .
Oil P a n S c r e w s
Oil P u m p Cover Bolt
Oil P u m p Attaching Bolt
R o c k e r S h a f t B r a c k e t Bolt
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Mounting Bolt
T r a n s m i s s i o n C a s e to B l o c k
Vibration D a m p e r Belt Pulley Bolts . . . . . .
Valve T a p p e t Cover E n d Bolt
Water P u m p to H o u s i n g Bolt . . . . . . . . . . . .
Water P u m p H o u s i n g to C y l i n d e r
Block Bolt
Foot-Inch
Founds
30
55
270
55
30
50
85
20
200
10
30
25
30
50
30
200
9
30
30
A.
GROUP
9A
CLEANER AIR SYSTEM
CONTENTS
CLEANER A i l SYSTEM
HEATED AIR S Y S T E M . . . . . . .
C A R B U R E T O R S AND CHOKE
IDLE S P E E D SOLENOID
Page
1
1
4
5
CLEANER AIR S Y S T E M (CAS)
The Federal government has imposed more stringent exhaust emissions requirements on a l l U.S. and
most i m p o r t e d cars. These new standards require that
exhaust emissions f r o m a l l cars n o t exceed 2.2 grams
of hydrocarbons and 23 grams of carbon monoxide
per vehicle mile as measured d u r i n g a prescribed
test. This constitutes about a 3 3 % decrease i n exhaust
emission levels. The new grams per mile standards
take into consideration that t o t a l emission levels are
a function of vehicle weight.
Several changes have been made to our engines to
meet these new standards and m a i n t a i n or improve
vehicle driveability (Fig. 1).
HEATED AIR S Y S T E M
A l l engines have a heated air intake system. This
Page
LOWER COMPRESSION RATIOS .
DISTRIBUTOR SOLENOID
EVAPORATOR CONTROL S Y S T E M
S
s
s
system provides a faster more efficient engine w a r m
up w i t h i m p r o v e d fuel economy and reduced exhaust
emissions (Fig. 2).
The H E A T E D A I R SYSTEM is basically a t w o air
flow c i r c u i t system.
(1) W h e n the under hood air temperature is 10° F
or lower, the a i r flow w i l l be t h r o u g h the stove, i n t o a
flexible connector, i n t o the adaptor on the b o t t o m of
the snorkel and i n t o the air cleaner.
(2) W h e n the u n d e r hood air temperature is above
100° F, the air flow w i l l be t h r o u g h the s n o r k e l i n t o
the air cleaner.
W h e n the under hood air temperature is between
approximately 10° F and 100° F, there w i l l be air
flow t h r o u g h b o t h circuits after the engine has been
started and the exhaust manifold starts t o give off
heat. The colder the under hood air the greater the
CARBURETOR
• IMPROVED DISTRIBUTION
• LEANER MIXTURES
• FASTER A C T I N G CHOKE
• EXTERNAL IDLE MIXTURE LIMITER
SOLENOID THROTTLE STOP
IMPROVED MANIFOLD HEAT V A L V E
CRANKCASE
VENTILATOR
VALVE
HEATED
INTAKE AIR
REDUCED COMPRESSION
INTAKE
RATIOS
MANIFOLD
PY943
Fig. I—1970 Cleaner Air
System
9A-2
C L E A N E R AIR
SYSTEM
VACUUM
A
THERMOSTAT
HEATED AIR
ENTERS
CARBURETOR
Fig. 2— Heated Inlet Air
PY944
System
flow of air t h r o u g h the stove, and the warmer the air
the greater the flow t h r o u g h the snorkel. The q u a n t i t y
of air t h r o u g h each circuit is controlled by a heat
control door i n the snorkel so as to m a i n t a i n a temperature of 9 5 ° to 105° F at the temperature sensor
mounted inside the air cleaner housing.
The modulation of the i n d u c t i o n air temperature is
performed by intake m a n i f o l d vacuum, a temperature sensor and a vacuum diaphragm w h i c h operates
the heat c o n t r o l door i n the snorkel.
A vacuum hose connects to a hose nipple on the
base of the carburetor and leads to one side (either
side) of the sensor and another hose connected to the
opposite side of the sensor and leads to the vacuum
diaphragm on the snorkel.
The sensor is simply a bimetahc strip attached
r i g i d l y at one end and controls a small air valve at
the other end. This valve is connected i n t o the same
vacuum chamber on the bottom of the sensor that the
2 hoses connect into. When the temperature at the
sensor is less than 95° F the valve is closed and the
intake manifold vacuum is communicated to the
vacuum diaphragm w h i c h i n t u r n lifts the heat cont r o l door and allows heated air f r o m the exhaust
manifold stove to enter the air cleaner. When the
temperature at the sensor is above 105° F, the valve
i n the sensor opens and decreases the vacuum at the
vacuum diaphragm and the spring i n the diaphragm
housing pushes the heat control door downward decreasing the heated air flow f r o m the stove and i n creases the air flow t h r o u g h the snorkel.
The vacuum diaphragm is simply a bellows type
diaphragm mounted i n a housing w i t h a spring between the diaphragm and the top of the housing and
a hose nipple i n the side of the housing to connect to
the vacuum hose f r o m the sensor. Permanently connected to the piston of the vacuum diaphragm is a
l i n k w h i c h hooks i n t o the heat control door. Since the
diaphragm is opposed by a spring, i t requires not less
than 5 " H g to l i f t the heat control door off the floor
of the snorkel and not greater than 9 " H g to raise the
door to the top of the snorkel.
W i t h the vacuum diaphragm opposed by a spring
i t is obvious that temperature modulation w i l l occur
only at road load t h r o t t l e positions or when the intake
manifold vacuum is above the operating vacuum of
the vacuum diaphragm. B u t should a burst of power
be required, and the t h r o t t l e is opened wide, the i n take manifold vacuum drops and the heat c o n t r o l door
drops to the floor of the snorkel closing off the hot
air and opens the snorkel to eliminate any undue
resistance to free breathing of the engine.
SERW1GE PROCEDURES
HEATED AIR
SYSTEM
I m p r o p e r f u n c t i o n i n g of this system w i l l affect
driveability as w e l l as affecting the vehicle exhaust
emission c o n t r o l system and may result i n f a i l u r e of
the vehicle to meet Federal Emission regulations.
To determine whether the system is f u n c t i o n i n g
properly, the f o l l o w i n g procedure should be used:
(1) Make sure a l l vacuum hoses (Figs. 3 and 4), and
the stove to air cleaner flexible connector are prope r l y attached and are i n good condition.
(2) W i t h a cold engine and ambient temperature
i n the engine compartment of less than 100 degrees
F., the heat c o n t r o l door (valve plate) i n the snorkel
should be i n the up position or heat on position.
(3) W i t h the engine warmed up and r u n n i n g , check
the air temperature entering the snorkel or at the
sensor. When the air temperature entering the outer
end of snorkel is 105 degrees F. or higher the door
should be i n the down position (heat off).
(4) Remove the air cleaner f r o m the engine and
allow i t to cool down to 90 to 95 degrees F. W i t h 2 0 "
H g vacuum applied to the sensor the door should be
i n the up position (heat on position). Should the door
not rise to the heat on position, check the vacuum
diaphragm for proper operation.
(5) Check the vacuum diaphragm by applying vacuu m directly to the vacuum diaphragm (with Tool C3707 and vacuum p u m p C-4081) w i t h a vacuum gauge
i n the line and a bleed valve to control the vacuum
C L E A N E R AIR S Y S T E M
9A-3
VACUUM PUMP
/
'
/
<>
VACUUM TEST
SET C-3707
•;
V A C V L M DIAPHRAGM
I
^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^
BLEED VALVE
Fig. 5—Inspecting Vacuum
^
PY947
Dmpkmgm
quately b u t proper temperature is n o t maintained,
replace the sensor and repeat the temperature checks
i n steps 2 and 3.
PY945
Fig. 3—Routing of Vacuum Moses Single
Air Cleaner
Snorkel
inserted i n the line between the gauge and the vacuu m source. A p p l y 20 inches H g to the vacuum
diaphragm and stop off t h e line and check f o r diaphragm leaks (Fig. 5). The diaphragm should hold 2 0 "
H g f o r five minutes. Next release the vacuum on t h e
vacuum diaphragm. Then w i t h the use of the bleed
valve b u i l d the vacuum slowly and observe the door
operation. The door should l i f t off the bottom of the
snorkel at not less than 5 inches H g and be i n the f u l l
up position w i t h no more than 9 inches H g .
(6) Should t h e vacuum diaphragm n o t p e r f o r m
adequately, replace i t and repeat the checks i n steps
2 and 3.
(7) Should t h e vacuum diaphragm p e r f o r m ade-
DUAL
SNORKEL
The dual snorkel air cleaner performs at low temperatures and above 105 degrees F. basically l i k e a
single snorkel air cleaner w i t h one exception:
(1) On deep t h r o t t l e accelerations, b o t h snorkels
are open (when intake manifold vacuum drops below
the 5 inches Hg).
(2) The non-heat a i r snorkel is conencted t o manifold vacuum t h r o u g h a "TEE" i n the vacuum hose between the carburetor and the sensor (Fig. 4).
Check second snorkel vacuum diaphragm as one
w i t h heat connector.
VACUUM DIAPHRAGM
W i t h air cleaner housing removed f r o m vehicle.
(1) Bend down lock tab (Fig. 6) and carefully l i f t
f o r w a r d edge t o clear lock tab, then slide f o r w a r d t o
disengage rear lock tab, then slide t o r i g h t t o unhook
operating r o d f r o m heat c o n t r o l door (Fig. 7).
(2) W i t h t h e vacuum diaphragm removed, check
the door f o r freedom of travel. When t h e door is
mm
TO C A R B U R E T O R
V A C U U M FITTING
tt
PY946
Fig. 4—Routing of Vacuum Hoses Dual Snorkel
Air Cleaner
Fig. 6—Opening Front Lock Tab
9A-4
CLEANER AIR SYSTEM
VACUUM
A
DIAPHRAGM
1
PY949
Fig. 7—Removing or installing Vacuum
Diaphragm
raised t o the u p position, i t should f a l l freely when
released. I f i t does not, observe door t o snorkel side
walls f o r interference o r foreign matter. Also check
hinge p i n f o r foreign matter. T r y t o release b y blowi n g w i t h compressed a i r o r b y releasing the interference.
Installation
(1) Insert operating r o d i n t o heat control door,
then slide rearward engaging t h e rear lock tab, when
f r o n t lock is i n position press f o r w a r d edge down.
(2) W h i l e holding vacuum diaphragm down, apply
9 inches of vacuum t o diaphragm hose nipple, door
should operate freely. I f door operates freely, bend
lock tab f o r w a r d . W h i l e supporting snorkel and t h e
lock tab w i t h a piece of flat steel held securely under
lock tab, flatten flush w i t h snorkel. Manually operating
heater door could cock r o d and diaphragm which
would restrict operation of the heater door.
(3) Assembly air cleaner, install on vehicle and test
operation.
Fig, S—Removing Retainer
Clips
should be made to adjust sensor.
(3) Install vacuum hoses (Figs. 3 and 4).
(4) Install a i r cleaner and test operation. Refer t o
Exhaust System, Group 11, f o r service procedures on
A i r Heaters.
CARBURETORS A N D CHOKES
A l l carburetors have leaner mixtures and m i x t u r e
d i s t r i b u t i o n has been improved o n a l l engines. A l l
two and f o u r b a r r e l carburetors w i l l have dual idle
m i x t u r e screws w i t h an external adjustment l i m i t i n g
device f o r better control of idle mixtures. Other carburetor changes include: idle fuel discharged i n t o a
bypass a i r slot f o r better atomization (383 CID 2V).
Used i n conjunction w i t h heater intake a i r is a new
fast acting automatic choke control. This u n i t reacts
quickly t o hot exhaust gases t o provide a shortened
period of m i x t u r e enrichment, and hence improved
SENSOR
Removal
W i t h a i r cleaner housing removed f r o m vehicle.
(1) Disconnect vacuum hoses f r o m sensor, remove
retainer clips (Fig. 8), and discard (new clips are supplied w i t h a new sensor).
(2) Remove sensor w i t h gasket and discard.
Installation
(1) Position gasket o n a i r cleaner housing and i n stall sensor (Fig. 9).
(2) Supporting sensor o n outer diameter, install
new retainer clips securely being sure gasket is compressed t o f o r m an air seal. Supporting sensor on plastic guard could damage bi-metal strip. No attempt
fig. 9—Installing Gasket and Sensor
CLEANER AIR SYSTEM
fuel economy and reduced emissions. T h i s is achieved
by using a removable, t h i n stamped, stainless-steel
cup between the thermostatic choke c o n t r o l u n i t and
the exhaust passage gases i n place o f the t h i c k e r casti n m a n i f o l d pocket used previously. A gasket is i n stalled between the steel cup and m a n i f o l d t o ensure
that no exhaust leak occurs. Also a p a r t o f the heated
air system is a heat insulating spacer between the i n take m a n i f o l d and carburetor. This is used i n place of
a gasket and is essential for correct operation.
IDLE SPEED SOLENOID
The 440 high performance engines employ idle
speeds between 800 and 1000 r p m t o obtain acceptable lower emissions d u r i n g idle and deceleration. I n
order to prevent " a f t e r r u n n i n g " w i t h such h i g h idle
speeds, these engines have an electrical solenoid
t h r o t t l e stop which holds the t h r o t t l e at the correct
idle position when energized but de-energizes when
the i g n i t i o n is t u r n e d off, allowing the t h r o t t l e blades
to close more completely. Refer t o " F u e l System"
Group 14 for service procedures.
9A-5
LOWER COMPRESSION RATIOS
The 383 and 440 CID engines have new pistons t o
reduce compressions by about 0.5. The lower compression ratio reduce hydrocarbon emissions b y produci n g a better combustion chamber shape and by leaving
more heat i n the exhaust t o assist the after combust i o n reaction.
DISTRIBUTOR SOLENOID
A l l 383 and 440 engines have a solenoid incorporated i n the distributor vacuum advance mechanism
to r e t a r d t h e i g n i t i o n t i m i n g w h e n t h e throttle is
closed. A t closed t h r o t t l e , electrical contacts o n the
carburetor t h r o t t l e stop and w i t h idle adjusting screw
i n the closed position, causes the distributor solenoid
to energize. This retards the i g n i t i o n t i m i n g to provide
reduced exhaust emissions under hot idle conditions.
Cold or part t h r o t t l e starting is not penalized because
the distributor solenoid is not energized unless the hot
idle adjusting screw is against the t h r o t t l e stop contact. Timing must be set at closed throttle to give
ignition full retard.
SERVICE PROCEDURES
IGNITION TIMING ( 3 8 3 C u . l n . 4 4 0 C u . l n . )
(Solenoid
Distributor)
To obtain m a x i m u m engine performance, the dist r i b u t o r must be correctly positioned o n the engine
to give proper i g n i t i o n t i m i n g . T h e i g n i t i o n t i m i n g
test w i l l indicate the t i m i n g of the spark at No. 1
cylinder at c u r b idle (Hot only).
Test procedure as follows:
(1) Disconnect vacuum hose at distributor, and p l u g
hose.
(2) Connect the secondary lead of a power t i m i n g
l i g h t to No. 1 spark plug, r e d p r i m a r y lead to positive
t e r m i n a l of the battery and the black p r i m a r y lead t o
the negative battery t e r m i n a l . Do not puncture cables,
boots o r nipples w i t h test probes. Always use proper
adapters. Puncturing the spark plug cables with a
probe will damage the cables. The probe can separate
the conductor and cause high resistance. In addition
breaking the rubber insulation may p e r m i t secondary
c u r r e n t to are t o g r o u n d .
(3) Loosen t h e distributor hold-down m o u n t i n g
screw j u s t enough so distributor housing can be rotated i n its m o u n t i n g .
(4) Start the engine and set the c u r b idle as shown
i n "Specifications." (Transmission i n N e u t r a l and Engine Hot).
(5) A i m the power t i m i n g l i g h t at the t i m i n g marks
on the chain case cover. I f the t i m i n g l i g h t flash occurs
w h e n the t i m i n g m a r k o n the v i b r a t i o n damper is
located ahead of specified degree m a r k on the t i m i n g
plate. The t i m i n g is advanced. To adjust t u r n distribu-
t o r housing (Not Vacuum Chamber) Counter clockwise.
Do not use vacuum chamber as a turning handle. I f
the t i m i n g l i g h t flash occurs w h e n the t i m i n g m a r k on
the v i b r a t i o n damper is located past the specified degree m a r k on the t i m i n g plate. The t i m i n g is retarded.
To adjust turn distributor housing clockwise. T i m i n g
may vary f r o m the specified specifications a plus o r
minus 2-1/2° and s t i l l f a l l w i t h i n range, b u t i f the
t i m i n g is checked i t should be adjusted to the specification shown on the d i s t r i b u t o r charts.
(6) To check t h e d i s t r i b u t o r solenoid f o r proper
operation, disconnect the w i r e at the carburetor. A i m
the power t i m i n g l i g h t at the t i m i n g marks o n t h e
chain case. The t i m i n g should advance above 5-1/2°
and the engine speed should increase.
(7) Stop the engine and t i g h t e n the distributor holddown screw.
(8) Reconnect the w i r e at the carburetor t h r o t t l e
stop.
(9) Reconnect the vacuum hose to the distributor.
(10) Remove the t i m i n g light.
EVAPORATION CONTROL SYSTEM
Chrysler Corporation cars sold i n California have
an Evaporation C o n t r o l System (ECS) t o reduce the
loss of f u e l f r o m the f u e l system t o the atmosphere
by evaporation. This is a closed system w h i c h controls
fuel expansion and feeds f u e l evaporation emissions
f r o m the carburetor o r f u e l tank. T h e vapors pass
t h r o u g h vent lines t o the crankcase b y way o f the
crankcase inlet air cleaner. Since fuel vapors are two
9A-6
C L E A N E R AIR
SYSTEM
Fig.
10—Evapora
to f o u r times heavier than air, they settle to the bott o m of the crankcase. W i t h the engine r u n n i n g the
fuel vapors are purged f r o m the crankcase and together w i t h the n o r m a l crankcase vapor are d r a w n
via the crankcase v e n t i l a t i o n system, w h i c h is an
existing p a r t of the Cleaner A i r System (CAS) i n t o
the base of the carburetor to be b u r n t by engine combustion.
The possible expansion of f u e l i n a f u l l f u e l tank,
due to a rise i n temperature, is allowed f o r by a 1.4
gallon over-fill l i m i t e r t a n k inside the m a i n f u e l t a n k
w h i c h fills m u c h slower than the m a i n tank. W h e n the
m a i n tank is filled, i t remains essentially empty to
allow f o r t h e r m a l expansion ((Fig. 10).
The loss of any f u e l or vapor out of the filler neck
is prevented by the use of a filler cap w h i c h w i l l release only under significant pressure (1/2 to 1 psi) or
vacuum (1/4 to 1/2 psi). This cap is identified by the
words pressure-vacuum and must be replaced by a
similar u n i t i f replacement is necessary, i n order f o r
the system to r e m a i n effective.
Because the f u e l tank is flat on top, f o u r vents are
used, one i n each corner of the t a n k and are connected to a vapor-liquid separator by r u b b e r hoses.
The vapor-liquid separator is a piece of two i n c h steel
t u b i n g mounted at an angle inside the t r u n k of the
vehicle (quarter panel) w h i c h i n t e r n a l l y holds f o u r
vent lines f r o m the tank and a vent line w h i c h leads
to the crankcase i n l e t air cleaner. These lines are of
different heights so the tank w i l l always be vented
regardless of vehicle attitude, and f u e l vapor w i l l be
transferred to the crankcase. One vent line f r o m the
t a n k is short to provide a d r a i n back to the t a n k f o r
any l i q u i d f u e l w h i c h may get i n t o the separator duri n g maneuvers or incline p a r k i n g . The vent to the
crankcase is at the highest point i n the separator and
has a small orifice to minimize l i q u i d f u e l transfer to
the crankcase.
The ECS system also includes closed ventilation of
f u e l vapor f r o m the carburetor bowl. On eight cylinder engines this is accomplished via a hose connection
f r o m the carburetor b o w l t o the crankcase i n l e t air
cleaner.
SERVICE DIAGNOSIS
The ECS sysem should not r e q u i r e any maintenance
i n n o r m a l service. A n y loss of f u e l or vapor f r o m the
fuel filler cap w o u l d indicate one or more of the fol-
lowing:
(1) A n unsatisfactory seal between cap and
neck.
filler
C L E A N E R AIR SYSTEM
(2X A m a l f u n c t i o n (tf I C S c i p r i t e
c h e c k of the E C S f u e l c a p m a y b e m a d e b y p l a c i n g
against the m o u t h a n d b l o w i n g into the hole i n the release v a l v e h o u s i n g . A n i m m e d i a t e l e a k w i t h light
b l o w i n g or l a c k of r e l e a s e w i t h h a r d b l o w i n g i n d i c a t e s
a defective or i n c o r r e c t uni t .
(3) A l l E C S l i n e s p l u g g e d b e t w e e n f u e l t a n k a n d
vapor separator.
(4) P l u g g e d E C S l i n e b e t w e e n the v a p o r s e p a r a t o r
9A-7
-andihexrankcase'-^airiinlet^filter.—
- (5) P l u g g e d f u e l t a n k e x p a n s i o n c h a m b e r i n l e t hole
i n m a i n tank. A r e m o v a b l e p l u g i s p r o v i d e d i n t h e top
s u r f a c e of E C S f u e l t a n k s , f o r access to e x p a n s i o n
c h a m b e r i n e v e n t of p l u g g i n g of its fill/drain hole. I f
p u r g i n g of the f u e l t a n k i s r e q u i r e d , the e x p a n s i o n
c h a m b e r m u s t be p u r g e d s e p a r a t e l y t h r o u g h the top
access p l u g hole.