Chrysler Imperial 1959, New Yorker 1959, Saratoga 1959 User Manual

CONTENTS

General Specifications 1

Section I—Suspension 4

Section II—Axle—Rear 16

Section III—Brakes 17

Section IV—Accessory Belt Drives 23

Section V—Cooling System 26

Section VI—Electrical System 27

Section VII—Engine 41

Section VIII—Fuel and Exhaust System 70

Section IX—Frame 74

Section X—Steering 76

Section XI—Transmission 80

Section XII—Universal Joints and Propeller Shaft 83

Section XIII—Wheels and Tires 84

Section XIV—Body and Sheet Metal—Town and Country Models 85

Section XV—Lubrication 88

Section XVI—Radio and Heater 88

Section XVII—Heater—Air Conditioning 97

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CHRYSLER SERVICE MANUAL

SERVICING THE 1959 CHRYSLER AND IMPERIAL

GENERAL SPECIFICATIONS—1

This supplement contains advanced service information

on perial Models. Only changes and improvements affecting are included. procedures will remain the same as those

If

the information desired cannot

be

found

for

corresponding models covered

Chrysler and Imperial Service Manual D-16350.

In order Service Manual D-l 6350, the corresponding The supersedence

The service tools referred Company, 17640 Grand River, Detroit 27, Michigan,

Extra copies Order from Chrysler Division, P.O.

to

use this supplement to best advantage with

or

of

these models is as follows:

Chrysler Models:

Windsor Saratoga New Yorker

Imperial Models

Custom,

and LeBaron

of

this Supplement

Crown,

to in

this manual are available through the Miller Manufacturing

are

available at $2.00 each, under part number D-l6798.

Box

1958

LC-1 LC-2 LC-3

1958

LY-1

1658, Detroit 31, Michigan.

the

superseding car models must be understood.

U.S.A.,

the new 1959 Chrysler^ and Im-

the

servicing

in

this supplement

of the new

the

models

servicing

in the 1958

previous Chrysler and Imperial

1959

MC-1 MC-2 MC-3

1959

MY-1

unless otherwise specified.

CHRYSLER DIVISION

Chrysler Corporation

DETROIT 31, MICHIGAN

Chrysler Corporation reserves

ments

in its

manufactured.

D-l 6798 12M-SD & TO-10-58

product without imposing

the

right

to

make changes

any

obligations upon itself

in

design

to

or to

make additions

install them

on its

products previously

to or

LITHO

improve-

IN

U.S.A.

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2—GENERAL SPECIFICATIONS

CHRYSLER SERVICE MANUAL

MC-l WINDSOR

MC-2 SARATOGA

MC-3 NEW YORKER

MY-1 fMPERiAL

1959 Chrysler and Imperial Models

59 x 143

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CHRYSLER SERVICE MANUAL

GENERAL DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS—3

Item Body Style

Four Door Sedan Four Door Sedan Four Door Sedan Four Door Sedan Four Door Sedan Four Door Sedan

Wheelbase Four Door Sedan

Convertible Coupe Two Door (hard top) Town & Country Wagon Four Door (hard top)

Tread Four Door Sedan

(Front) Convertible Coupe

Two Door (hard top) Town & Country Wagon Four Door (hard top)

Tread Four Door Sedan

(Rear) Convertible Coupe

Two Door (hard top) Town & Country Wagon Four Door (hard top)

Length with Four Door Sedan

Bumper Convertible Coupe

Two Door (hard top) Town & Country Wagon Four Door (hard top)

Width with Four Door Sedan

Bumper Convertible Coupe

Two Door (hard top) Town & Country Wagon

Four Door (hard top) Rear Axle Four Door Sedan with Torque- Convertible Coupe Flite Trans. Two Door (hard top)

Town & Country Wagon

Four Door (hard top)

Tire Size Four Door Sedan

Convertible Coupe

Two Door (hard top)

Town & Country Wagon

Four Door (hard top)

Starting Vehicle Numbers

Detroit

M511-100,001 M531-100,001 M551-100,001 M617-100,001 M637-100,001 M657-100,001

Los Angeles

M514-100,001 M534-100,001 M554-100,001

MC-1

Windsor

122 122 122 122 122

60.9

59.8

216.6

215.9

216.6

79.3

2.93

8.00x14

8.50x14

8.00x14

1959 Models

MC-2

Saratoga

126

60.9

59.8

220.6

79.3

2.93

8.50x24

8.50x14

MC-3

New Yorker

126 126 126 126 126

61.2

60.0

220.9

220.1

220.9

79.5

2.93

9.00x14

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MY-1

Imp. Imp. Imp.

9.50x14

Custom Crown Lebaron

129 129 129

129

61.8

62.4

226.3

81.0

2.93

4—SUSPENSION

CHRYSLER SERVICE MANUAL

Section I

SUSPENSION (FRONT SUSPENSION)

DATA AND SPECIFICATIONS

FRONT HEIGHT SPECIFICATIONS

MC-1,

MC-2, MC-3 and MY-1

Town and Country Models and Cars Equipped with Heavy Duty Springs

On Gars With True-Level Torsion Aire

MC-1,

MC-2,

MY-1

CASTER AND CAMBER WITH MANUAL STEERING

MC-3..

.iyg"+or

•

2Vs"+0T

Caster

~H° ± H°

Caster Camber

Type Length Width Number of Leaves—Std. Susp Rate—Std. Susp Number of Leaves—True-Level. . . Rate—True-Level

Steering Axis

Camber

0° ± M° (right)

+ H° ± H° (left)

Inclination

5° to 7°

At 0° Camber

(Vs"

WITH POWER STEERING

Steering Axis

Inclination

0°± M° (right)

Ji°.± M°(left)

5° to 7°

At 0° Camber

REAR SUSPENSION

REAR SPRINGS

MC-1

Sedans &

Coupes

Semi-Elliptic Semi-Elliptic Semi-Elliptic Semi-Elliptic Semi-Elliptic

57"

2.5" 5

95

# per in.

5

80 # per in.

Town &

Country

57"

2.5"

125

# per in.

95

# per in.

6

5

MC-2

Sedans &

Coupes

60"

2.5" 6

90

# per in.

6

75

# per in.

Sedans &

Coupes

60"

2.5" 7

90

# per in.

6

75

# per in.

MC-3

Town &

Country

60"

2.5"

135

# per in.

100

# per in.

7

Toe-In

y%

± w

Preferred)

Toe-In

± W

Preferred)

Semi-Elliptic

90

83

MY-1

Sedans &

Coupes

60"

2.5"

7

# per in.

6

# per in.

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CHRYSLER SERVICE

MANUAL

REAR SUSPENSION (Cont'd)

SUSPENSION—5

FRONT PIVOT

REAR

SHOCK ABSORBERS

TYPE

Silent Block Rubber'

Shackle with Rubber

Oriflow, Double Acting

Bushings

Bushing

Hydraulic

TRUE-LEVEL TORSION AIRE

CAR REAR HEIGHT (Axle Housing

Imperial Models Only MC-1,

MC-2, MC-3 Models Only 4%

HEIGHT CONTROL VALVE

Make Midland-Ross Type Bleed-Feed

AIR PRESSURE

High Pressure Tank 220 Low Pressure Volume Tank

COMPRESSOR

Make Tecumseh Type Balanced Head

4% + or

to

Frame)

(1

pass, load) (6 pass, load) 70 (9 pass, load)

20 psi

90 psi

+ or — y% inch

+ or

approximately

psi

approximately

—y% inch

—20

psi

TORQUE SPECIFICATIONS

AIR LINE

Elbow Mounting Screw 100 High Pressure Tank Air Hose Assembly Compressor Check Valve Compressor

AIR SPRING

Retainer Bolt

COMPRESSOR

Adjusting Strap Bolts Adjusting Strap Bracket Bracket Cylinder Head Bolt 155 Front Bearing Housing Bolt Oil Inlet Connector 130 Rear Cover Plate Bolt Strap Bolt Suction Muffler Retaining Screw Support Bracket Support

to Air

to

Support Bolt

to Air

Nut 35 ft. lbs.

to

Cylinder Head Bolt 70

to

Low Pressure Tank Height Control Valve Tube Nuts

to

High Pressure Tank Tube

to Air

Line Check Valve 130

Nut

10

30 ft. lbs.

to

T-Nut Bolt 15

30 ft. lbs.

Conditioning Compressor Bolt

17 in. lbs.

to

Water Pump Body

Hose Assembly Tube

f

17 in. lbs.

(or

Nut

125 Nut 90 in. lbs.

Nut 30 ft. lbs.

17 in. lbs.

Cylinder Block

or

Cylinder Head Bolt) 30

(4) 85 in. lbs.

Pounds Torque

in. lbs. in. lbs. in. lbs.

ft. lbs.

in. lbs. in. lbs.

ft. lbs. ft. lbs.

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6—SUSPENSION

CHRYSLER SERVICE MANUAL

TORQUE SPECIFICATIONS (Cont'd)

HEIGHT CONTROL VALVE

Axle Housing Link Bracket Bolt

Minimum Pressure Valve 130 Mounting Nuts 100

Nut 30 ft. lbs.

Pounds Torque

in. lbs. in. lbs.

HIGH PRESSURE TANK

Drain

and

Charging Valve 140 in. Mounting Bolts (%>) 10 Mounting Bolts

LOW PRESSURE VOLUME TANK

Mounting Bracket Screw 100

(%)

*

100

TOOL LIST

C-3128 Snap Ring Pliers C-3293 300 C-3569 Detector Torch C-3670 C-3677 Crankshaft Support Stand C-3680 Front C-3693 Adapter—used with Tool C-3293, C-3694 Hold-Down Straps

PO-11 Pulley Puller

Air

lb.

Pressure Gauge

Spring Height Gauge

Oil

Seal Protector

(Pr.)

300 lb.

lbs. ft. lbs. in. lbs.

in. lbs.

pressure gauge

SUSPENSION (FRONT SUSPENSION)

The

new

upper control

plify

the

method Tool C-3669 trol arm bushings.

OPERATION (FIG. The upper control arms attach

welded welded openings bolts have matching removable cam end.

is

required

to the to its

frame. Each bracket has cam retainers

front and rear faces, around

for the

an

integral

arm and

of

adjusting caster

for

installation

1)

attaching bolts. Each

cam at the

is

installed

frame brackets

and of

upper con-

to

brackets which

the

of the

head

of the

at the

Section

sim-

camber.

are

slotted

four

bolt.

A

threaded

I

Cams can be adjusted only

of

the

bolt. Turning ball joint fore camber). Turning both bolts amount ball joint is 180°, therefore direction specifications

ADJUSTMENT Apply MoPar solvent, Part

brushing dirt

in the

or aft to

in or out to

of

rotation

on

to

one

bolt will move

affect

same direction will move

affect camber. Full bolt travel

it

may

be

necessary

of the

both caster

expose bolt threads.

bolts

No.

by

turning the head

the

caster (more than

on one

and

side

an

the

to

reverse

in

order

camber.

1879318, after wire

In

addition

to

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end

upper

equal

upper

the

attain

to

CHRYSLER SERVICE MANUAL

SUSPENSION—7

RONT ADJUSTING JOLT

59x120 *&' .•- mmi

Fig.

1 — Caster and Camber Adjusting Bolts

the regular checks of tire size, tread wear, air pressure,

car loading, looseness and wear before measuring car height, caster and camber, the car must be kept at one level whenever measurements are made. Do this operation the same way every time a measurement is to be made: bounce the car, front first, then rear, several times by grasping the center of the bumpers. Release the bumpers on the down

stroke each time after the same number of bounces.

CASTER AND CAMBER

Front suspension height must be correct before

measuring caster and camber.

After Solvent No. 1879318 has loosened any rust, carefully loosen the upper control arm attaching nuts while holding the bolts from turning. Once caster and camber has been adjusted, a very small turn of the bolts will affect the gauge readings.

Turning one bolt affects caster more than camber.

By bringing caster to approximate specifications,

then turning both bolts an equal amount in the same direction to bring camber to the preferred specification, will usually bring caster to the preferred setting. Tighten nuts to 60-70 foot pounds torque using Tools C-3675 and C-3696. However, due to length of Tools C-3675 and C-3696 used with torque wrenches

Tool C-524 or Tool C-3005 a recalibration will be

necessary in order to obtain proper torque. Using Tool C-3675, the torque reading on wrench must show 45 foot-pounds torque, which is equivalent to 60-70 foot-pounds torque; and using wrench C-3696, torque reading must be 55 foot-pounds torque, which again is equivalent to 60-70 foot-pounds torque. Recheck gauge readings.

All Chrysler Models with True-Level Torsion Aire

must maintain the specified rear height of 4% inches

-f or — i/8 inch, the Imperial (MY-1), rear height if 4%

+ or — % inch while setting the front end, with

engine running (see True-Level Torsion Aire).

REAR SUSPENSION

REAR SPRINGS

The rear springs remain the same with the following exception: the springs have a rubber pad between the springs and the axle housing. The "U" bolt nut torque is 70 + or — 15 foot-pounds.

SHOCK ABSORBERS

The 1959 model cars are equipped with Oriflow shock absorbers of the same type as used on the 1958 mod-

TRUE-LEVEL TORSION AIRE

The True-Level Torsion Aire System (Figs 2 and 3) available as optional equipment on the 1959 Chrysler

and Imperial cars consists of an engine driven bal-

anced head compressor, compressor drive belt, check

valve, high pressure air lines, high pressure reser-

voir tank, low pressure volume tank, height control

NOTE;

equal amount will change camber with little or no

change of caster. Turning both cams an equal amount in opposite directions will change the caster with little or no change of camber.

els.

ual,

Turning both cams in the same direction an

Refer to the 1958 Chrysler and Imperial Man-

D-16350, for information on the removal and

installation of the Oriflow shock absorbers.

CAUTION

When car is equipped with True-Level Torsion Aire, do not use a frame contact type hoist when removing

shock absorbers, as the air springs will become unseated from the upper spring seat.

valve assembly, air springs and valve (actuating)

rubber linkage.

On cars equipped with True-Level Torsion, Aire

System, conventional steel semi-elliptic leaf springs and shock absorbers are used, however, spring load and rate have been reduced approximately ten per cent.

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8—SUSPENSION

CHRYSLER SERVICE MANUAL

HEIGHT CONTROL VALVE

LOW PRESSURE

VOLUME TANK

AIR SPRING

PISTON.

HIGH PRESSURE TANK

COMPRESSOR

Fig.

2 - True-Level Torsion Aire System (Models MC-1, 2 and 3)

HEIGHT CONTROL VALVE

LOW PRESSURE

VOLUME TANK

SPRING PLATE

59 x 70

HIGH PRESSURE TANK

COMPRESSOR

Fig.

3 —True-Level Torsion Aire System (Model MY-1)

SPRING PLATE

59x67

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CHRYSLER SERVICE MANUAL

SUSPENSION—9

CHECK VALVE

PRESSURE LINE

SUCTION MUFFLER

59x75

OIL INLET LINE

CONNECTION

CYLINDER HEAD

VALVE PLATE

Fig.

4 — Compressor Assembly

True-Level Torsion Aire produces a better quality ride as well as maintaining a constant rear height. The rear height is comparable to that of a car without True-Level Torsion Aire and with a three passenger load.

The compressor (depending on car model) (Fig.

4) is located either at the front of the engine or above the fuel pump. The check valve is located in

the compressor head. A high pressure line from the

check valve is connected to the high pressure reservoir tank under the right front fender. A second high pressure line connects the high pressure" tank to the

height control valve (Fig. 5) on the low pressure volume tank. The low pressure volume tank is mounted between the frame side rails above the rear axle.

Two air springs from the low pressure volume tank are connected to the two air spring pistons on the rear spring plates. The height control valve actuator

arm is connected to the rear axle assembly by a rubber link.

OPERATION

With the engine running, the compressor maintains

220 + or — 20 psi air pressure through the air lines

and high pressure tank to height control valve end

cap.

(The amount of pressure is determined in the design of the balanced head.) The check valve at the compressor and the control valve confine the high pressure when the engine is stopped.

The operating pressure in the low pressure volume tank and air springs is controlled by the height control valve. The pressure varies with the load, from approximately 20 psi with or without a driver only load, through 70 psi with six passenger load to

approximately 90 psi for the Town and Country models with a nine passenger load. Pressures within

FRONT OF CAR

LOW PRESSURE

VOLUME TANK

HIGH PRESSURE

BRACKET ON

DIFFERENTIAL HOUSING

•NUT ON CARRIER

VALVE

ADJUSTING

CAM

LOCKWASHER

CAP

NUT

WASHER

LOCKWASHER

NUT

59x64

Fig.

5 —Height Control Valve

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10—SUSPENSION

CHRYSLER SERVICE MANUAL

this range vary instantly as the car moves over chuck holes and expansion strips in the road surface,

in order to maintain the constant rear height. Since these pressures are variable, it is not necessary to test them.

The height control valve contains a minimum pres-

sure valve to maintain 8-15 psi in the air springs

SERVICE PROCEDURES

MAINTENANCE

The high pressure air tank (located under the right front fender) should be drained at least once a month. Depress the non-removable core in the drain valve. (Should it ever be necessary to remove the valve, remove the high pressure line at the check valve FIRST.)

TESTING FOR LEAKS (Liquid Soap Method) With the engine running, apply a diluted liquid soap

solution at the following locations where leaks would

cause bubbles: air springs and seats, height con-

trol valve mounting, air line connections, high pressure air tank, drain valve connection and outlet.

Stop the engine and remove the air line and check valve from the compressor. Connect the air line and check valve. Apply air pressure through the tank drain valve. Coat check valve with soap solution. If no leak is evident, wipe off soap solution before reinstallation.

Refrigerator Method (Refrigerant 12) Add 150 pounds of weight to the center area of the

luggage compartment and raise car on a hoist. Discharge the high pressure tank by depressing the valve core in the valve. Remove the minimum pressure valve from the height control valve. Disconnect the rubber linkage from the differential housing bracket and move the actuator arm manually to discharge all air from the low pressure volume tank. With all air removed from the system, connect the rubber linkage and install the minimum pressure valve.

Install adaptor Tool C-3693 between the high pressure air line and the compressor check valve. Connect manifold gauge set, Tool C-3627 (used with air conditioning) on adaptor, Tool C-3693, using the gauge set suction hose. Attach the refrigerant tank to the gauge set. Open the suction side of the gauge set and charge the system with 40 psi of refrigerant 12. Shut off the gauge set and start the car

during a no-load operation as in changing tires by use of a bumper jack. This pressure prevents damage to the air spring as the jack is lowered and a load condition restored to the system.

The height control valve also contains a high pressure relief valve (150 psi) to protect the system under extreme heavy load conditions.

engine. Operate the car engine until normal operat-

ing pressure of 200 + or — 20 psi is obtained.

Using leak detector, Tool C-3659, (used with air conditioning) check the entire True-Level Torsion Aire System for leaks and make all necessary repairs.

CAUTION

Be sure no gasoline is leaking from the car system when checking the True-Level Torsion Aire System with Tool C-3659.

With the car engine running, purge the refrigerant from the system by disconnecting the rubber linkage from the differential housing and manually operating the height control valve actuator arm.

With the refrigerant purged from the system, connect the rubber linkage to its bracket. Shut off the car engine and again discharge all air from the high pressure tank. Remove adaptor Tool C-3693 from the air line and check valve. Connect the air line to

the check valve. Lower the hoist and remove the

weight from the luggage compartment. Operate the car engine approximately three minutes before removing the car from the hoist.

CHECKING The vehicle must have recommended tire pressures,

full tank of fuel (or equivalent weight added to luggage compartment over the tank). (Gasoline weighs approximately 6% pounds per gallon.) The front suspension height should be correct and equal on both sides before placing car on level floor with no passenger load.

The rear suspension height must be set to a speci-

fied vertical distance between, the top of the axle

housing and highest part under the axle bumper

straps, sides of the car (Fig. 6). Clean the bumper straps and axle housing tubes before measuring.

Rear suspension height is measured (both sides) twice, once with load and again without load. Both pairs of figures are compared as well as averaged.

AND

ADJUSTING SUSPENSION HEIGHT

to the rear of the rubber bumpers on both

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CHRYSLER SERVICE MANUAL

SUSPENSION—11

taching nuts. Rotate cam on lower attaching stud to adjust to correct car height. DO NOT BOTTOM CAM TIGHTLY AGAINST VALVE BODY. (LOW PRESSURE VOLUME TANK PORT COULD BE

DAMAGED.) Tighten attaching nuts to 100 inch pounds torque. Recheck rear suspension heigths.

Fig. 6 — Checking Rear Suspension Heights

The four figures are also averaged. Run the engine three to fiwe minutes to assure proper pressure in the system and proceed as follows:

a. With engine running, add 150 to 200 pounds of load to center of luggage compartment. The height control valve should feed additional air to the low pressure system, causing car to return to original height.

Measure height at both sides using Tool C-3670, and record the figures. The difference should not ex-

ceed */2 inch. If greater than % inch, recheck the front suspension height, particularly the difference between the two sides, and reset if necessary. If rear height difference still exceeds */2 inch, inspect rear springs, (for spring specifications in this supplement). When difference is under

y%

inch, average

the two figures for use later. This is Step (a).

b.

Remove added weight from compartment and allow height control valve to bleed the system for approximately three minutes. The engine may be shut off during this operation.

Measure rear heights and average the two figures. The difference between this average and the average obtained in step (a) above should not exceed % inch.

(This difference is called the height control valve

correction error.) Adjust valve if necessary.

Average the four measurements. (Do not average the two averages.) The average should be 4% inches

+ or — y8 inch on Models MC-1, MC-2, MC-3 and

4%

inches -(-or — Vs inch on Model MY-1. Adjust

valve if necessary.

To adjust height control valve: Loosen both at-

DISCHARGING

THE

SYSTEM

CAUTION

Do not use a frame contact type hoist when discharging system.

Discharge the high pressure system by depressing the valve core in the high pressure air tank drain

and charging valve. DO NOT REMOVE VALVE

FROM TANK.

Discharge low pressure system by pulling the height control valve actuator arm off the pivot pin on the rubber linkage at the axle housing and moving the arm down.

AIR SPRINGS

AND

PISTONS

CAUTION

During jacking operations, the minimum pressure

valve must retain pressure in air springs to prevent

buckling.

Removal and Disassembly

(Fig.

7)

With car on hoist, refer to paragraph "Discharge the System." Remove nut holding air spring piston

to spring plate. Raise piston off spring plate and re-

move air spring from low pressure volume tank by pulling it outward and down.

Remove piston mounting bolt and retainer assembly from piston using a soft mallet. Push piston out of air spring by inserting hammer handle (or equivalent) into the air spring.

Fig, 7 —

Air

Spring

and

Piston Assembly

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12—SUSPENSION

Fig.

8 — Installing Air Spring on Piston

CAUTION

Under no circumstances should the small end of the

air spring be pulled out to a fully extended position, as special tools are required to place in correct position.

CHRYSLER SERVICE MANUAL

Reassembly and Installation

With piston upright on bench, place small end of air spring over rounded end. Roll spring down to cover piston completely (Fig. 8). Insert retainer bolt assembly and examine for snug fit in piston.

Remove rear shock absorbers. Make hold down straps or use Tool C-3694 straps (Fig. 9) and install them in place of shock absorbers. Strap will hold weight of body on leaf springs and assist in seating air spring.

Position piston and air spring assembly on spring

plate. Install retainer bolt, washer and nut (Fig. 10).

Tighten to 5 foot-pounds torque temporarily. Coat

mounting rim of air spring with diluted liquid soap.

If both springs were removed from the low pressure volume tank, it will be necessary to install both

simultaneously.

Start the engine. Hold air spring (s) tightly in position against tank seat (s) and operate control valve manually. Air pressure entering air spring (s) will force spring up on its seat.

Cleaning and Inspection

Clean all parts with clean, dry cloth. Inspect piston

and mounting bolt assembly for nicks, burrs or

cracks. Remove burrs with crocus cloth. Replace a cracked piston with a new piston.

Mounting bolt assembly must be a snug fit in pis-

ton and retainer section must seat solidly against

piston. If necessary, peen piston around bolt hole to obtain snug fit.

Inspect air spring for cuts, cracks, holes and ex-

cessive carcass wear. Install a new air spring if necessary, however, small surface cracks in outer rubber cover are permissible provided there is no leak.

CROSSMEMBER

NUT

Check seating of air spring on tank flange and

seating of piston on spring plate. Align piston and tighten nut to 100 inch-pounds torque. Piston alignment can be checked by depressing around wall of air spring and noting if piston is properly centered. Remove hold down straps and install shock absorbers.

Connect actuator arm to rubber linkage. Check for air leaks paragraph "Testing for Leaks." Check car heights.

RUBBER LINKAGE

The rubber linkage which connects pivot pins on the

valve actuator arm and the bracket on the axle hous-

ing is removed by pulling the linkage off the pivot

pins.

Before installing, apply water or soap solution

BOLT

AIRSPRING

59 x 66

Fig.

9 — Body to Frame Hold Down Straps

PISTON

WASHER

LOCKWASHER

Fig.

10 — Installing Air Spring and Piston Assembly

NUT

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CHRYSLER SERVICE MANUAL

SUSPENSION—13

around pivot ed

end up

left side

HEIGHT CONTROL VALVE (Fig. a. Removal

Refer

to

move high pressure line from valve

valve mounting nuts

NOTE:

holes. Position linkage with round-

toward actuator

of car.

Push linkage

arm and

on

paragraph "Discharging

and

remove valve assembly.

Height control valves

stop boss

pivot pins.

5)

the

System."

end

are

serviced only

cap. Remove

an assembly.

The

"0"

ring valve

seal

is

serviced separately.

b.

Installation

Apply diluted liquid soap

boss.

Install valve assembly

tank, inserting

the

the "O" ring. Install adjusting

to low

boss

pressure volume tank

to "0"

on low

in

tank without damaging

ring

on

pressure volume

cam in

housing

lower mounting stud.

Install mounting nuts finger tight. Connect

line

to

valve

end

cap. Start

valve

for

operation.

Tighten mounting nuts Connect actuator leaks,

refer

arm to

to

paragraph "Testing

car height, paragraph "Checking

Suspension Height"

LOW PRESSURE VOLUME TANK (Fig. a. Removal

Discharge by pulling Disconnect tuator

the

top of

air

arm at

HEIGHT CONTROL VALVE

and

system. Remove

springs downward

line

at

rubber linkage. Loosen

the

engine

to 100

and

inch pounds torque.

rubber linkage. Check

for

Leaks." Check

and

adjust

as

necessary.

11)

air

springs from tank

and

valve

end cap.

Disconnect

DIFFERENTIAL HOUSING

Adjusting

and

to the

Re-

as

housing

at the

air

check

the

for

outward.

ac-

lower

HIGH PRESSURE TANK

AIR OUTLET

59x63

2 and 3)

Fig.

GASKET

SCHRADER

VALVE

'FLAT WASHER

\ NLOCKWASHER

NUT

12 -

High Pressure Tank (Models MC-1,

right tail pipe only.

Support axle move self-tapping screws tank

to

frame side rails. Remove tank from right

side

of car.

and adjusting

b.

Installation

Install

new "0"

and

remove right rear wheel.

(two

each side) holding

Re-

Remove height control valve assembly

cam.

ring

on

height control valve

air

spring boss. Coat ring with diluted liquid soap solu-

tion. Install valve assembly

Tighten nuts

to 100

inch pounds torque. Install tank making sure that insulating pads tween frame mounting screws

Connect

springs paragraph

tion

and

wheel. Check system

and

tank mounting flanges. Tighten

to 100

air

line

to

"Air

tighten right tail pipe. Install right rear

for

and

adjusting

are in

cam.

position

inch pounds torque.

control valve. Install

Springs

and

Pistons." Posi-

leaks. Adjust

car

be-

air

rear

height.

HIGH PRESSURE AIR TANK (Figs. 12 a. Removal

Discharge

the

system. Disconnect both tank. Remove bolts holding tank cradle Remove tank

and

bracket assembly.

and 13)

air

to the car.

lines

at

LOW PRESSURE VOLUME TANK

Fig.

11 — Low

Pressure Volume Tank

59 x 61

GASKET

SCHRADER VALVE

FLAT WASHER

LOCKWASHER

NUT

Fig.

13 - High Pressure Tank (Model

HIGH PRESSURE TANK

AIR OUTLET

AIR INLET

BOLT

MOUNTING BRACKET

59x74

MY-1)

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14—SUSPENSION

CHRYSLER SERVICE MANUAL

SUCTION MUFFLER

FELT

CYLINDER BLOCK

SCREW

C3)

\

FRONT SEARING HOUSING

Fig.

14

—Air Compressor (Disassembled View)

b.

Installation

Position tank and bracket assembly and install bolts. Tighten 14 i 5/16 inch bolts

ncn

bolts to 100 inch pounds torque, and

to

130 inch pounds torque. Connect

air lines to tank. Check

AIR COMPRESSOR (Fig.

for

14)

BOLT

ASSY.

leaks.

(6)

CYLINDER HEAD

^^

GASKET

REED VALVE

VALVE PLATE ASSY.

GASKET

CRANK SHAFT

GASKET

SEAL'**

BOLT

59x90

(4)

a. Testing Compressor

Discharge the system. Disconnect

air

line from com-

pressor check valve. Connect adapter, Tool C-3693,

used with Tool C-3293,

300 lb.

pressure gauge,

to

check valve.

COMPRESSOR ASSEMBLY

PULLEY

LOCKWASHER

NUT>

BOLT

MOUNTING BRACKET

SUPPORT

ADJUSTING STRAP

WASHER

LOCKWASHER

Fig.

16 — Compressor Mounting (with Air Conditioning

(Models MC-2, 3 and MY-1)

With engine running reading should gauge and install

b.

Removal

Remove move line erator

oil

air

at

engine end. Loosen belt adjusting bolt in gen-

and

be 220 psi

air

line.

pressure line

line from check valve. Remove

remove belt from compressor. Remove

i^LOCKWASHER «^- SCREW

WASHER

LOCKWASHER

SCREW

at

1800-2000

or

+

at

rear

o

ADAPTER

—

20 psi.

of

compressor.

59x72

rpm,

Remove

oil

gauge

Re-

return

compressor bracket bolt. Remove bolts holding com-

pressor support to engine and remove compressor as-

sembly from

car.

PU

MOUNTING BRACKET

ADJUSTING STRAP

LOCKWASHER

SUPPORT

WASHER

SCREW

LOCKWASHERO^

SCREW

Fig.

15— Compressor Mounting (with Air

Conditioning — Model MC-1)

I I

LOCKWASHER

SCREW

OCKWASHER

SCREW

59x65

COMPRESSOR ASSEMBLY

GASKET

MOUNTING BRACKET

WASHER

SCREWS ^ Vi^

Fig.

17 —

Compressor Mounting (without

Conditioning

LOCKWASHER

JSCREW

*

LOCKWASHER

'SCREW

59x76

— All

Models)

-

Air

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CHRYSLER SERVICE MANUAL

SUSPENSION—15

c. Installation

(Figs.

15,16 and 17)

With compressor attached to support, attach support to engine, tightening- bolts to 30 foot pounds torque.

Install compressor bracket. Tighten bolt to 30 foot pounds torque.

Install belt (see "Accessory Belt Drives" in this

supplement for adjustment). Connect oil pressure

line,

air line and oil return line. Start engine and

check lines for leaks. Test air pressure.

COMPRESSOR RECONDITIONING

The following components parts are available for

service:

(1) Cylinder head and gasket (2) Valve plate assembly and gasket (3) Pulley and key

(4) Bottom plate, mounting plate and gasket (5) Front bearing, housing and oil seal assembly (6) Check valve assembly

(7) Suction muffler felt

CYLINDER HEAD AND/OR VALVE PLATE ASSEMBLY

Discharge the system. Remove air line from check valve. Remove cylinder head bolts. Remove cylinder head and valve plate assembly. If the plate does not separate from the head, tap the plate lightly with a

soft mallet. Do not pry apart.

Clean piston heads, top of the cylinder block and head bolt holes, cylinder head and valve plate, using mineral spirits. Do not use scraper. Inspect pistons and cylinder walls. If damaged, replace the compressor. If valve plate or cylinder head is damaged, replace. Remove check valve only if replacement is necessary.

Use new gaskets when installing valve plate and

cylinder head. Tighten bolts to 155 inch pounds

COMPRESSOR

59x91

TOOL

PULLEY

Fig.

18 — Removing Air Compressor Pulley

torque. Connect air line to check valve. Check for

leaks and test compressor.

PULLEY AND/OR FRONT BEARING, HOUSING AND OIL SEAL ASSEMBLY

Remove compressor. Original pulley is a .002 press fit on crankshaft. A replacement pulley, in addition,

is pinned to the crankshaft. Remove pin before re-

moving pulley. Remove pulley with Tool PO-11 (Fig.

18). Remove front bearing, housing and oil seal assem-

bly. Clean and inspect bearing and housing assembly. If any component is damaged, replace the assembly. Install front bearing housing, using Tool C-3680 to protect oil seal. Tighten bolts to 17 inch pounds torque.

Remove crankshaft rear cover plate and install

Tool C-3677 to support crankshaft while pressing

pulley on crankshaft. Using an arbor press, press

pulley into contact with flange on crankshaft. Remove tool. Install rear cover plate. Tighten bolts to 17 inch pounds torque.

A new replacement pulley has a hole through one

side of the hub. Use this hole as a guide to drill 5/32 inch hole in the crankshaft and the opposite side of

hub of pulley. Install the roll pin. Install compressor.

TRUE-LEVEL TORSION AIR

CAR

DOES

NOT

MAINTAIN CORRECT

POSSIBLE

a. Leaks in System

b. c. Incorrect Front Height Adjustment

CAUSES

Incorrect Rear Height Adjustment

SERVICE DIAGNOSIS

HEIGHT

UNABLE TO OBTAIN

POSSIBLE

a. Broken or Pinched Air Line

b.

c. Leak in Height Control Valve

CAUSES

Leak in Air Spring

CORRECT

HEIGHT

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16—AXLE—REAR

CHRYSLER SERVICE MANUAL

d. Fast Leak in Low Pressure Volume Tank e. Height Control Valve Out of Adjustment f. Rubber Linkage Loose or Broken at Differen-

tial

g. Broken Height Control Actuator Arm

LOW AIR PRESSURE

POSSIBLE CAUSES

a. Leak in Air Line

b.

Compressor Belt Broken or Out of Adjust-

ment

c. Slipping Drive Belt

d. Plugged Check Valve

REAR AXLE

DATA AND SPECIFICATIONS

e. Leaking Cylinder Head Gasket f. Leaking Valve Plate Gasket g. Cracked Cylinder Head h. Worn Reed Valves i. Excessive Cylinder Wall Wear j.

EXCESSIVE AIR PRESSURE

POSSIBLE CAUSES

a. Carbon Build Up on Cylinder Head b. c. Excessive Oil on Top of Piston

Section II

Excessive Piston Ring Wear

Carbon Build Up on Pistons

MODELS MC-1, MC-2, MC-3, MY-1

TYPE Semi-Floating GEAR TYPE -.. Hypoid RINIG GEAR DIAMETER... 8.75 inch PINON BEARING 2

TYPE .....: Tapered Roller

ADJUSTMENT Shim Pack DIFFERENTIAL BEARINGS 2 TYPE Tapered Roller

ADJUSTMENT Threaded Adjuster

DRIVE GEAR AND PINION. Matched Sets DRIVE GEAR RUNOUT .005 inch Maximum DRIVE GEAR AND PINION BACKLASH. .006 to .008 inch DIFFERENTIAL SIDE GEAR CLEARANCE .001 to .012 inch

MODELS MC-1, MC-2, MC-3, MY-1

Including Town

AXLE RATIO

Standard Ratio .. 2.93 to 1 Ratio with Air Conditioning 2.93 to 1

No.

of Drive Gear Teeth 41

No.

of Drive Pinion Teeth 14

8B

Country Models

WHEEL BEARINGS

Type. Tapered Roller Adjustment Select Shims Axle End Play .013 to .018 inch

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CHRYSLER SERVICE MANUAL

BRAKES—17

REAR AXLE

There is no basic design change in the rear axle and sure grip differential except the larger diameter

pinion shaft is now used on all models for 1959. The

Service Procedures will remain the same on the Rear

Section

Axle and Sure Grip Differential as specified in the 1958 Chrysler and Imperial Service Manual, D-

16350.

III

BRAKES

DATA

MODELS

TYPE Total Contact (Floating Shoe) Hydraulic

DRUM DIAMETER LINING

MC-1

... ,

Type Moulded Asbestos Attachment Cyclebond Width 2Y2 in. Thickness

l

AND

SPECIFICATIONS

MC-2, MC-3,

11

in.

12

%i

MY-1

in.

in-

BRAKE SHOE RETURN SPRING TENSION USING

FISH SCALE HOOKED

BRAKE PEDAL FREE PLAY

WHEEL CYLINDER BORE

Front—Upper Rear

1K mMASTER CYLINDER BORE V/% in. PISTON CLEARANCE .003

and

AT TOE OF

% in. to J^ in.

Lower 1%

SHOE 35

to

45 lbs. required

between shoe

(in models with Power Brakes)

in. to

to

break contact

and

push

in.

.0065

in.

HAND BRAKE

MODELS MC-1, MC-2, MC-3,

TYPE Internal Expanding LOCATION Propeller Shaft DRUM DIAMETER. LINING TYPE

Length 13.06 inch Width

2 in. Thickness Clearance .015

%

7

,

Moulded

at

Rear

inch

and

Compressed Asbestos

m

in. to

MY-1

of

Transmission

-

.020

in.

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rod

18—BRAKES

CHRYSLER SERVICE MANUAL

TOTAL CONTACT SERVICE BRAKES

Servicing procedures outlined in the 1958 Chrysler and Imperial Service Manual, D-16350, will apply to the 1959 models with the exception of the removal

and installation of the new brake shoe retainer.

All brake shoes have a coil spring type guide. The

guide retainer pin extends through the dust shield, the web of the shoe, a flat washer, the coil spring and the cupped retainer.

Removal — While holding retainer pin in dust

shield, push retainer toward brake shoe, turning the

retainer to unlock it from the pin.

Remove retainer, spring and washer from pin.

Remove retainer pin from dust shield. Installation — Insert retainer pin through the dust

UPPER CYLINDER

ADJUSTING

CAM

DUST SHIELD-v.

SHOE RETURN SPRING

SUPPORT-^

shield and brake shoe. Install washer, spring and retainer on retainer pin.

While holding retainer pin in dust shield, push retainer toward brake shoe, turning the retainer to lock it on the pin.

MASTER CYLINDER

The master cylinder used with power brakes has an

adjustable pushrod. A new master cylinder assembly is used on Chrysler Models without power brakes.

The new master cylinder has a non-adjustable

push rod-and-piston stop which is permanently attached to the piston. The boot retainer is also a part of the assembly. The assembly is attached to the mounting face of the master cylinder body with two

(Figs.

.- SHOE

AND

UNING

— SHOE RETAINER

SHOE RETURN

:

SPRING

19 and 20)

SHOE RETAINE

CYLINDER ASSEMBLY

SHOE

RE'

SPRINGS

SUPPORT

SHOE AND LINING

Fig.

19

—Total Contact Brake Assembly (Front)

^**z~~-

-ADJUSTING

CONNECTING TUBE

LOWfi? CYLINDER

ADJUSTING CAMS

CAM

DUST SHIELD

SHOE RETAINERS

ANCHORS

Fig.

20 — Total Contact Brake Assembly (Rear)

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CHRYSLER SERVICE MANUAL

BRAKES—19

screws. No attempt should be made to disassemble

this push rod and piston.

The combined action of the piston return spring and the pressure in the master cylinder is sufficient to hold the brake pedal in the "off" position, without a pedal return spring and pedal stop. The brake pedal should never be pulled back beyond the limit controlled by the piston stop. A minimum pull of 50 pounds could pull the piston off the push rod.

PISTON TYPE POWER BRAKE UNIT

The 1959 Chrysler and Imperial Models will have both the "Bellows Type" Power Brake as well as the

"Piston, Type." The servicing procedure for the "Bellows Type" is the same as that in the 1958 Chrysler and Imperial Service Manual. The servicing procedure for the "Piston Type" is outlined below:

The piston type power brake is an oval-shaped air-vacuum unit (Fig. 21) mounted on the engine side of the dash panel and is connected mechanically to the brake pedal linkage through the power unit push rod.

A yoke at the end of the piston rod is in contact with the power lever pin of the reactionary linkage. The valve operating rod is located at the center of piston rod and is always in contact with a ramp at the upper end of the valve trigger arm of pedal linkage.

A control valve operating rod (Fig. 21) moves within the piston rod to actuate the vacuum valve and poppet.

The mechanical contact between the power unit

and the brake linkage exists only when the power

unit is assisting in a brake application. In the event there is a loss of engine vacuum, the brake pedal is free to function independent of the power unit to apply the brakes in the conventional manner.

PEDAL LINKAGE ADJUSTMENTS (ON CAR)

It should seldom be necessary to adjust the brake

pedal trigger arm. Adjustment, however, may be necessary, occasionally, to eliminate the following

conditions:

If the pedal pressure releases slowly, adjust by rotating the adjustment screw in a counter-clockwise direction. A time delay (noted during a fast brake application), can usually be corrected by mak-

ing a clockwise adjustment on the adjusting screw. Should the pedal vibrate (booster chatter), turn the adjusting screw in a counter-clockwise direction.

NOTE: Rotation of adjustment screw should be limited to plus or minus 90 degrees about original setting.

ASSEMBLY OF PEDAL LINKAGE IN PEDAL BRACKET

CAUTION

Use extreme care during assembly or handling of

the linkage as the power brake pedal trigger arm is

easily damaged.

After reinstalling the brake pedal linkage in the pedal bracket, a wooden wedge should be placed between the power brake lever and the forward edge of the triangular hole in the pedal bracket (if power

VACUUM HOSE VACUUM CHAMBER

VACUUM TUBE / VALVE PASSAGE

AIR

CLEANER

ATMOSPHERIC

CHAMBER

ATMOSPHERIC VALVE

(PORT CLOSED)

Fig.

VACUUM

VALVE

(PORT OPEN)

21

—Power Brake Unit (Sectional View)

/

VALVE OPERATING ROD

VACUUM

RETURN SPRING

GASKET

SPRING

SEAL

VALVE

RETURN SPRING

£

DIRECTION

ROD

57x176

MyMopar.com

20—BRAKES

CHRYSLER SERVICE MANUAL

ARBOR f-< (TOOL) ^

Fig.

22 - Power Brake Unit (Exploded View)

unit has been removed). This will prevent the trigger arm from extending beyond the extremities of the bracket.

LUBRICATION

Except for an occasional few drops of SAE 10W Engine Oil on the power brake lever pin bushings, the brake pedal linkage requires no further lubrication. The power unit will require no lubrication under normal usage.

PEDAL FREE PLAY ADJUSTMENT

After the master cylinder, booster, and pedal linkage are completely installed (and wooden wedge removed), a free play adjustment check should be made at no vacuum as follows:

NOTE: Removing vacuum hose and pressing the

brake pedal several times will aid in obtaining the

no vacuum condition.

Insert the blade of a screw driver between the

rubber collar of the power brake trigger pivot and

the rear side of elongated hole in the power brake lever, forcing them apart.

NOTE: If the brake pedal and the power brake lever

are not wedged apart, a false free play setting (which

GAUGE

BLOCK

(TOOL)

57x17

includes booster valve travel) will be measured at

the pad end of the pedal.

Check free play with linkage in this position by pushing lightly at the pad end of the brake pedal. Pedal free play travel should be between 1/32 and Vs inch. If pedal free play movement does not come

within the required limits, adjustment is made by lengthening or shortening the push rod as required.

ALTERNATE METHOD OF MEASURING PEDAL FREE PLAY

Remove master cylinder push rod end pin. Using light finger pressure, move push rod forward until

contact is made with the master cylinder piston. Attempt to insert the push rod pin through the power lever and push rod end hole. If the push rod

must be pulled back to allow passage of the push rod

end pin, free play is present.

If the push rod must be pushed further into the master cylinder to allow passage of push rod end pin, no free play is present and an adjustment must be made at the push rod.

POWER BRAKE

a. Removal (Fig. 22)

Place a wood wedge between power brake lever and

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CHRYSLER SERVICE MANUAL

BRAKES—21

forward edge prevent trigger ities

of

NOTE: hole

If

in

of

triangular hole

arm

bracket.

pedal linkage

dash panel

from extending beyond extrem-

the

trigger

Disconnect vacuum hose

attaching bolts

at

dash panel

power unit assembly. NOTE: Use care

cross

pin.

b.

Disassembly

Scribe across flange

guide

to

correct assembly (Fig.

NOTE:

Do not

to

prevent loss

of

clamp yoke

tion.

Remove

ing

the

cylinder shell

vacuum hose from

CAUTION

The vacuum tube must

(Fig.

4).

diaphragm

Make certain

is in the

the

annular groove

plate assembly.

Install valve

rod

poppet

NOTE: Before installing the following test.

Depress to blow through through

the

valve

the

hose indicates

rod and at the

vacuum hose. Failure

properly seated.

VACUUM CYLINDER

AIR CLEANER

COVER

AIR CLEANER

HAIR

NUT (4)

in

pedal bracket,

is

allowed

to

extend through

arm may be

at

power unit. Remove

and

carefully remove

cylinder

of the

and end

pedal linkage

23).

in

vise during any opera-

and

gasket, disconnect-

the air

be in the

bead

cleaner cover.

lowest quadrant

at

outer diameter

of the

and

applying diaphragm.

the

vacuum cylinder, make

same time,

the

poppet assembly

END PLATE

MATING MARKS

damaged.

plate

as a

tube

and

try

to

blow

GASKET

to

of

is

END PLATE SPRING ROD

RETAINER PLATE

POPPET DIAPHRAGM

APPLYING DIAPHRAGM

VALVE

ROD

APPLYING

SCREW

Fig.

Install

TUBE

AND

PLATE

ASSEMBLY

(4)

24

— Disassembly

a new

SPRING VALVE

VACUUM HOSE 57x201

of

Tube

and

vacuum cylinder gasket vacuum hose. Align vacuum cylinder scribe marks

and

assembly.

END

SPRING

RETAINER

WASHER

PISTON

ROD

Plate Assembly

and

and end

c. Installation Position

so that

(Fig.

NOTE:

that

nylon bushings stall

nuts securely, and hose clips, operate engine play. Refer adjustment

the

power brake unit

its

axis inclines down toward front

28) As

yoke passes through dash panel,

it

engages pedal linkage correctly

on

power brake lever cross

and

connect master cylinder.

Replace four

hex

nuts

and

release pedal. Install vacuum hose

on

"pedal free play."

on

dash panel

by

sliding over

lockwashers, tighten

and

check pedal free

d. Lubrication The power unit will require

normal use. or repair,

If the

all

unit

oil seals

is

and

no

lubrication under

disassembled

for

"0" rings must be suitably

coated with silicone grease before assembly.

RETAINING PINS

STOP WASHER

VALVE

ROD SEAL

connect

plate

of car

of car.

be

sure

pin. In-

overhaul

SCREWS

LOCKWASHER

(3)

Fig.

23 — Removal of Air Cleaner and

Vacuum Cylinder)

BOLT

57 x 200

AND

(4)

PISTON

ROD

END PLATE

57x202

Fig.

25 — Removal of Vacuum Piston, Spring and Piston Rod

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22—BRAKES

CHRYSLER SERVICE MANUAL

LEATHER PACKING EXPANDER SPRING RETAINER PLATE

COTTON WICK

EXPANDER SPRING

SCREW

(6) W 57x203

Fig.

26

— Disassembly

of

Vacuum Piston

PISTON

PISTON PLATE

PEDAL LINKAGE a. Removal from Pedal Bracket (Power Unit Installed)

Remove pedal return spring, master cylinder push rod end pin and power brake pedal lever shaft.

Rotate pedal linkage assembly counter-clockwise while withdrawing power lever cross pin from booster unit yoke.

Scribe across the tube plate and piston plate to insure correct assembly. Remove the vacuum rod applying pin, and tube and plate assembly (Fig. 24).

Remove the retainer plate, spring and valve as an assembly. Remove the nylon button and the valve rod seal. Remove the valve rod snap ring and remove the washer and spring. Remove the valve rod from the piston rod end.

INSPECTION PORT SCREW

GASKET

PISTON

ROD

SEAL

SCREW

AND

SEAL WASHER

Fig.

27 —

Removal

(4)

GASKET END PLATE

of

Mounting Ring, Seal

and Washer

MOUNTING RING

SPRING

57x204

Remove the piston rod retaining pins from the piston and separate the piston and piston rod. Remove the piston rod and rubber stop washer (Fig.

25).

Refer to Figure 26 and disassemble the piston.

Separate the mounting ring from the end plate

(Fig. 27). Remove the retaining spring, seal retainer, piston seal and rubber gasket. Remove the inspection port screw from the mounting ring.

b.

Cleaning and Inspection

Clean all rubber parts in alcohol. Thoroughly wash all metal parts. If inspection reveals nicks or scratches on the piston rod, valve seat at end of valve rod,

PEDAL TRIGGER

RETURN SPRING

PEDAL MOUNTING

BRACKET

PUSH

ROD

END

!

^ . MASTER CYLINDER PUSH

ARM

\

POWER BRAKE

CYLINDER ASSEMBLY

MASTER CYLINDER

FRONT

ROD

Fig.

28 —

Power Brake Unit Installed

ASSEMBLY

OF

DASH PANEL

W

:

POWER LEVER

•——YOKE POWER LEVER

TRIGGER

*~^" PIVOT BOLT

ADJUSTING

BRAKE PEDAL

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TRIGGER

SCREW

SHAFT

CHRYSLER SERVICE MANUAL

ACCESSORY BELT DRIVES—23

or valve seat at center of piston plate, replace parts.

Replace an excessively worn leather packing or

piston rod leather seal. c.

Assembly

Be sure all metal parts are clean and thoroughly dry. Refer to Figure 26 and assemble piston plate as follows:

With ribbed portion up, position the leather packing and piston plate. Install the wick, expander spring and wick retainer plate.

NOTE: Dip the wick in vacuum cylinder oil prior to installation.

Refer to Figure 27 and assemble the mounting

ring and end plate as follows:

Insert the end plate mounting plate screws in the

end plate and install the rubber gasket. Apply sili-

cone grease to outer face of gasket around center

hole.

Position the piston rod seal and retainer and retaining spring. Coat the bearing surface of mounting1 ring with silicone grease and install the mounting ring (ribbed portion up).

Slide the piston rod stop washer on the piston rod.

CAUTION

Before inserting the piston rod through the leather seal, cover approximately 1*4 inches of the piston

rod with scotch tape to prevent the sharp edges of the piston rod from damaging the seal.

Insert the piston rod through the seal and position

the piston spring on the end plate. Insert the piston

rod into the piston and install the retaining pins

(Fig. 25).

Insert the valve rod in the piston and install the valve rod spring, washer and snap ring. Install the valve rod seal and valve rod nylon button.

Position the retainer plate, spring, and poppet on

the piston. Install the tube and plate assembly. NOTE: Pedal is slotted to provide clearance for re-

moval of brake pedal assembly. d. Installation of Pedal Linkage in Pedal Bracket

CAUTION

Use extreme care during assembly or handling of the linkage, as the power brake pedal trigger arm is easily damaged.

After reinstalling brake pedal linkage in pedal bracket, a wooden wedge should be placed between power brake lever and forward edge of triangular hole in pedal bracket (if power unit has been removed). This will prevent trigger arm from extending beyond extremities of bracket.

SERVICE DIAGNOSIS

PEDAL RELEASES SLOWLY AFTER APPLICATION OR BRAKE PEDAL VIBRATES (BOOSTER CHATTER)

Pedal trigger arm improperly adjusted. Rotate linkage adjusting screw in counter-clockwise direction.

See paragraph "Adjustments."

DELAY IN BRAKE APPLICATION)

Pedal trigger arm improperly adjusted. Rotate the linkage adjusting screw in a clockwise direction. See paragraph ''Adjustments."

APPLICATION (NOTED DURING FAST

Section

ACCESSORY BELT DRIVES

The satisfactory performance of the belt driven accessories depends on the maintenance of the proper belt tension. If the specified tensions are not main-

LACK OF POWER ASSISTANCE (WHEN COLD)

NOTE: This condition only occurs when the car has

been setting for a long period of time ( storage must be disassembled, cleaned of all old lubricants,

seals and diaphragm must be softened with silicone

grease before unit will function properly. LEAKS IN

a. Air leaks in vacuum lines. b.

power cylinder assembly.

BOOSTER (Whistle when Brake is Applied)

Leaks in power cylinder. Recondition complete

).

Unit

IV

tained, belt slippage may cause engine overheating,

lack of power steering assist, loss in air conditioning

capacity, air suspension height control failure, re-

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CHRYSLER SERVICE MANUAL

ACCESSORY BELT DRIVES—23

or valve seat at center of piston plate, replace parts.

Replace an excessively worn leather packing or

piston rod leather seal. c.

Assembly

Be sure all metal parts are clean and thoroughly dry. Refer to Figure 26 and assemble piston plate as follows:

With ribbed portion up, position the leather packing and piston plate. Install the wick, expander spring and wick retainer plate.

NOTE: Dip the wick in vacuum cylinder oil prior to installation.

Refer to Figure 27 and assemble the mounting

ring and end plate as follows:

Insert the end plate mounting plate screws in the

end plate and install the rubber gasket. Apply sili-

cone grease to outer face of gasket around center

hole.

Position the piston rod seal and retainer and retaining spring. Coat the bearing surface of mounting1 ring with silicone grease and install the mounting ring (ribbed portion up).

Slide the piston rod stop washer on the piston rod.

CAUTION

Before inserting the piston rod through the leather seal, cover approximately 1*4 inches of the piston

rod with scotch tape to prevent the sharp edges of the piston rod from damaging the seal.

Insert the piston rod through the seal and position

the piston spring on the end plate. Insert the piston

rod into the piston and install the retaining pins

(Fig. 25).

Insert the valve rod in the piston and install the valve rod spring, washer and snap ring. Install the valve rod seal and valve rod nylon button.

Position the retainer plate, spring, and poppet on

the piston. Install the tube and plate assembly.

NOTE: Pedal is slotted to provide clearance for removal of brake pedal assembly.

d. Installation of Pedal Linkage in Pedal Bracket

CAUTION

Use extreme care during assembly or handling of the

linkage, as the power brake pedal trigger arm is eas-

ily damaged. After reinstalling brake pedal linkage in pedal

bracket, a wooden wedge should be placed between power brake lever and forward edge of triangular hole in pedal bracket (if power unit has been removed). This will prevent trigger arm from extending beyond extremities of bracket.

SERVICE DIAGNOSIS

PEDAL RELEASES SLOWLY AFTER APPLICATION OR BRAKE PEDAL VIBRATES (BOOSTER CHATTER)

Pedal trigger arm improperly adjusted. Rotate linkage adjusting screw in counter-clockwise direction.

See paragraph "Adjustments."

DELAY IN BRAKE APPLICATION)

Pedal trigger arm improperly adjusted. Rotate the linkage adjusting screw in a clockwise direction. See paragraph ''Adjustments."

APPLICATION (NOTED DURING FAST

Section

ACCESSORY BELT DRIVES

The satisfactory performance of the belt driven accessories depends on the maintenance of the proper belt tension. If the specified tensions are not main-

LACK OF POWER ASSISTANCE (WHEN COLD)

NOTE: This condition only occurs when the car has

been setting for a long period of time ( storage must be disassembled, cleaned of all old lubricants,

seals and diaphragm must be softened with silicone

grease before unit will function properly. LEAKS IN

a. Air leaks in vacuum lines. b.

power cylinder assembly.

BOOSTER (Whistle when Brake is Applied)

Leaks in power cylinder. Recondition complete

).

Unit

IV

tained, belt slippage may cause engine overheating,

lack of power steering assist, loss in air conditioning

capacity, air suspension height control failure, re-

MyMopar.com

24—ACCESSORY BELT DRIVES

CHRYSLER SERVICE MANUAL

duced generator charging rates, and greatly reduced belt life. To avoid any such adverse effects, the following service procedure should be followed:

1.

Adjust all belts "in use"* to the specified belt

tension at new car preparation.

2.

Readjust all belts at the 2,000 mile inspection

and service.

3.

Check all belts by the deflection method at serv-

icing and readjust if needed,

4.

The new belt tension specifications should be used on all new belt installations and the above procedure followed thereafter.

There are two methods by which belt tensions can

be properly established:

Torque Method — All generator and power steering pump belts can be tightened to the specified tension

(see Tension Specifications that follow), by use of a

torque wrench. The generator belts are tensioned by

using a special tool C-3379, and torque wrench. The power steering belts are tightened by inserting the torque wrench in the square hole provided in the bracket. Other belts can also be tightened by this method if the adjusting bracket has a square hole.

To tighten belts by the torque method, loosen all mounting bolts and apply the specified torque to the accessory or idler. Tighten all mounting bolts while the torque is applied to the accessory. If it is not possible to use the torque wrench because of clearance, use an extension.

Belt Deflection Method — All belts can also be adjusted by measuring the deflection of the belt at the mid-point between two pulleys under a five-pound push or pull. A small spring scale can be used to establish the

five-pound

load. See Figure 29 for correct

location at which to measure deflection.

This method should be used only when it is not possible to use the torque method, as it is a less accurate method. To tension the belts by the deflection method, loosen all mounting bolts and use a bar to apply tension to the belts being careful not to damage the accessory. A Johnson bar can be used if the accessory has a square hole. Tighten the mounting bolts and check the deflection, (see Belt Tension specifications). It may be necessary to repeat this procedure several times to establish the correct tension.

* Any belt that has operated for a minimum of a

half-hour is considered to be "in use."

1.

CS-Crankshaft

2.

WP-Water Pump

3. G—Generator

4. PS—Power Steering

MC-2,

MC-3, MY-1 MC-1

Fig.

29 — Belt Deflection Location

59xll8

5.

I—Idler

6. AC-Air Conditioning

7. SC—Suspension Compressor

MyMopar.com

CHRYSLER SERVICE MANUAL

BELT TENSION SPECIFICATIONS

Torque (Ft. Lbs.) to be Applied to Components

ACCESSORY BELT DRIVES—25

TORQUE METHOD

ACCESSORY

POWER STEERING BRACKET GENERATOR—WITHOUT AIR CONDITIONING

MC-1 WITH AIR CONDITIONING MC-2,

MC-3, MY-1 WITH AIR CONDITIONING

WITH SUSPENSION COMPRESSOR FAN IDLER BRACKET AIR CONDITIONING IDLER BRACKET (MC-1)

BELT DEFLECTION METHOD

Deflection (inches) to be Applied at Mid-Point of Belt Segment Under a 5 pound Load—See Figure 29

ACCESSORY

POWER STEERING FAN BELT—IDLER GENERATOR—WITHOUT AIR CONDITIONING

WITH SUSPENSION COMPRESSOR MC-1 WITH AIR CONDITIONING MC-2,

MC-3, MY-1—WITH AIR CONDITIONING

SUSPENSION COMPRESSOR BELT MC-1 WITH

AIR CONDITIONING

SUSPENSION COMPRESSOR BELT MC-2, MC-3, MY-1 WITH

AIR CONDITIONING

BELT IN USE

55

20

10 35 30

35 50

NEW BELT

90

30

15 65 40

50 85

BELT IN USE NEW BELT

%,

Vs

VA

%>

Vs

Hi

Vs % Vs

M

Vs

Hi

SERVICE DIAGNOSIS

Insufficient Accessory Output Due to Belt Slippage

Check belt tension and belt condition. If belt is excessively glazed or worn, install new belts and adjust as specified.

Belt Squeal when Accelerating Engine

a. Belts too loose—retighten.

b.

Belts glazed—install new belts.

Belt Squeak at Idle

a. Misaligned pulleys—align accessories

brackets or use spacers as required).

b.

Non-uniform groove or eccentric pulley—re-

place pulley.

(file

c. Non-uniform belt—replace belt. d. Dirt and paint imbedded in belt—replace belt.

e. Belt too loose—retighten.

f. Belts glazed—install new belts and tighten to

specified tension. Belt Rolled Over in Groove

Broken cord in belt—replace belt.

Belt Jumps Off

a. Belt too loose—retighten.

b.

Misaligned pulleys—align accessories.

MyMopar.com

26—COOLING SYSTEM

CHRYSLER SERVICE MANUAL

Section V

COOLING SYSTEM

DATA AND SPECIFICATIONS

MODELS MC-1, MC-2, MC-3, MY-1

COOLING

Type Pressure Vent Capacity

With Heater 17 qts. Without Heater 16 qts.

Radiator Cap Relief

Valve Pressure—psi 14 With Air Conditioning—psi 16

WATER PUMP

Type Centrifugal Bearing Type Ball Bearing

THERMOSTAT

Type Choke (Permanent By-Pass) Starts to Open (up to) 177° to 182° F. Fully Open 202° F.

FAN BELT

Number Used (Standard Steering) One Power Steering Two Type V Tension See Accessory Belt Drive, Section IV

FAN

Number of Blades , *Four Diameter 18 inches

MC-3,

MY-1 with Air Conditioning 18J^ inches

RADIATOR-TO-BLADE

Clearance Top—% inch

Bottom—% inch

MC-1 & MG-2 MC-3 & MY-1

RADIATOR

Type (Standard) Cellular Tubular Cellular Tubular

or Fin and Tube Thickness 1J/2 inch 2 inch Type (Air Conditioning) Cellular Tubular Fin and Tube

Thickness 2^ inch 2lA inch *MC-1 with Air Conditioning have box shroud six blade fan with 234 inch radiator. *MC-2,

*On MC-1, five blade Silent Flite fan is not available.

MC-3, MY-1 with Air Conditioning have a box type fan shroud, five blade Silent Flite fan and the fan to engine

ratio is 1.20 to 1.

MyMopar.com

CHRYSLER SERVICE MANUAL

ELECTRICAL SYSTEM—27

COOLING SYSTEM

The cooling system servicing is the same for 1959 with the exception of the following: The capacity of the radiator cooling system is 17 quarts with a heater and 16 quarts without a heater.

The radiator oil cooler located in the bottom of the

pan in the radiator tank has a new service proce-

dure.

Testing for Leaks Remove the two oil cooler lines at the radiator. Con-

nect a pressure gauge to one cooler outlet. Connect a source of air pressure with a shut-off valve (closed

Section VI

ELECTRICAL SYSTEM

DATA AND SPECIFICATIONS

BATTERY

position) to the other outlet. Do not use pipe sealers since the sealer may get into transmission oil circuit. Open valve slightly and admit air pressure not to exceed 50 psi gauge reading, then close valve. If the cooler and all fittings are leak ing will remain constant.

When a leak is detected, remove radiator from car.

Remove radiator lower tank (soft solder). Test the

cooler with 50 psi air pressure in water to locate leak.

Repair the leak using silver solder. If necessary, have a competent radiator repair shop repair the leak or install a new cooler.

MG-1,

proof,

MG-2, MG-3, MY-1

the gauge read-

Voltage

Capacity Terminal Ground

78 Plate 70 Amp Hour

12

Negative

STARTER

MC-1,

MC-2, MC-3, MY-1

Car Model Usage MDT-6002-1770712

Starter Model „ MDT-6002

Voltage 12 No.

of Fields 4

No.

of Poles 4 Brushes 4 Spring Tension 32 to 48 Ounces

Drive Solenoid Shift Overrunning Clutch End Play .005" Minimum

Free Running Test

Voltage 11 Amperage Draw 80 Amps Minimum Minimum Speed rpm 3800 Minimum

Stall Torque Test

Torque Foot-Pounds 8.5 Voltage 4 Amperage Draw 350

Pinion to Housing .070" to .120"

Clearance Between Pinion Stop

(with Armature End Play removed)

MyMopar.com

CHRYSLER SERVICE MANUAL

ELECTRICAL SYSTEM—27

COOLING SYSTEM

The cooling system servicing is the same for 1959 with the exception of the following: The capacity of the radiator cooling system is 17 quarts with a heater and 16 quarts without a heater.

The radiator oil cooler located in the bottom of the

pan in the radiator tank has a new service proce-

dure.

Testing for Leaks Remove the two oil cooler lines at the radiator. Con-

nect a pressure gauge to one cooler outlet. Connect a source of air pressure with a shut-off valve (closed

Section VI

ELECTRICAL SYSTEM

DATA AND SPECIFICATIONS

BATTERY

position) to the other outlet. Do not use pipe sealers since the sealer may get into transmission oil circuit. Open valve slightly and admit air pressure not to exceed 50 psi gauge reading, then close valve. If the cooler and all fittings are leak ing will remain constant.

When a leak is detected, remove radiator from car.

Remove radiator lower tank (soft solder). Test the

cooler with 50 psi air pressure in water to locate leak.

Repair the leak using silver solder. If necessary, have a competent radiator repair shop repair the leak or install a new cooler.

MG-1,

proof,

MG-2, MG-3, MY-1

the gauge read-

Voltage

Capacity Terminal Ground

78 Plate 70 Amp Hour

12

Negative

STARTER

MC-1,

MC-2, MC-3, MY-1

Car Model Usage MDT-6002-1770712

Starter Model „ MDT-6002

Voltage 12 No.

of Fields 4

No.

of Poles 4 Brushes 4 Spring Tension 32 to 48 Ounces

Drive Solenoid Shift Overrunning Clutch End Play .005" Minimum

Free Running Test

Voltage 11 Amperage Draw 80 Amps Minimum Minimum Speed rpm 3800 Minimum

Stall Torque Test

Torque Foot-Pounds 8.5 Voltage 4 Amperage Draw 350

Pinion to Housing .070" to .120"

Clearance Between Pinion Stop

(with Armature End Play removed)

MyMopar.com

28—ELECTRICAL SYSTEM

Solenoid Switch

Pull-in Coil Hold-in Coil

CHRYSLER SERVICE MANUAL

STARTER (Cont'd)

28.6 to 32.9 Amps at 6 Volts

10.2 to 11.8 Amps at 6 Volts

LIGHT BULBS

Number Mazda

Required Number

Headlights Inner (High Beam Only) 2 Headlights Outer (High and Low Beam) 2 Headlight Beam Indicator Light 1 Parking and Front Turn Signal 2 Rear Tail, Stop and Turn Signal Light 2 License Plate Light 2 Glove Box Light 1 Instrument Lights 4 Map Light 1 Turn Signal Indicator Light 2 Dome Light 1 or 2 Hand Brake Warning Light 1

Back Up Light 2

Transmission Push Button Light 1

Radio Dial Light 2

Clock Light 1

Trunk Light 1

CIRCUIT PROTECTORS

4001 4002

57

1034 1034

67 57 57

1004

57

1004

90

1073

57

1891

57

1003

C.P. or Chrysler

Watts Part No.

37J^ W

50-37^ W

2 32-4 32-4

3 2 2

15

2

15

6

32

2

15

1753435

1753436 127934 151567 151567 142450 127934 127934 151578 127934 151578 142453 142456 127934

127934 151577

Circuit

Type

Rated Capacity

Location

Lighting System Circuit Breaker 22J^ Ampere Integral with Headlight Switch Clock Fuse 1 Ampere At Fuse Block* Windshield Wiper Circuit Breaker 6 Ampere At Fuse Block* Radio Fuse 7*^ Ampere At Fuse Block* Dome Lamp Fuse 6 Ampere At Fuse Block* Window Lifts Circuit Breaker 20 Amp-30 Amp At Terminal Block

Behind Left Front Kick Panel Back-Up Light Fuse 6 Ampere At Fuse Block* Cigar Lighter Fuse 14 Ampere At Fuse Block* Six-Way Seat Circuit Breaker 40 Ampere At Terminal Block

Behind Left Front Kick Panel Rear Defroster Fuse 6 Ampere At Fuse Block* Heater Circuit Breaker 20 Ampere At Fuse Block* Air Conditioner (front) Circuit Breaker 30 Ampere At Fuse Block* Air Conditioner (rear) Circuit Breaker 20 Ampere At Fuse Block* Air Conditioner (dual) Circuit Breaker 30 Ampere At Fuse Block*

*Fuse block is located at instrument panel (driver's compartment) to the left of radio.

MyMopar.com

Gar Model

Generator Model

Standard

With Air Conditioning Front Unit Only

Dual Air Conditioning Front and Rear

MC-1

GJM-8001A;

GHM-8005B;

GENERATORS

1842801

1889400

GJM-8001A; 1842801

GJM-8002A; 1842797

GHM-8001A; 1842774

MC-2,

MC-3

MY-1

GHM-8005A; 1842778

GHM-8001A; 1842774

Gas Heater Heavy Duty Heavy Duty True-Level Torsion Aire.. Generator Model

Rotation

Voltage

Rated Output

Control Ground Polarity Poles '.. Brushes Brush Spring Tension Bearings End Play Field Coil Draw (Arm. to field term.)

GGA-6003E;

GGA-6001N

GGA-6003E Clockwise at

Drive End

12

40 Amperes

Vibrating Regulator

Negative

2 2

34 to 41 ounces

Ball—Both Ends

.003"-.010"

1.2 to 1.3 Amps at 10 Volts

1842603

GHM-8001A

Clockwise at

Drive End

12

30 Amperes

Vibrating Regulator

Negative

2 2

35 to 53 ounces

Ball—Both Ends

.003"-.010"

1.2 to 1.3 Amps at 10 Volts

GHM-8005A; 1842778 GGA-6003E; 1842603

GGA-6001N; 1658863

GHM-8005A

GHM-8006B

Clockwise at

Drive End

12

30 Amperes

Vibrating Regulator

Negative

2

35 to 53 ounces

Ball & Sleeve

.003"-.010"

1.2 to 1.3 Amps at 10 Volts

GHM-8005A; 1842778 GGA-6003E; 1842603 GGA-6001N; 1658863

GJM-8001A

Clockwise at

Drive End

12

35 Amperes

Vibrating Regulator

Negative

2

18 to 36 ounces

Ball & Sleeve

.003'/-.010'

/

1.4 to 1.7 Amps at 10 Volts

GJM-8002A

Clockwise at

Drive End

12

35 Amperes

Vibrating Regulator

Negative

2 2

18 to 36 ounces

Ball—Both Ends

.003"-.010"

1.6 to 1.7 Amps at 10 Volts

Motoring Draw

2.9 to 3.4 Amps at 10 Volts

Output Tests (at 70° F.) 10 Amps, 13.4 Volts

at 1020 max. rpm

40 Amps, 15 Volts

at 1800 max. rpm

3.3 to 3.8 Amps at 10 Volts

10 Amps, 13.5 Volts

at 1040 max. rpm

30 Amps, 15 Volts

at 1800 max. rpm

3.3 to 3.8 Amps at 10 Volts

10 Amps, 13.5 Volts

at 1040 max. rpm

30 Amps, 15 Volts

at 1800 max. rpm

3.8 to 4.3 Amps at 10 Volts

10 Amps, 13.4 Volts

at 1480 max. rpm

35 Amps, 15 Volts

at 2400 max. rpm

3.8 to 4.3 Amps at 10 Volts

10 Amps, 13.4 Volts

at 1480 max. rpm

35 Amps, 15 Volts

at 2400 max. rpm

MyMopar.com

30—ELECTRICAL SYSTEM CHRYSLER SERVICE MANUAL

REGULATOR

MC-1,

Car Model

MC-2, MC-3, MY-1

Regulator Model VRX-6301A-1842798

(For 35 Amp Generators) Volts Ground Polarity

12

Negative

VRX-6201A-1642333

(For 30 Amp Generators)

12

Negative

VAT-6201-1662137

(For 40

Amp Generators)

12

Negative

Resistors

Marked 60.. Marked 38.. Marked 30..

34.5 to 45 ohms

55.0 to

34.5 to

28.0 to

70.0

42.0

34.5

ohms

Voltage Regulator

Voltage Winding Resistance. Armature Air Gap

44.0 to 49.0 ohms .048 to .052 inch

Contacts closed with high limit gauge installed.

Contacts open with low limit gauge installed.

Gauge on contact side and next to brass stop pin.

Voltage Setting (operating voltage)

After 15 minutes run at 7 amperes Temperature in degrees F 50°

Maximum Setting 15.04 Minimum Setting 14.42

60°

14.97

14.36

70°

14.90

14.30

80°

14.83

14.23

90°

14.76

14.16

100°

14.69

14.09

110°

14.01

14.62

120°

14.54

13.94

Current Limiting Regulator

Armature Air Gap

.048 to .052 inch

Contacts closed with high limit gauge installed.

Contacts open with low limit gauge installed.

Gauge on contact side and next to brass stop pin.

Current Setting (After voltage Regulator Setting) Operating Amperage after 15 minutes at 7 amperes. Then followed with a 15 minute run at rated current regulator

setting below 13.5 volts).

Temperature (F)....

Model VRX-6201A (1642333) 30 Amp. Max. Setting. .. .

Min. Setting

Model VRX-6301A (1842798) 35 Amp. Max. Setting. . . .

Min. Setting....

Model VAT-6201 (1662137) 40 Amp. Max. Setting....

Min. Setting....

50°

35 31

39 35

46 42

60

33 29

38 34

45 41

c

70°

32

28

37

33

44

40

80°

31 27

36 32

43 39

90°

30 26

35 31

42 38

100°

29 25

34 30

41 37

Cut-Out Relay:

Voltage Winding Resistance Air Gap (contacts open)

107 to

.031 to

121 ohms

.034 inch

(Measure gap as near to hinge as possible) Point Gap (Minimum) Contacts Close (Volts) Contacts Open (after charge of 10 amperes)

Discharge Amperes

.015 inch

12.6 to

0

to 6 amperes (discharge)

8.2 to

13.6 Volts

9.3 Volts

MyMopar.com

CHRYSLER SERVICE MANUAL

Car Model

DISTRIBUTOR

MC-1,

MG-2

ELECTRICAL SYSTEM—31

MC-3,

MY-1

Distributor Model....

Contact Gap Dwell

Condenser Capacity Breaker Arm Tension

Drive Side Play (shaft) End Play (after assembly)

Firing Order

Rotation Timing Automatic Advance

Distributor Degrees and rpm.

Vacuum Advance

Distributor Degrees and Inches of Vacuum

IBP-4006-1842804

.015 to .018 inch

27° to 32°

.25 to .285 Microfarad

17 to 20 ounces

Camshaft

.005 inch Max.

.003 to .010 inch

18436572

Counter-clockwise

10° BTC

0°@ 270 to 540

0° to2°@ 540 2° to4°@ 800

4° to6°@ 1500

6.5° to

8.5° @ 2350

0° to 7.2 to 9.1"

4.5° to

7.5° @ 12"

9.5° to

12.5° @

16.5"

IBS-4010A-1842805

.015 to .018 inch

(one set points 27° to 32°)

(both sets points 34° to 40°)

.25 to .285 Microfarad

17 to 20 ounces

Camshaft

.005 inch Max.

.003 to .010 inch

18436572

Counter-clockwise

10° BTC

0°@310to490

0° to

2° @

490

3.5° to 5.5° @ 800 6°to8°@ 1550

8.5° to

10.5° @

0°@7.5to9.1"

6.0° to

11.5° to 14.5°© 18.2"

9° @

2300

13"

CAR MODEL

Spark Plugs

Type Size Gap...

SPARK PLUGS AND COIL

MC-1,

MC-2

A-42

14 mm

.035 inch

HIGH TENSION CABLES WITH BUILT-IN RESISTANCE

No.

1 Cable 8,300 to 16,600 Ohms

No.

2 Cable 5,500 to 11,000 Ohms

No.

3 Cable 8,100 to 16,200 Ohms

No.

4 Cable 6,000 to 12,000 Ohms

No.

5 Cable 8,800 to 17,600 Ohms

No.

6 Cable 6,300 to 12,600 Ohms

No.

7 Cable 9,400 to 18,800 Ohms

No.

8 Cable 7,200 to 14,400 Ohms

MC-3,

A-42

14 mm

.035 inch

MY-1

MyMopar.com

32—ELECTRICAL SYSTEM CHRYSLER SERVICE MANUAL

SPARK PLUGS

CAR MODEL MC-1, MC-2, MC-3, MY-1

Coil

Model CAH-4001

Ballast Resistor PU-5001 Amperes

Engine Stopped 3.1 Amperes Engine Idling 2.5 Amperes

AND

COIL (Cont'd)

HORNS

All Models

Make Auto-Lite, Spartan Current draw at 12.4 volts 9 to 10 amps

ELECTRIC WINDSHIELD WIPER

All Models

Variable Speed Motor

Rated Volts. 12 Resistor (ohms) (Variable speed wiper) 17-40 Field Current Draw at 13.5 volts . 13^ to 2 amps

Motor Current Draw (with dry glass)

High Speed Low Speed 3 amps at 35 to 40 rpm

1

j/£

amps at 66 to 75 rpm

POWER SEAT LIFTS

All Models

Type Motor Series Wound Rated Voltage 12 Current Draw with Passenger Load Pounds Amps Volts

Vertical Lift 500 50-60 10.5

200 40-45 10.6

Horizontal Lift 600 60 10.4

150 35 11.0

WINDOW LIFTS

All Models

Type Motor Series Wound Rated Voltage 12 Maximum Stall Current 25 amps at 8.9 volts

MyMopar.com

CHRYSLER SERVICE MANUAL

ELECTRICAL SYSTEM

Servicing the electrical system for the 1959 Chrysler and Imperial Models is the same as for the 1958 models with the following added information.

SPEEDOMETER REMOVAL Chrysler—Disconnect battery. Disconnect speedom-

eter cable housing. Remove the two nuts and washers from the rear of the speedometer. Slide speedometer out the rear of panel.

Imperial—Disconnect battery. Disconnect speedom-

eter cable housing. Remove 7 screws from the rear of speedometer and pull out speedometer from rear of panel.

SIX-WAY ELECTRIC POWER SEAT — OPTIONAL The six-way electric power seat is driven by a two-

way electric motor which operates through a solenoid and clutch assembly that supplies power through

ELECTRICAL SYSTEM—33

flexible cables to slave units located in the seat tracks.

The control switch is located on the left side of the front seat and is wired through relay to a 40 amp circuit breaker which is located behind the left front kick panel.

CONTROL CIRCUITS Power is supplied to the motor relay from the circuit

breaker. Three wires go to the switch from the motor relay.

One wire (red) is used for power and two wires

(white and blue) are used for directional control of

the motor.

Three additional wires go from the switch (yellow, green and brown) to the solenoid and clutch assembly which control movement of front, rear and horizontal risers. (See chart below.)

For Forward Horizontal

For Forward Tilt

[Red

Connect Wires<j White

[Green

For Rearward Horizontal

fRed

Connect Wires^j Blue

Green

REMOVAL

CABLES — POWER SEAT

Refer to the Chrysler Service Manual D-16350 for removing and installing the power seat flexible cables.

Seat guides should be in the up and forward position

when installing cables. Make sure guides are at the same position (in alignment).

REMOVAL AND INSTALLATION OF MOTOR — POWER SEATS

Removal—Disconnect the motor wires at relay. Re-

move the two nuts holding the motor to the drive

unit. Remove the motor from drive unit and rubber coupling.

AND

INSTALLATION OF FLEXIBLE

CAUTION:

Connect

For Rearward Tilt

Connect Wires^j White

For Straight Up

[Red

Wires*)

White

[Yellow

fRed [Brown

Installation—Install rubber coupling on motor shaft.

Align rubber coupling with the slot on the slave unit shaft. Install motor and reconnect wires to relay.

DRIVE UNIT AND SOLENOID ASSEMBLY POWER SEATS

Disassembly—Remove the drive unit from the seat assembly. Remove the two screws holding plate and solenoids to the drive unit. Remove the plate and so-

lenoid assembly. Be careful not to lose the three

springs under the solenoid when removing the sole-

noid coils. Bend back the tabs of the solenoid cover.

Unsolder the coil ground wire at the cover tab. Remove the cover from the coil. Remove the screws holding the cover on the drive unit. Remove the cover and lift out the clutch lever and shaft.

Assembly—Install the clutch lever and shaft. Make

sure the lever is properly seated on the drive collar.

Connect Wires J White

For Straight Down

Connect Wires j Blue

fRed

I Yellow

[Brown

[Red

I

Yellow

[Brown

—

MyMopar.com

RT. PARK & T/SIG. LAMP

RT. AUTO. DOOR I

| 9* CA

18

RADIO

LAMP

YELLOW-4 p*<*

GLOVE BOX SW.

181 YELLOW

r

.RT. MAP LP.

-CIGAR LIGHTER

FUSE BLOCK

RT.

DUAL HEADLAMP

SP.

EQ. HORN

t=Q

HORNS

16 DK. GREEN

LT.

DUAL HEADLAMPS

LT.

PARK & T/SIG. LAMP

IGNITION DISTRIBUTOR

RADIO CONDENSER

TEMP.

GAUGE

SENDING

UNIT

18 VIOLET

GENERATOR

HORN RELAY

"18 TAN"

-16 BLACK

18 LT. GREEN"

BATTERY

GENERATOR REGULATOR/GRD.

0«

12 RED

16 BROWN-

-16 RED-

18 YELLOW

18 DK. GREEN

STARTEI

RELAY

GRD.

NEUTRAL SAFETY SWITCH

WIPER

IGNITION

COIL RESISTOR

LAMP^

ITCH-

NOTE: 18-BLACK CIRCUIT

WITHOUT POWER STEERING

STARTER MOTOR &

STARTER SOLENOID

SER

12 BROWI

tfpPIp

—18 BLACK-

18 DK. BLUE

VIOIET_10 RED

t—12 BLACK

BATT.

ARM

MOTOR

COIL

LUE

18D

TO SEAT ADJ. SW.

¥*** SIGNAL LAMP SWITCH

TAN TO W/LIFT SW.

18 ORANGE

r-18 YELLOW-

BACK UP LP. SW.

LT. AUTO. DOOR SWITCH

PUSH BUTTON

"GEAR

SHIFT LP.

OIL GAUGE FUEL GAUGE

,RT. T/SIG. LP.

-2I T/SIG. SW.

LT. MAP LP. HI BEAM IND. LP. CLOCK LP. HANDBRAKE IND. LAMP LT. T/SIG. LP.

I—LJ

18 LT. BLUE

-18 BLACK-^

14 LT. GREEN-

18 WHITE-

DISCONNECT

TO HORN

BUTTON

REAR WINDOW DEFROSTER SW.

REAR OF FRONT SEAT

CIGAR LIGHTER MC3

4 DR. SEDAN 4 DR. HT.

4 DR. SUB.

fT8 PINK

18 VifrlTE

•-C/LITER

-DOME CLOCK

••RR. A/C

-RADIO

*B/UP LP

RR. DEFR

Fig. 30 — Chassis and Instrument Panel Wiring Diagram — Models MC-1, 2 and 3

59x58

MyMopar.com

RT.

PARK & T/SIG. LAMP

TRIAD HORN

IGNITION DISTRIBUTOR

2 4 6 8

SPARK PLUGS

13 5 7,

RADIO CONDENSER

TEMPERATURE GAUGE

IGNITION COIL

COIL RESISTOR

TURN SIGNAL RELAY

16

BLUE

"YELLOW

TURN SIG.

..AUTO.

RT. DOOR

GLOVE BOX

LAMP MAP

SW

SW.

TURN

SIG.

AUTO.

SW.

SWIT

A/C & HTR. RR. A/C

RADIO REAR WINDOW

INSTRUMENT PANEL

R

DEFROSTER MOTOR

REAR WINDOW

REAR SHELF PANEL

LT.

PARK &

r/SIG. LAMP

16 LT.

-IB— ROWN SAFETY

ROWN-0*-

I NEUTRAL

12BLXCK SWITCH

., HAND BRAKE

AD

ARM

- LAMP FLASHER

BATT.

WINDOW LIFT,

RD

„'

SEAT ADJUSTER

ELD

CIGAR LIGHTER

MYI-L CLOTH TRIM 4

Fig. 31

—Chassis

FOOT DIMMER

1 REQ'D. 2 REQ'D

GREEN

SWITCH

CIRCUIT BREAKERS

LEATHER TRIM

14 LT. GR

and

Instrument

-18 BRO

HAND BRAKE SW.

•TO REAR SEAT CIGAR LIGHTER

LT.

DOOR SW.

FO SEAT ADJ.

Panel

Wiring

BUTTON

R SHIFT LP.

MANUAL T/SIG.

CANCELING SW

Diagram — Model

LT.

f'/SIG. LP.

DO.

MY-1

LAMP

w/s

WASHER

SWITCH

6 RED

BLUE

6

BLACK

16

YELLOW

59x59

MyMopar.com

36—ELECTRICAL SYSTEM

LOCK RELAY

BATTERY

C/LITER C/B 8 AMP.

S/ADJ. C/B 40 AMP

W/L C/B. 30 AMP.

12-LT. BLUE CIRCUIT GOES TO W/LIFT

C/B ON 4 D'RS

& C/LT'R.

C/B ON 2 D'RS.

-14 YELLOW

RT. FRT.

SW. &

PINK

14 VIOLET

14 VIOLET-

PINK

GRAY-

14 WHITE-

16 ORANGE-pn—UNLOCK

12 LT. BLUE+M—FEED 16 PINK 1£*—LOCK

12 ORANGE

RT.

14 DK. BLUE p [_

LT.

FRT. DR.

BLACK-

•VIOLET-L-T

14

RT.

FRT.

DOOR LOCK

14

LT.

GREEN

FRT.

DOOR LOCK SOLENOID

LT.

FRT.

LT.

FRT.

DOOR LOCK

14 BROWN-|o f>T

MASTER

SW. & MTR.

ORANGE-

14 WHITE

SW

RT.

RR.

CIGAR LIGHTER

LT.

RR.

CIGAR LIGHTER

14

LT.

GREEN-

ORANGE

DOOR LOCK SOLENOID

SW.

CHRYSLER SERVICE MANUAL

^^---RT.

fff—

rtsJ

ff=] ORANGE

rty RED

J SW.

RR. SW. & MTR

GRAY-*

DK.

GREENL

\T. RR.

DR.

GRAY-foj

RT.

RR.

DOOR

LOCK SOLENOID

LT.

RR.

DOOR

LOCK SOLENOID

ORANGEF~~|

Fig.

32 — Window Lifts, Cigar Lighter and Electric Door Locks Wiring Diagram

Install the cover and screws. Install the coil in the coil cover with the coil ground wire next to one of the tabs. Position the cover tabs in the slots on the coil plate. Bend over the tabs and solder the coil ground wire to the tab and plate.

Install the three solenoid springs and position the solenoids over the springs. Fasten the solenoids to the drive unit. Install the drive unit.

REMOVAL AND INSTALLATION OF SLAVE UNIT — POWER SEATS

Remove the drive unit and cables. With the seat guide in the up and forward position, remove the long clevis pin from the front of the guide.

Remove the front rack clevis pin. To facilitate the

POWER SEAT SERVICE DIAGNOSIS

ENTIRE UNIT INOPERATIVE

Remove all wires from seat switch and connect to-

gether as shown in the chart for the six various con-

trols operations, if the operation is normal, by

connecting wires. Replace switch.

MOTOR INOPERATIVE

removal of the slave unit, remove the slave unit cap.

Do not lose the springs under the cap. The springs

are between the racks and slave cap. Remove the

nuts holding the slave unit to the guide. Remove

unit. Installation—Position the slave unit over the studs

on the guide base. Position the racks in the slave

unit so they will be in the up and forward position.

Fasten the racks to the guide assembly. Position the

springs on the rack and install slave unit cap. Install the slave unit mounting nuts. Install the front guide clevis pin. Install cables in slots and check the operation of power seats. Install drive unit and cables.

Figures 30, 31 and 32 show new wiring diagrams

for Chrysler and Imperial cars for 1959.

does not light, check for continuity in #10 red feed wire,

faulty circuit breaker or poor connection between circuit breaker and starter relay. If test light lights,

connect #10 red feed wire with red and black or red and green wires from motor. If motor runs, relay was faulty, replace relay. If motor does not

run, the motor is faulty, replace motor.

Check red wire at relay with test light. If test light

SEAT INOPERATIVE (MOTOR RUNS)

MyMopar.com

CHRYSLER SERVICE MANUAL

ELECTRICAL SYSTEM—37

Jump wire from #10 feed wire to each solenoid

terminal on clutch assembly. Solenoids should each

"click" as jumper is connected. If solenoid does not

click:

(a) Check wire in harness for open circuit. Re-

pair.

(b) Possible seized solenoid armature in coil. Re-

place coil.

(c) Possible burned-out solenoid. Replace sole-

noid.

SEAT INOPERATIVE (MOTOR RUNS SOLENOIDS CLICK)

Check drive unit for stripped or broken gear. Replace drive unit if necessary.

SLAVE UNIT INOPERATIVE (MOTOR, SOLENOIDS & DRIVE UNIT O. K.)

Check for broken drive cable and replace as necessary.

SEAT HAS ROCKING MOTION

&

(e) Remove horizontal stops located on slide at

(D).

(f) Separate seat slide (C) from base (N) by pressing slide rearward which will allow rollers (A) to jump retaining rivets (E, F, G, H) thereby separating slide from base.

(g) Remove rivet (F) and replace with 5/16-18

x 1/2" cap screw (1) to retain proper position.

NOTE: A frayed drive cable may be repaired by

applying light coating of solder and then grinding to cable size.

SEAT TRACK EXCESSIVELY LOOSE

Due to loose rivet joints.

(a) Disassemble upper track seat support (B) by

removing cotter keys and pins.

(b) Remove seat support and tighten all riveted

joints (J) by peening with a ball peen hammer.

LOOSE FRONT LEVERS

Excessive movement between slide and base of track

assembly. This condition is possible due to roller

being out of position.

(a) Remove power seat assembly from vehicle. (b) Remove seat drive tubes from slave unit.

CAUTION:

Do not run motor with drive cables and tubes disassembled or unit will be placed out of synchroni-

zation.

(c) Remove seat support (B).

(d) Remove seat slave unit from seat track slide

(C).

RESISTANCE TYPE SPARK PLUG CABLES

All 1959 Chrysler and Imperial engines incorporate

conventional spark plugs (without resistors), along

with resistance type spark plug cables to eliminate radio interference.

Arc weld front levers (K) to prevent movement between the two sections comprising the front lever assembly.

SEAT CHUCK FORE AND AFT

Due to loose horizontal rack support arm to lower track base.

(a) Remove seat track assembly from vehicle and

arc weld.

(b) Tighten rack attaching pins (M) by arc weld-

ing.

(c) Check for loose horizontal rack in slave unit

gear train. If loose, replace slave unit.

the center of conventional spark plug cable. Full

contact is made between the core and terminals by means of a short wire pin pushed into the ends of the cable.

For identification purposes, this new cable has

"RADIO" printed on it.

The new cable uses a graphite or composition type

conducting core replacing the copper wire found in

Precautions must be observed in handling to prevent damage to the core. The cable should be removed from the spark plug by grasping the cable

cover and pulling straight off with a steady, even

MyMopar.com

38—ELECTRIGAL SYSTEM

CHRYSLER SERVICE MANUAL

pull. Pulling sideways could jam the terminal on the

spark plug and cause the cable

to

separate from the terminal. The cable terminal should not be crimped to

the

point that excessive force

move

it

from the spark plug.

The cables should never

be

is

required

removed

by

to re-

giving them a quick jerk. Doing so can stretch the core and cause a high resistance or open circuit.

core

is

suspected, a resistance check with

meter should be made. The resistance

If a

damaged

an

of

the various

ohm-

plug cables will vary because of the different lengths, see chart below:

SPARK PLUG CABLES WITH

BUILT-IN RESISTANCE

No. 1 Cable No. 2 Cable 5,500 No. 3 Cable 8,100 No. 4 Cable 6,000 No. 5 Cable

No. 6 Cable 6,300 No. 7 Cable 9,400 No. 8 Cable 7,200

8,300

8,800

to

16,600 Ohms

to

11,000 Ohms

to

16,200 Ohms

to

12,000 Ohms

to

17,600 Ohms

to

12,600 Ohms

to

18,800 Ohms

to

14,400 Ohms

If any cable has appreciably more resistance than

specified, check tact with the pin and the pins the core. stalled specified,

If

and the

the

to

be sure the terminals are

is in

full contact with

in

the terminals and pins are properly

cable resistance

cable should

is

be

replaced with

still more than

a new

con-

in-

resistance type cable.

A new terminal should never

be

attached

to the

resistance core cables unless the wire pin is in place; otherwise, contact will core. This will result

core which will cause engine malfunctioning

not be

in

maintained with

arcing and burning

the

of the

and

radio interference.

CAUTION

Resistor type spark plugs

the

new

resistance type cable.

of

the

spark plugs

may ignition system. When replacing a spark plug, sure

to

use the

correct type specified

are

never

to be

used with

The

added resistance

cause malfunctioning

for

of

the be

the par-

ticular engine.

SERVICE DIAGNOSIS

If the radio develops excessive noise pronounced engine miss, check

for

or if

faulty

there

or

is a

broken

cables.

THE AUTOMATIC BEAM CHANGER

The automatic beam changer

light control unit which senses the headlight intensity from other vehicles the headlights ed,)

to

the upper

(of

or

the vehicle

lower beam position.

A scanner and base assembly (Fig. 33),

ed on top

of

the instrument panel, directly of the steering column. The control unit Fig. 33 mounted on a convenient structural part (grounding purposes)

of

the vehicle's body. (Figure 34).

OPERATION

The Automatic Beam Changer will change the headlight

to

the "lower beam" when

approached

at

a distance The unit will reset the headlights to the "high beam" position within 1/2 second after the approaching car has passed.

The headlight beam setting can be interrupted by using the conventional dimmer switch. an "upper beam" setting and

is an

and

automatic head-

automatically adjusts

in

which

it is

mount-

is

in

an

oncoming car

of

approximately 1200 feet.

If

the unit has

the

driver feels that

mount-

front

is

A0JUSTIN8 KNOB

Fig.

33 — Scanner

—LOCKING-SCREW

SCANNER

CONTROL UNIT

and

Control Unit

MyMopar.com

CHRYSLER SERVICE MANUAL

ELECTRICAL SYSTEM—39

"SCANNER"

INSTRUMENT

PANEL

Fig.

34 — Location

AIMING

of

Beam Changer Control Unit

THE

AUTOMATIC BEAM CHANGER

PRE-AIMING INSTRUCTIONS

Before attempting to aim the automatic beam changer, complete the following pre-aiming instructions.

Place vehicle on a level floor. If the vehicle is placed in an area in which the

floor is not level, it will be necessary to take this condition into consideration when "aiming" the "scanner" unit. Refer to aiming the "scanner" unit.

Check front spring height. Adjust to specifications —if necessary.

Check tire inflation. Tire pressure should not vary

more than 3-5 pounds among tires. Rock vehicle sideways to allow spring shackles,

et cetera to assume a normal position. If gasoline tank is not full, place a 100 pound

weight in trunk of vehicle.

There should be no other load in the vehicle, other

than the driver.

the "lower beam" is required, he can override the

automatic control by depressing the dimmer switch to obtain the "lower beam" condition, Automatic operation is restored when the driver again depresses the dimmer switch.

DRIVER ADJUSTMENTS A knob, located at the rear of the scanner unit (Fig.

33),

provides a sensitivity adjustment. If the headlights do not change beam quickly enough upon approaching another car, it is an indication that sensitivity is set too low and correction is made by turning

the scanner knob clockwise (to the right).

If the headlights "change beam" too soon, the sensitivity can be decreased by turning the scanner knob counter-clockwise (to the left).

33) just enough to permit free movement of the "scanner" through its arc, as controlled by the mounting base. (Total angular deflection of the "scanner" unit is six degrees).

Using headlamp aimer kit, Tool C-3674, use the split image transit and target assembly to determine slope of floor, as outlined in the directions contained in the aimer kit.

Move "scanner" forward or backwards on base

(through arc) to bring the leading edge of the bubble of "scanner" aimer, Tool C-3697, in alignment with the proper "plus" or "minus" value (on level dial) which was obtained from the transit of aimer kit, Tool C-3674.

Example: If transit indicates that a minus 2 correction for slope is necessary, bring leading edge, of bubble of aimer Tool, C-3697, to the minus 2 index

TOOL

AIMING

THE

"SCANNER" UNIT

Vertical alignment of the "scanner" unit is critical.

Mount "scanner" aimer, Tool C-3697, on the "scanner" unit, as shown in Figure 35. Make sure that all

conditions listed under "pre-aiming instructions" have been performed, before proceeding with the aiming operation.

Loosen the cross-recess head locking screw (Fig.

LOCKING

BASE

Fig.

35 — Mounting Scanner Aimer Tool

SCREW

"SCANNER'

MyMopar.com

40—ELECTRICAL SYSTEM

line.

(Figure 35). Tighten locking screw (Fig. securely and then recheck position tion

of

bubble

has

changed, loosen locking screw

of

bubble.

If

33)

posi-

THE ELECTRONIC REAR VIEW MIRROR

("MIRROR-MATIC")

The electronically operated rear view mirror

ror-matic),

as

shown

in Fig. 36 is a

self-dimming

rear view mirror which provides maximum rear-

ward vision

face

of the

light strikes

at

night, since

mirror

its

is in use

surface.

the

bright reflection

except when glaring

The electronic glare detecting mechanism housed entirely within is selected

by a

three-position switch

the mirror bezel (Fig. 36).

the

mirror case. Sensitivity

on the

"Off"

locks the mirror

the normal "bright" position. Selection

"City" ror to respond to glare conditions.

sitive when "City"

response

or

"Hi-way" switch position permits

It is

has

been selected

to

neon signs, streetlights, etc.

less light-sen-

and

minimum. OPERATION

The heart

(FIG.

of the

37)

automatic tripping mechanism tiny photo-electric cell which "sees" through a small aperture

Light striking

in the

silvered mirror surface

the

cell generates a small voltage which increases with increasing light intensity. When

the

light intensity becomes high enough

cause annoying glare,

vate a miniature amplifier

which pulls

to reflect

glass

and

the

a dim

into

the present, the mirror will remain returning immediately tion when

the

glare drops below a pre-set level.

the

voltage

prism mirror

image

off the

driver's eyes.

to its

is

enough

and

solenoid assembly

a few

degrees upward

front surface

As

long

in its

"dim" position,

normal "bright" posi-

DRIVER ADJUSTMENT (POSITIONING MIRROR)

When adjusting the position

LIGHT SENSITIVE

CELL

of

mirror-matic

(mir-

sur-

is

front of

in

of

either

the

mir-

therefore

is

held

to a

is a

(Fig. 36).

to

acti-

of the

as

glare

is

for

best

CHRYSLER SERVICE MANUAL

slightly and make necessary correction ble once more into desired position. Retighten lock-

ing screw securely and remove "scanner" aimer Tool.

LIGHT-SENSITIVE CELL / SURFACE

Fig.

visibility, first turn

SILVERED MIRROR

BRIGHT REFLECTION

FRONT SURFACE

OF

MIRROR

"OFF"

POSITION

"CITY" OR "HI-WAY" POSITION

MIRROR-MATIC ELECTRONIC REARVIEW MIRROR

37

— Positioning Mirror

off

the headlights (headlight cir-

DIM

cuit energizes mirror system) and brightest image.

When adjustment lock mirror -in position wise)

at the

mirror support base.

for

best visibility

by

turning lock

SERVICE ADJUSTMENTS If a glare condition exists with

set either

indication that these positions

Sensitivity

adjustment

in

the "City"

the

is too low.

can be

at the

or

sensitivity

raised

mirror assembly

the

"Hi-way" position,

in

by

making

(a) Remove plastic knob from 3-position switch

(Fig.

36) by

carefully pulling outward

plastic knob.

to

NON-GLARE

REFLECTION

in

Operation

set

the mirror

is

nut

switch (Fig.

either

or

an

as

follows:

POTENTIOMETERS

bring bub-

I BRIGHT \ LIGHT

1

RAYS

for

obtained,

(clock-

37)

it is an

both

of

internal

on

Fig.

36

— Mirror-Matte Rear View Mirror

Fig.

38

— Mirror-Matic Back Cover

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—41

(b) Remove the two screws and remove bezel by

lifting bezel outward and upward (to clear metal retaining tabs).

(c) Expose internal mechanism of mirror assem-

bly by lifting top portion of back cover up-

ward (to clear metal retaining tabs) and

moving back cover rearward over mirror support. Move back cover rearward only far enough to provide access to potentiometer adjusters (Fig. 38).

(d) To increase sensitivity of the "City" position,

turn the arm of the potentiometer marked "City" in the direction indicated by the arrow.

(e) To increase sensitivity for "Hi-way" driving,

turn the arm of the potentiometer marked

"Hi-way" in the direction indicated by the

arrow.

Section VII

ENGINE

DATA AND SPECIFICATIONS

NOTE: To decrease sensitivity of either or both the

potentiometers, turn potentiometer arms in the di-

rection opposite to direction indicated by arrow.

(f) Replace back cover by positioning back cover

over the two metal tabs and aligning screw holes in bottom of cover with threaded holes in mirror support.

(g) Install bezel by aligning slots at top of bezel

with metal tabs and aligning screw holes in bottom of bezel with threaded holes in mirror support replace screws (Fig. 36) and

tighten securely. (h) Replace plastic switch knob. (i) Adjust mirror to desired position and test

operation of unit.

ENGINE

Type Number of Cylinders Bore—MC-1,

Stroke Piston Displacement—MC-1, MC-2

Compression Ratio Compression Pressure at 150 rpm (plugs removed) Wide Open Throttle Maximum Variation Between Cylinders (any one engine) Firing Order

CYLINDER NUMBERING

Left Bank Right Bank

CRANKSHAFT

Type Bearings Journal Diameter

Crank Pin Diameter

Maximum Out-of-Round Permissible Number Main Bearings

Diametral Clearance Desired End Play Thrust Taken By

Finish at Rear Seal Surface

Interchangeability of Bearings

MC-3,

MC-2 MY-1

MC-3,

MY-1

90° V

8

4.031"

4.188"

3.750"

383 cu. in.

413 cu. in.

10.0 to 1

150 to 180 lbs.

25 lbs.

1-8-4-3-6-5-7-2

1-3-5-7

2-4-6-8

Fully Counter-Balanced

Steel Backed Babbitt

2.7495 to 2.7505"

2.374 to 2.375" .001"

5

.0005 to .0015"

.002 to .007"

No.

3 Main Bearing

Diagonal Knurling Upper Nos. 1, 2, 4, 5 Lower Nos. 1, 2, 4, 5

MyMopar.com

42—ENGINE

CHRYSLER SERVICE MANUAL

ENGINE (Cont'd)

MAIN BEARINGS (Service) All Available in Standard and the following

Undersizes .001, .002, .003, .010, .012"

CONNECTING RODS AND BEARINGS

Type Drop Forged "I" Beam Length (Center to Center) 6.766—.770" Weight (less bearing shells) 29.4 oz. Bearings Steel-Backed Babbitt Diameter and Length 2.375 x .927" Diametral Clearance Desired .0005 to .0015" Maximum Allowable before Reconditioning .0025" Side Clearance .009 to .017" Bearings for Service Standard .001, .002, .003,

.010,

.012" U.S.

Piston Pin Bore Diameter

CAMSHAFT

Drive Chain Bearings Steel Backed Babbitt Number 5 Thrust Taken by Cylinder Block Diametral Clearance .001 to .003" Maximum Allowable before Reconditioning .005"

1.0925

to 1.0928"

CAMSHAFT BEARING JOURNALS

Diameter

No.

1 1.998 to 1.999" No. 2 1.982 to 1.983" No. 3 1.967 to 1.968" No. 4 1.951 to 1.952" No. 5 1.748 to 1.749"

CAMSHAFT BEARINGS

Diameter (after reaming)

No.

1 2.000 to

No.

2 1.984 to

No.

3 1.969 to

No.

4 1.953 to

No.

5 1.750 to 1.751"

TIMING CHAIN

Adjustment None Number of Links , 50 Pitch .50" Width .88"

TAPPETS

Type Hydraulic

Clearance in Block .0005 to .0015"

Body Diameter .9040 to .9045"

Clearance Between Valve Stem and Rocker Arm Pad Dry Lash

.060 to .210"

2.001"

1.985"

1.970"

1.954"

PISTONS

Type Horizontal Slot w/Steel Struts Material Aluminum Alloy Tin Coated

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—43

ENGINE (Cont'd)

Land Clearance (diametral) Clearance at Top of Skirt Weight (std. through .040 oversize)

MC-1,

MC-2

MC-3,

MY-1 Piston Length (overall) Ring Groove Depth

No.

1—MC-1

No.

2—MC-1

No.

3—MC-1

Pistons for Service

PISTON PINS

Type Diameter Length Clearance in Piston Interference in Rod Piston Pins for Service. . . Direction Offset in Piston

PISTON RINGS

Number of Rings per Piston. Compression Oil Width of Rings (Compression)

(Oil)

Piston Ring Gaps (all)

& MC-2

MC-3 & MY-1

&MC-2

MC-3 & MY-1

& MC-2

MC-3 & MY-1

.041 to .047"

.0005 to .0010"

724 gms.

780 gms.

3.95" .213"

.216" .213" .216" .195" .200"

Std. .005, .020, .040" O.S.

Press Fit in Rod

1.0935

to

1.0937"

3.4440

to 3.450"

.00045 to .00075"

.0007 to .0012" Standard Only

Toward Right Side of Engine

3 2

1

.0775 to .0780" .1860 to .1865"

.013 to .025"

RING SIDE CLEARANCE

(Compression)

Upper Intermediate

(Oil)

VALVES—Intake

Material Head Diameter

Length (to top of valve face) Stem Diameter Stem to Guide Clearance

Maximum Allowable Before Reconditioning. Angle of Seat Adjustment

Lift

VALVES—Exhaust

Material

Head Diameter.

MC-1, MC-3,

MC-2 MY-1

.0015 to .0030" .0015 to .0030"

.0010 to .0030"

Silicon—Chromium Steel

1.95"

2.08"

4.79"

.372 to .373"

.001 to .003"

.004"

45°

None

.389"

Nitrogen Treated Manganese

Chromium—Nickel Steel

1.60"

MyMopar.com

44—ENGINE

CHRYSLER SERVICE MANUAL

ENGINE (Cont'd)

Length (to top of valve face) 4.79" Stem Diameter .371 to .372" Stem to Guide Clearance .002 to .004"

Maximum Allowable Before Reconditioning .006" Angle of Seat 45° Adjustment None

Lift .389"

VALVE SPRINGS

Number 16

Free Length 2.34"

Load when Compressed to (valve closed)

Load when Compressed to (valve open)

Valve Springs I.D 1.010 to

CYLINDER HEAD

Number Used 2

Combustion Chamber Wedge Type

Valve Seat Runout (maximum) .002'

Intake Valve Seat Angle 45 Seat Width (finished) .060 to .085" Exhaust Valve Seat Angle 45° Seat Width (finished) .040 to .060" Cylinder Head Gasket Compressed (thickness) .022"

1.860"

1.470"

@ 95 —105 lbs. @ 188—252 lbs.

1.030"

C

•o

ENGINE LUBRICATION

Pump Type Rotary, Full Pressure

Capacity (qts.) 5* Pump Drive Camshaft Operating Pressure at 40 to 50 mph 45 to 70 lbs. Pressure Drop Resulting from Clogged Filter 7 to 9 lbs.

*When Filter Element is Replaced, add 1 qt.

TIGHTENING REFERENCE

Torque Thread

Foot-Pounds Size

Connecting Rod Nut—Plain Connecting Rod Nut—CST (Black) Cylinder Head Bolt Main Bearing Cap Bolt Spark Plug

Camshaft Lockbolt Carburetor to Manifold Nut Chain Case Cover Bolt Torque Converter Housing Bolt Clutch Housing Bolt Crankshaft Rear Bearing Seal Retainer Crankshaft Bolt Cylinder Head Cover Stud and Nut Distributor Vacuum Line Tube Nut Distributor Clamp Bolt

45 40

70 85 30

35

7

15 30 30 30

135

40 in.-lbs.

95 in.-lbs.

15

^8-24 ^-24

%-14

J4-13

14 mr %>—14 %-24

5

/i6-18

•HJ-16

^-16

%~1Q

%-W

J4-28

^-24 ^fi-18

MyMopar.com

CHRYSLER SERVICE MANUAL

TIGHTENING REFERENCE (Cont'd)

Engine Front Mounting to Frame Nut 85 Engine Front Mounting to Block Nut „ 45 Exhaust Manifold Bolt „ 30 Exhaust Pipe Flange Nut 40 Exhaust Pipe Clamp Bolt 20 Exhaust Pipe Support Clamp Bolt 20 Fan Attaching Bolt 15-18 Fan Belt Idler Pulley Nut . 45 Fan Belt Idler Pulley Bracket Bolt 30 Flywheel Housing to Cylinder Block Bolt 50 Flywheel Housing Cover Bolt , 7 Fuel Pump Attaching Bolt 30 Generator Bracket Bolt 50 Generator Mounting Nut 20 Generator Adjusting Strap Bolt . 15

Generator Adjusting Strap Mounting Bolt 30 Intake Manifold Bolt 40 Manifold Heat Control Counterweight Bolt 50 in.-lbs. Oil Pan Drain Plug 35 Oil Pan Bolt 15 Oil Pump Cover Bolt 15 Oil Pump Attaching Bolt 35 Oil Filter Attaching Stud 30 Rocker Shaft Bracket Bolt 30 Starter Mounting Bolt 50 Vibration Damper Bolt 15 Valve Tappet Cover End Bolt 8 Water Pump to Housing Bolt 30 Water Pump Housing to Cylinder Block Bolt 30 A/C Compressor to Engine Bolt 30

ENGINE—45

#10-32

56-16

ENGINE

The new V-8 Engine, as shown in Figure 39, 40 and

41,

ia one of the finest, most efficient engines to be

designed by Chrysler Engineering. It contains many weight reducing features.

Some of the new features, as shown in Figures

42,

43 and 44, are in-line overhead valves, wedge

shaped combustion chambers, full length cylinder

water jackets, rigid crankshaft and series flow cool-

ing system. In addition, the volume of coolant in the engine has been reduced to improve engine warm up.

The ignition distributor is located at the upper

front end of the engine for easier servicing.

The lubrication system consists of an externally mounted rotor type oil pump of greater capacity, full flow oil filter and a series of passages where the oil is delivered to the engine. The oil filter can be installed by hand.

The engine has 10:1 compression ratio, is equipped

with a dual carburetor on the Windsor Model

(MC-1),

els,

tional smoothness and performance throughout the

entire speed range.

MINOR TUNE UP

A periodic engine tune up will assure maximum engine performance and fuel economy. The following procedures should be followed when performing minor engine tune up.

sary and clean and tighten battery connections. Clean and adjust the spark plugs (.035 inch gap). Tighten to 30 foot-pounds torque with Tool C-3054. Adjust the distributor contact points (.015 to .018

and a 4-barrel carburetor on all other mod-

and uses premium fuel. The engine has excep-

Check battery specific gravity, add water if neces-

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46—ENGINE

CHRYSLER SERVICE MANUAL

Fig.

39 — Chrysler Engine Assembly

59x151

Fig.

40 — Engine End Sectional View

59x54

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—47

inch gap). Install new points if necessary. Check the distributor cap for cracks and corrosion,. Inspect the rotor, rotor spring and plunger. Inspect the distributor to spark plug wires for brittle, cracked or frayed insulation. Inspect small lead wires for tightness,

or damaged insulation. Check for excessive play in distributor vacuum advance plate bearing. Install a new plate if necessary. Reset the ignition timing. Inspect accessory belt drives referring to "Accessory Belt Drives," for proper adjustments.

Tighten the carburetor flange nuts to 7 foot-pounds torque. Set carburetor idle mixture adjustment. Ad-

just the throttle stop screw so engine idles at 450 to

500 rpm. Check manifold heat control valve in the right exhaust manifold for proper operation and

apply Manifold Heat Control Valve Solvent Part

Number 1879318 to the bushing and shaft, as shown in Lubrication Section.

MAJOR

TUNE

UP

Perform all the steps of a "Minor Tune Up" and in addition, the following procedures should be followed when performing Major Engine Tune Up.

Tighten the manifold nuts. Perform the cylinder compression test. Compression pressures can be read from the top side of engine without interference using a 30 degree bend extension on, the gauge. The compression should not vary more than 25 pounds between cylinders.

Refer to specifications for compression pressures. Test the coil, and condenser. Inspect the primary and secondary wires. Service the air cleaner — DO NOT WASH OR OIL. Service more frequently under severe dusty conditions. Replace air cleaner filter cart-

ridge every 15,000 miles. Test fuel pump for pressure and vacuum. Refer to Fuel Section Specifications. Perform a combustion analysis. Adjust the

carburetor. Road test the car as a final check.

REMOVAL OF

THE

ENGINE ASSEMBLY (From Car)

Drain the cooling system and remove the battery. Remove the fan shroud and radiator. Scribe the outline of hinge brackets on hood to assure proper adjustment when installing. Remove the hood. Disconnect fuel lines and wires attached to engine units.

Fig.

41 —

Engine Side Sectional View

58x135

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48—ENGINE

CHRYSLER SERVICE MANUAL

O>

MyMopar.com

CHRYSLER SERVICE MANUAL

Fig.

42 — Engine External Parts

1.

Carburetor Air Cleaner

2.

Coil

3. Vacuum Line

4.

Wiring Harness (bracket)

5. Fuel Line

6. Tappet Chamber Cover and Intake Manifold Gasket

7. Reinforcement, silencer and

Retainer

8. Wiring Harness (brackets)

9. Oil Filler Cap

10.

Rocker Cover L

11.

Rocker Cover Gasket L

12.

Spark Plug Heat Shield

13.

Cylinder Head L

14.

Oil Level Indicator

15.

Exhaust Manifold L

16.

Oil Level Indicator Tube

17.

Cylinder Head Gasket

18.

Distributor Clamp

19.

Water Pump Housing Gasket

20.

Oil Pump Housing Gasket

21.

Outlet Elbow

22.

Outlet Elbow Gasket

23.

Thermostat

24.

Temperature Sending Unit

25.

Water Pump Housing

26.

Water Pump Body Gasket

27.

Water Pump Body

28.

Hub

29.

Water Pump Pulley

30.

Bolt

31.

Washer

32.

Crankshaft Pulley

33.

Vibration Damper

34.

Oil Filter

35.

Oil Pump

36.

Chain Case Cover

37.

Chain Case Cover Gasket

38.

Oil Pan Gasket

39.

Oil Pan

40.

Chain Case Cover Oil Seal

41.

Cylinder Block

42.

Oil Screen Suction Pipe

43.

Fuel Pump

44.

Fuel Pump Gasket

45.

Exhaust Manifold

46.

Starter

47.

Solenoid

48.

Torque Converter Housing Dust Shield

49.

Generator Bracket

50.

Ring Gear

51.

Torque Converter

52.

Torque Converter Housing

53.

Manifold Heat Control Valve

54.

Spark Plug

55.

Spark Plug Heat Shield

R

ENGINE—49

56.

Cylinder Head R

57.

Crankcase Vent Tube

58.

Rocker Cover Gasket

59.

Rocker Cover

60.

Wiring Harness (brackets)

61.

Crankcase Vent Tube Cap

62.

Generator

63.

Distributor Gasket

64.

Distributor

65.

Wires

66.

Reinforcement

67.

Generator Adjusting Strap

68.

Intake Manifold

69.

Automatic Choke

70.

Control Spring Bracket

71.

Carburetor Gasket

72.

Carburetor

73.

Carburetor Air Cleaner Gasket

R

Remove the air cleaner and carburetor. Attach the engine lifting fixture Tool C-3466 to carburetor flange studs on the intake manifold and attach a

chain hoist to the fixture eyebolt. Disconnect the pro-

peller shaft, wires and linkage at transmission. Disconnect exhaust pipes at manifolds. Be sure the exhaust system is sufficiently supported while the en-

gine is removed. Remove rear crossmember to transmission support attaching bolts.

NOTE: Place a roUaway jack under the transmission

RIGHT BANK

LUBRICATION

NO.

4 CAMSHAFT

BEARING

to relieve weight from the crossmember. Place a wood block between jack and transmission to avoid

damaging transmission oil pan.

The jack supports the weight of rear of engine and must be able to roll with the power plant as it is removed from the chassis. Remove rear crossmember engine support. Remove front engine mounting nuts.

Raise the engine with chain hoist and work

the engine out of the chassis. Remove transmission.

Place the engine in repair stand C-3167 and Adapter

ROCKER SHAFT

ROCKER ARM

RIGHT MAIN OIL GALLERY

OIL FILTER

Oil PUMP RELIEF VALVE

Fig.

OIL PRESSURE

43 — Engine Oiling System

LEFT ROCKER SHAFT

59x24

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50—ENGINE

CHRYSLER SERVICE MANUAL

WASHER

CAMSHAFT

BOLT\

RETAINER

SPACER

ROCKER

BRACKET

GEARAND SHAFT

SPROCKET

CHAIN

BOLT

(SERVICED IN PACKAGE)

OIL SEAL

RETAINER -

SCREW

CAP

SCREW

NUT

CAP

Fig.

44 — Engine Internal Parts

BEARING

CRANKSHAFT

SPROCKET OIL SLINGER

_~-—~—SCREW

CAP {SERVICED IN ROD)

59x53

MyMopar.com

CHRYSLER SERVICE MANUAL

3662 for disassembly using the transmission mounting bolts.

INSTALLING THE ENGINE ASSEMBLY (In Car)

Remove the engine from repair stand and install transmission. Install the engine lifting fixture Tool

C-3466 and attach the chain hoist to fixture eyebolt. Raise the engine. Lower the engine carefully into the car until front and rear of engine are approxi-

mately positioned. Place a rollaway jack under the

transmission to support the weight of rear of the engine. Install the engine rear support crossmember. Position the engine and install the nuts at front en-

gine mounts. Position and install rear engine sup-

port bolts and remove the jack, hoist and engine

lifting fixture.

Install the carburetor, fuel lines, wiring and link-

age.

Install the radiator, fan shroud and radiator

hoses.

Connect exhaust pipes, using new gaskets. Install the hood, being sure to align hood by the scribe marks placed on the inside of hood at disassembly. Connect the propeller shaft at the transmission. Connect linkage and wires. Be sure all drain cocks are closed, and fill cooling system. Fill the engine crankcase and transmission. Refer to the lubrication Section for quantities and lubricants to use. Check the entire system for leaks and correct as necessary.

NOTE: Whenever an engine has been rebuilt and a

new camshaft and/or new tappets have been installed, add one quart of factory recommended oil additive

to engine oil to aid break-in (MoPar Engine Oil Additive, Part No. 1643234). The oil mixture should

be left in engine for a minimum of 500 miles, and

drained at the next normal oil change.

INTAKE VALVES

&&^5>-

k:a

EXHAUST

VALVES

ENGINE—51

58x137

Fig.

46 — Tightening Sequence

Start the engine and run until normal operating" temperature is reached. Check the timing and adjust carburetor as necessary. Road test the car.

CYLINDER HEADS

The chrome alloy cast iron cylinder heads as shown in Figure 45 are held in place by 17 bolts. The spark

plugs enter the cylinder head horizontally and are

located at the wide edge of the combustion, chambers.

a. Removal

Drain the cooling system. Remove generator, carburetor air cleaner and fuel line. Disconnect the accel-

erator linkage. Remove the vacuum control tube at carburetor and distributor. Disconnect the distrib-

utor cap, coil wires and heater hose. Disconnect the

heat indicator sending unit wire. Remove spark plugs located under the manifolds. Remove the in-

take manifold, ignition coil and carburetor as an assembly. Remove the tappet chamber cover. Remove cylinder head covers and gaskets.

NOTE: On air conditioned cars, number eight cyl-

inder exhaust valve must be open to allow clearance

between the right bank cylinder head cover and the heater housing.

Remove the generator. Remove exhaust manifolds. Remove the rocker arms and shaft assembly. Remove the push rods and place them in their respective slots in holder Tool C-3068. Remove the 17 head bolts from each cylinder head and remove cylinder heads.

Place cylinder head in holding fixture Tool

C-3626.

Fig.

45 — Cylinder Heads

58x136

b.

Installation

Clean the gasket surfaces of cylinder block and cyl-

inder head. Check all surfaces with a straight edge

if there is any reason to suspect leakage. Coat the

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52—ENGINE

CHRYSLER SERVICE MANUAL

EXHAUST MANIFOLD - RiGHT

, TOOL

mam*

V> X 1

M

Fig.

47 — Checking Cylinder Head Bolt Torque

new gaskets with a suitable sealer, MoPar Part Number 1122893. Install heads.

Install cylinder head bolts. Starting center, tighten pounds torque

all

cylinder head bolts

in

sequence, and using Tool C-3666 Figure 47.

Repeat

the

procedure, retightening to 70 foot-pounds torque. Inspect push rods place worn small ends rod,

as

or

in

shown

bent rods. Install push rods with tappets maintaining alignment using in

Figure 48.

Install the rocker arm and shaft assembly starting

each push

rod

into

its

NOTE: Use extreme care pounds torque,

so the

down to their operating length. Bulged tappet bodies,

CYLINDER HEAD INTAKE PUSH RODS ASSEMBLIES

the

gaskets

as

shown

to

check torque,

and

in

all

respective rocker

in

tightening bolts

tappets have time

cylinder

at top

to 70

Figure

as

shown

head bolts

and re-

arm

socket.

30

to

bleed

foot-

46,

in

the

foot-

LOCATING ARROW ROCKER ARMS-RIGHT

;

• . ROCKER ARMS-RIGHT

58xl?9

Fig.

bent push rods, may result

if

the tappets are forced down too rapidly.

LOCATIMOARROW

49 — Rocker Arms Installed

and

permanently noisy operation

i

Place the new cylinder head cover gaskets in posi-

tion

and

install cylinder head covers. Tighten

the bolts to 40 inch-pounds torque. Install exhaust manifolds and tighten the bolts Adjust spark plugs plugs,

and

tighten

to

to 30 Tool C-3054. Install tighten end bolts

to 8

Install intake manifold, carburetor

coil

as an

assembly and tighten manifold bolts

to

30 foot-pounds torque.

.035 inch

gap and

install

foot-pounds torque with

the

tappet chamber cover

foot-pounds torque (Fig.

and

the

and

49).

ignition

to 40

food-pounds torque. Install the distributor cap. Con-

nect

the

coil wire, heat indicator sending unit wire, accelerator linkage, spark plug cables and insulators. Install

the

vacuum tube from carburetor

to

distributor. Install generator and tighten generator bracket bolts to 50 foot-pounds torque, and generator mounting nut to 20 foot-pounds torque. Install the fuel line and carburetor Adjust belt tensions Drives"

in

air

cleaner. Fill

as

outlined

this supplement.

the

cooling system.

in

"Accessory Belt

INSTALLING

ROD

EXHAUST PUSH RODS "58x138

Fig.

48 — Push Rods Installed

-BRACKETS-

OIL FEED GROOVE THIS SIDE

58x140

Fig.

50 — Rocker Arms & Shaft Assembly

OIL FEED GROOVE THIS SIDE

SPACERS-

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—53

ROCKER ARMS The rocker arms

AND

SHAFT ASSEMBLY

are of

stamped steel

and are arranged on one rocker arm shaft, per cylinder head. The push rod angularity tends

to

force the pairs of

rocker arms toward each other where oilite spacers

carry the side thrust

ets attach each rocker shaft

at

each rocker arm. Five brack-

to

the cylinder head.

a. Removal Remove cylinder head cover and gasket. Remove the

bolts that attach rocker

arm

support brackets

to cylinder head and remove the rocker arms, brackets and shaft as an assembly.

If the rocker arm assemblies have been disassem-

bled

for

cleaning, inspection,

to Figure 49 and 50 b.

Installation

NOTE: The right and left rocker arms must be in-

stalled on rocker shaft, as shown in Figure 49. The

stamped arrow on rocker shaft must be on top and the arrow must point toward the push rod socket of

the rocker arm. This is necessary to provide proper lubrication to the rocker assemblies. The two wide brackets must be installed with the oil feed grooves facing the push rod side of rocker arm, as shown in Figures 49 and 50.

Install

the

rocker arms, brackets,

for

or

replacement, refer

proper reassembly.

and

shaft

as-

sembly.

NOTE: Use extreme care

in

tightening the bolts

so

"OOU

58x142

Fig.

52 —

Using Sleeve Tool

in

Checking Wear

that tappets have time to bleed down to their operating length. Bulged tappet bodies, bent push rods and

permanent noisy operation may result

if

the tappets

are forced down too rapidly.

Tighten the bolts

VALVES

AND

to

30 foot-pounds torque.

VALVE SPRINGS

Valves are arranged in-line in the cylinder heads and

inclined 30° outward from vertical. Intake and

ex-

haust valves operate in guides that are integral with

the heads. a. Removal

With

the

cylinder head removed, compress valve

springs using

Tool.

C-3422, as shown in Figure 51.

CYLINDER HEAD

ASSEMBLY

Fig.

51

— Compressing Valve Spring

TOOL

REPAIR" STAND

(TOOL)

58x141

Remove

the

valve retaining locks, valve spring retainers, valve stem cup seals and valve springs. Remove the burrs from valve stem lock grooves to pre-

vent damage

to

the valve guide when valves are re-

moved.

b.

Valve Inspection

Clean

the

valves thoroughly,

and

discard burned, warped and cracked valves. Measure valve stems for wear. Intake valve stem diameter should measure .372

to

.373 inch

should measure .371 to .372 inch.

and

exhaust valve stem diameter

If

the wear exceeds .002 inch, replace the valve. Remove carbon and varnish deposits from

the

inside

of

valve guides with

cleaner, Tool C-756.

Measure

the

valve stem guide clearance

as fol-

lows : Install sleeve Tool C-3026 over the valve stem,

as shown in Figure 52, and install valve.

MyMopar.com

54—ENGINE

CHRYSLER SERVICE MANUAL

VALVE

58x143

Fig.

53 — Measuring Guide Wear

The special sleeve places the valve at the correct height for checking with a dial indicator. Attach the dial indicator Tool C-3339 to cylinder head and set it at right angle of the valve stem being measured

(Fig. 53).

Move valve to and from the indicator. The total dial indicator reading should not exceed .010 inch on intake valves, and .014 inch on exhaust valves. Ream

the guides for valves with oversize stems if dial indi-

cator reading is excessive or if the stems are scuffed

or scored.

Service valves with oversize stems are available in .005,

.015 and .030 inch oversizes. Reamers to accom-

modate the oversize valve stem are as follows: Ream-

er Tool C-3433 (.379 to .380 inch) Reamer Tool C3427 (.404 to .405 inch). Slowly turn reamer by hand

and clean guide thoroughly before installing new

valve.

CAUTION

Do not attempt to ream the valve guides from standard directly to .030 inch. Use step procedure of .005,

MARGIN

FACE

VALVE

MAXIMUM MEASUREMENT 58x144A

Fig.

55 — Measuring Valve Stem Length

TOOL

^MINIMUM MEASUREMENT

.015 and .030 inch so the valve guides may be reamed true in relation to the valve seat.

c. Referring valves

and

valve seats

The intake and exhaust valve faces have a 45° de-

gree angle. Always inspect the remaining margin

after the valves are refaced (Fig. 54). Valves with less than 3/64 inch margin should be discarded.

The angle of both valve and seat should be identi-

cal.

When refacing the valve seats with Tool MTH-

80,

it is important that the correct size valve guide

pilot be used for reseating stones. A true and com-

plete surface must be obtained. Measure the concentricity of valve seat using a dial indicator. The total runout should not exceed .002 inch (total indicator

reading). When the seat is properly positioned, the width of intake seats should be 1/16 to 3/32 inch. The width of exhaust seats should be 3/64 to 1/16 inch.

When the valves and seats are reground, the position of the valve in the cylinder head is changed, shortening the operating length of hydraulic tappet. This means that the plunger is operating closer to its bottomed position, and less clearance is available for thermal expansion of valve mechanism during

STEM-

VALVE SPRING RETAINER

LOCK GROOVES

Fig.

54 — Intake and Exhaust Valve

54x33CC

VAtve

SPRiNG

Fig.

56 — Checking Valve Spring Squareness

MyMopar.com

CHRYSLER SERVICE MANUAL

high speed driving. The design of the valve mechanism includes a safety factor to allow for a limited amount of wear, and the refacing of valves and seats.

To insure that the limits have not been exceeded, the dimension from valve spring seat in head to valve tip should be measured with Gauge, Tool C-

3648,

as shown in Figure 55.

The end of the cylindrical gauge and the bottom of slotted area represent the maximum and minimum allowable extension of valve stem tip beyond the spring seat. If the tip exceeds maximum, grind the stem tip to within gauge limits. Clean tappets if tip grinding is required.

Fig.

58 — Installing Valves and Cup Seals

ENGINE—55

d. Testing Valve Springs

Whenever the valves have been removed for inspection, reconditioning or replacement, the valve springs should be tested. To test a spring, first determine the length at which the spring is to be tested. As an example, the compressed length of the spring

to be tested is C-647 until surface is in line with the

1-15/32

inches. Turn the table of Tool

1-15/32

inch mark on the threaded stud and the zero mark to the front. Place spring over stud on table and lift the compressing lever to set the tone device. Pull on torque wrench until a ping is heard. Take the reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at the

test length. Fractional measurements are indicated

on the table for finer adjustments. The valve springs should test 183 to 202 lbs. when compressed to 115/32 inch. Discard springs that do not meet these

specifications.

Inspect each valve spring for squareness with a

RETAINER

steel square and surface plate, as shown in Figure

56. If the spring is more than 1/16 inch out of square,

install a new spring.

e. Installation

Coat the valve stems with lubricating oil and insert

them in position in cylinder head. Install the cup

seals on intake and exhaust valve stems and over valve guides, as shown in Figure 57 and 58 and install valve springs and retainers.

Compress the valve springs with Tool C-3422. In-

stall locks and release tool.

NOTE: measure the installed height of springs. Make sure

measurement is taken from the bottom of the spring seat in cylinder head to the bottom surface of spring

retainer. (If spacers are installed, measure from the

top of spacer.) If height is greater than inches, install a 1/16 inch spacer in head counterbore to bring spring height back to normal to

If the valves and/or seats are reground,

1-57/64

inch.

1-57/64

1-53/64

EXHAUST

VALVE

INTAKE VALVE

Fig.

57 — Valve Assembly

SPRING

59x51

HYDRAULIC TAPPETS

a. Preliminary to Checking Hydraulic Tappets

Before disassembling any part of engine to correct

tappet noise, read the oil pressure at gauge and

check the oil level in the oil pan. The pressure should be between 45 and 70 pounds at 2000 rpm. The oil level in the pan should never be above "full" mark

on dip stick, or below "add oil" mark. Either of these two conditions could be responsible for noisy tappets.

Oil Level Too High — If oil level is above "full" mark on dip-stick, it is possible for the connecting

MyMopar.com

56—ENGINE

CHRYSLER SERVICE MANUAL

rods to dip into oil while the engine is running and create foam. Foam in the oil pan would be fed to the hydraulic tappets by the oil pump causing them to go flat and allowing the valves to seat noisily.

Oil Level Too Low — Low oil level may allow the oil

pump to take in air which, when fed to tappets,

causes them to lose length and allows the valves to

seat noisily. Any leaks on intake side of the pump through which air can be drawn will create the same tappet action. When tappet noise is due to aeration,

it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and

leaks have been corrected, the engine should be op-

erated at fast idle for sufficient time to allow all of

air inside of tappets to be bled out.

b.

Tappet Noises

To determine the source of tappet noise, operate the

engine at idle with the cylinder head covers re-

moved. Feel each valve spring or rocker arm to de-

tect the noisy tappet. The noisy tappet will cause

the affected spring and/or rocker arm to vibrate or

feel rough in operation.

NOTE:

sometimes mistaken for noisy tappets. If such is the

case, noise may be dampened by applying side thrust on valve spring. Inspect rocker arm push rod sockets and push rod ends for wear. If noise is not apprecia-

bly reduced, it can be assumed the noise is in the tappet.

heavy click. A light noise is usually caused by exces-

Worn valve guides or cocked springs are

Valve tappet noise ranges from a light noise to a

CYLINDER HEAD

ASSEMBLY

HYDRAULIC TAPPET

f 7*-PLUNGER RETAINING SPRING CLIP

v—'

y%+

-PLUNGER

VALVE SPRING-

VALVE RETAINER*

PLUNGER SPRING-

52x389B

Fig.

TAPPET BODY

60 — Hydraulic Tappet Assembly

CAP

TAPPET PLUNGER

FLAT VALVE

sive leakdown around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet check valve not seating, or by foreign particles becoming wedged between the plunger and tappet body, causing plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between valve stem and rocker arm as valve closes. In either case, the tappet assembly should be removed for inspection and cleaning.

c. Removal of Tappets

Tappets can be removed without removing the intake manifold by following this recommended procedure: remove the cylinder head covers. Remove rocker arms and shaft assembly. Remove the push rods and place them in their respective holes in Tool

C-3068. Slide puller Tool C-3661 through push rod

opening in cylinder head and seat tool firmly in the

head of tappet. Pull tappet out of bore with a twist-

ing motion, as shown in Figure 59.

Fig.

59 — Removing Tappet

If all tappets are to be removed, remove the hydraulic tappets and place them in their respective holes in tappet and push rod holder, Tool C-3068. This will insure installation of the tappets in their

original locations.

NOTE: engine numbering pad indicates that all tappet bodies are .008 inch oversize, see Figure 84.

Do not disassemble a tappet on a dirty work bench. 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 tap-

A diamond shaped marking stamped on the

CAUTION

MyMopar.com

CHRYSLER SERVICE MANUAL

3160,

in the

Engage ger. Check leakdown ger collapses almost instantly plied, disassemble tappet, clean tappet still does cleaning, install

groove

jaw of

of

tappet body

pliers with

by

compressing pliers.

not

operate satisfactorily after

a new

tappet assembly.

top of the

as

and

h. Installation Lubricate

the

tappets. Install tappets in their original positions. Install and shaft assembly. Start Warm

up to

normal operating temperature.

and

operate

ENGINE—57

(Fig. 61).

tappet plun-

If

pressure

test again.

and

the

is ap-

push rods

rocker

the

engine.

plun-

If the

arm

51x971D

Fig.

61 — Testing Tappet

pet

at a

time

to

avoid mixing

are

not

compatable.

d.

Disassembly

Pry

out

plunger retainer spring clip. Clean nish deposits from the plunger

plunger

cap,

(Fig.

60)

the

inside

cap.

Invert

the

plunger, flat check valve, check valve spring, check valve retainer Separate valve spring. Place

in

the

e. Cleaning

Clean all varnish unfit semble

f.

Inspection

If

the

scuffed,

the

plunger, check valve retainer

all

parts

tappet holder Tool C-3068.

and

Assembly

all

tappet parts

and

carbon. Replace

for

further service with

the

tappets,

tappet

or

shows signs

as

bore

in a

shown

in

of next oversize, using Tool C-3028. signs

of

scoring

the valve seat

or

wear

on end of

plunger indicates

of

parts. Mixed parts

the var-

of

tappet body above

tappet body

and

in

their respective place

and

remove

plunger spring.

and

check

solvent that will remove

the

tappets that

new

assemblies.

in

Figure

cylinder block sticking, ream

and

valve

56.

is

scored,

the

bore

If

plunger shows

is

pitted,

any

or if

condi-

are

As-

to

tion that would prevent valve from seating, install

a

new

tappet assembly.

NOTE: engine must hydraulic tappets have filled with

To

prevent damage

not be run

to

valve mechanism,

above fast idle until

oil and

come quiet.

CHECKING

Turn crankshaft until full open

Insert

pad

and the ond valve so that er

as spring load a solid tappet. Zero

Turn direction) until intake valve The timing

VALVE

and the

a *4

stern

on the

the

plunger contacts

nearly perpendicular

to

the

crankshaft clockwise (normal running

on the

TIMING

the No. 1

No. 1 piston

exhaust valve

is on TDC.

inch spacer between

tip of the No. 1

intake valve

left bank). Install a dial indicator

the

valve spring retain-

as

possible. Allow

bleed

the

tappet down giving

the

indicator.

has

lifted

timing indicator, located chain case cover, should read from 2° ATDC. limits:

timing chain

the

DC shaft counter-clockwise until remove

If the

Check

mark

the

spacer.

reading

the

sprocket index marks, inspect

for

wear,

on the

is not

and

within

check

timing indicator. Turn crank-

the

valve

-CHAIN CASE COVER

- - TIMING INDICATOR

- -CYLINDER BLOCK

- TIMING MARK

VIBRATION DAMPER

the

10°

the

have

rocker

in

.013

on the

BTDC

the

specified

accuracy

is

closed

the

all of

be-

is

arm

(sec-

the

effect

inch.

to

the

of

and

g. Testing

Fill

a pan

plunger

with clean kerosene. Remove

and

completely submerge

upright position.

Allow tappet and replace position

and

the cap.

insert

cap

the

tappet

to

fill with kerosene, remove tappet,

Hold

the

lower

tappet

jaw of

in an

upright

pliers, Tool

from

in an

C-

^

Fig.

62 — Removing Vibration Damper Assembly

MyMopar.com

58x149A

58—ENGINE

CHRYSLER SERVICE MANUAL

CAUTION

Do not turn crankshaft any further clockwise as the valve spring might bottom and result in serious damage.

TIMING SPROCKETS AND CHAIN

The timing chain has 50 links of i/2 inch pitch and is %

inch wide. Chain stretch is reduced because of

fewer joints to wear.

a. Removal Drain the cooling system. Remove the radiator and

water pump assembly. Remove the bolt holding vibration damper on crankshaft. Remove two of the

pulley bolts, install Tool C-3033, and pull the damper assembly off the end of crankshaft, as shown in Figure 62.

Remove the chain cover and gasket. Slide the

crankshaft oil slinger off end of crankshaft. Remove the camshaft sprocket attaching bolt. Remove timing chain with crankshaft and camshaft sprockets.

b.

Installation

Place both the camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. Place the timing chain around

both sprockets. Turn the crankshaft and camshaft to line up with the keyway location in crankshaft sprocket and the dowel holes in the camshaft sprocket.

Lift the sprockets and chain, (keep sprockets

tight against the chain in position as described).

Slide both sprockets evenly over their respective shafts.

Use a straight edge to check alignment of

the timing marks (Fig. 63). Install the washer and

TORQUE WRENCH

58x151

Fig.

64

— Measuring Chain Stretch

camshaft sprocket bolt and tighten to 35 foot-pounds torque.

c. Checking Timing Chain for Stretch

Place a scale next to timing chain so that any move-

ment of the chain may be measured. Place a torque wrench and socket over the camshaft sprocket attaching bolt and apply torque in the direction of

crankshaft rotation to take up the slack; 30 foot-

pounds torque (with cylinder heads installed) or

15 foot-pounds torque (cylinder heads removed).

Holding a scale with dimensional reading even with edge of a chain link, apply torque in the reverse di-

rection 30 foot-pounds (with cylinder heads in-

stalled) or 15 foot-pounds (cylinder heads removed),

and note the amount of chain movement, as shown in Figure 64. Install a new timing chain, if its movement exceeds 11/64 inch.

CAMSHAFT SPROCKET

CRANKSHAFT SPROCKET

Fig.

63

— Alignment

of

Timing Marks

58x150

NOTE:

With a torque applied to camshaft sprocket

bolt, the crankshaft should not be permitted to move.

It may be necessary to block the crankshaft to pre-

vent rotation.

If chain is satisfactory, slide the crankshaft oil

slinger over shaft and up against the sprocket

(flange away from sprocket.)

TIMING CHAIN

CASE

COVER OIL SEAL

REPLACEMENT a. Removal

Position puller screw of Tool C-3506 through case cover, the inside of case cover up. Position the puller blocks directly opposite each other, and force the angular lip between neoprene and flange of the seal retainer. Place washer and nut on puller screw.

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—59

PULLER BLOCKS (TOOL)

CHAIN CASE COVER

V

'. "

'.V-*.-

Fig.

65 — Puller Blocks Expanded to Pulling Position

/ '•

'^.?!^^T

>--•

LIP

OF

SEAL

RETAINER

58x152

Tighten the nut as tight as possible by hand, forcing

blocks into tainer only positioned retainer

into sleeve. Place

screw. Hold to remove seal (Fig.

b.

Installation of Oil Seal

gap to a

lip (Fig. 65).

at

this point). Place sleeve over

and

place removing

the

center screw

point

of

This

is

flat washer

66).

distorting

the

seal

important (puller and

installing plate

and nut on

and

tighten lock

puller

re is

the

nut

Insert puller screw through removing and installing plate

so

that

the

thin shoulder will

Insert puller screw with plate through

opening (inside

the seal

in

of

chain case cover facing up). Place

cover opening, with neoprene down. Place

be

facing

the

up.

seal

the seal installing plate into the new seal, with pro-

tective recess toward

Install the flat washer and

screw

and

tighten

The seal

is

properly installed when neoprene tight against the face inch feeler gauge between neoprene and cover

69).

If

the seal is installed properly, the feeler gauge

lip of

the nut

of

cover. Try

seal retainer (Fig.

nut

on puller screw, hold

(Fig.

68).

to

insert a .0015

67).

is

(Fig.

cannot be inserted.

PULLER SCRFW (TOOL) REMOVING

INSTALLING PLATE (TOOL)

AND

•- \

INSTALLING PLATE (TOOL)

SEAL"

ASSEMBLY

Fig.

67 — Positioning Installer Plate on New Seal

NOTE: collected between oil slinger after

It is

normal

the

to

find particles

seal retainer

seal has been

c. Installing Chain Case Cover

Be sure the mating surfaces cylinder block

PULLER SCREW (TOOL)

SEAL' RETAINER

SEAL

are

clean and free from burrs. Using

7

-: 58x155

Fig.

68 — Installing New Seal

FEELER GAUGE?

PULLER SCREW (TOOL)

CHAIN CASE COVER

58x154

of

neoprene

and

crankshaft

in

operation.

of

chain case cover and

INSTALLING PLATE (TOOL)

CHAIN CASE COVER

SLEEVE (TOOL)

^ "••*'

Fig.

66 — Removing Oil Seal

CHAIN CASE

COVER

58x153

CHAIN CASE

Fig.

69 — Checking Seal for Proper Seating

MyMopar.com

60—ENGINE

CHRYSLER SERVICE MANUAL

A

CHAIN CASE COVER

TIMING INDICATOR CYLINDER BLOCK TIMING MARK

VIBRATION DAMPER

/

TOOL

58x157A

Fig.

70 — Installing Vibration Damper Assembly

a new gasket slide the chain case cover over the locating dowels and tighten bolts to 15 foot-pounds torque.

d. Installing Vibration Damper

Place the damper hub key in slot in crankshaft, and

slide hub on crankshaft. Place the installing tool,

part of Puller set Tool C-3033 in position and press damper hub on the crankshaft (Fig. 70). Slide the pulley over the shaft and attach with bolts and lockwashers. Tighten the bolts to 15 foot-pounds torque. Install damper hub retainer washer and bolts. Tighten to 135 foot-pounds torque.

CAMSHAFT

The camshaft has an integral oil pump and distributor drive gear and fuel pump eccentric, as shown in Figure 71.

Rearward camshaft thrust is taken by the rear face of the cast iron camshaft sprocket hub, bearing directly on the front of the cylinder block, eliminating the need for a thrust plate. The helical oil pump and distributor drive gear and the camshaft lobe taper both tend to produce only a rearward thrust.

58x159

Fig.

72 — Removing Distributor Drive Shaft Bushing

tor drive shaft. Remove the fuel pump to allow the

push rod to drop away from the cam eccentric. Re-

move the camshaft being careful not to damage the

cam bearings with the cam lobes.

DISTRIBUTOR DRIVE SHAFT BUSHINGS a. Removal

Insert Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 72). Hold the puller screw and tighten puller nut until bushing is re-

moved.

b.

Installation

Slide new bushing over burnishing end of Tool C3053 and insert the tool and bushing into bore, as shown in Figure 73.

Drive bushing and tool into position, using a soft hammer. As the burnisher is pulled through bushing by tightening puller nut, the bushing is expanded tight in block and burnished to correct size, as shown in Figure 74. DO NOT REAM THIS BUSHING.

Removal

With the tappets and timing sprockets removed, remove distributor and lift out oil pump and distribu-

BOIT

WASHER

Fig.

CAMSHAFT SPROCKET CAMSHAFT

-DISTRIBUTOR DRIVE GEAR (CAMSHAFT;

FUEL PUMP ECCENTRIC (CAMSHAFT)

LOCATING DOWEL

71 — Camshaft and Sprocket Assembly

BUSHING

TOOL

Fig.

73 — Installing Distributor Drive Shaft Bushing

MyMopar.com

'•**?*

58x160

A*v

CHRYSLER SERVICE MANUAL

ENGINE—61

^58x161

Fig.

74

— Burnishing Distributor Drive Shaft Bushing

c. Camshaft Installation Lubricate the camshaft lobes and camshaft bearing

journals and insert the camshaft to within 2 inches of its final position in the cylinder block. Modify Tool C-3509 by grinding off the index lug holding

upper arm on the tool and rotate arm 180°. Install Tool C-3509 in place of distributor drive gear and shaft, as shown in Figure 75. Hold the tool in posi-

tion with distributor lock plate screw. This tool will restrict the camshaft from being pushed in too far and prevent knocking out the welch plug in the rear

of

the

cylinder block.

stalled until

the

The

camshaft

tool should remain

and

crankshaft sprockets

in-

and timing chain have been installed.

NOTE:

new camshaft and/or stalled,

tive should in.

minimum next normal

Whenever

one

The oil

TOOL

an

engine

quart

of

factory recommended

be

added

to

mixture should

of 500

miles. Drain

oil

change.

has

been rebuilt

new

tappets have been

the engine

be

left

oil to

in the

the oil

oil

aid

in

engine

mixture

ARM (TOOL)

and a

in-

addi-

break-

for a

at the

DISTRIBUTOR

CENTER LINE

Fig.

NOTE:

Whenever

the tappet faces must straight edge. served,

the

AND OIL

PUMP DRIVE

GEAR

OF

CRANKSHAFT

76

— Distributor Drive Gear Installation

the

camshaft

be

inspected

If any

tappet must

negative crown (dish)

be

d. Distributor (Basic) Timing

Before installing

shaft, time engine until

No. 1

stroke. When

the

as

cylinder

in

this position,

distributor follows: Rotate

is at top

the vibration damper should timing indicator. Coat shaft gine

oil.

Install rals into place, that

the

slot

center line

e. Installation

Hold distributor over block with center

of

ward

and to the tower terminal utor gasket

the

shaft

so

it

will index with

in

top

of

drive gear will

of

crankshaft

of

Distributor

the

vacuum chamber pointing toward

engine. Turn

as

the

mounting

approximate location

in the

in

position. Lower distributor

distributor cap. Place distrib-

is

replaced,

for

replaced.

and oil

dead center

the

straight line

be

under

and

drive gear with

that after

oil

be

shown

in

pad on

rotor until

all of

crown with

is ob-

pump drive

the

crankshaft

on

firing (DC) on the the

gear

pump shaft,

parallel with

Figure

76.

cylinder

it

points

for-

of the No. 1

and en-

a

on

en-

spi-

so

the

DISTRIBUTOR DRIVE GEAR (CAMSHAFT)

Fig.

75

— Camshaft Holding Tool

-C

58x162

Fig.

CRANKSHAFT MAIN BEARING

BEARING

77 —

OIL

HOLE]

Removing Camshaft Bearing

OIL

HOLE

58x164

MyMopar.com

62—ENGINE

CHRYSLER SERVICE MANUAL

gage shaft in slot of distributor drive shaft gear.

Turn distributor clockwise until the breaker contacts

are just separating and install hold down clamp.

REMOVAL AND INSTALLATION OF CAMSHAFT BEARINGS (Engine Removed from Car)

a. Removal

With the engine completely disassembled, drive out

the rear cam bearing welch plug. Install proper size

adapters and horse shoe washers (part of Tool C3132A) at back of each bearing shell to be removed and drive out the bearing shells.

b.

Installation

\

Install the new camshaft bearings with Tool C-3132A by sliding the new camshaft (bearing shell over the proper adapter. Position bearing in the tool. In-

stall horse shoe lock and by reversing removal pro-

cedure, carefully drive bearing sliell into place, as

shown in Figure 77. Install remaining shells in like

manner.

NOTE: Install the No. 1 camshaft bearing 1/32" inward from front face of the cylinder block.

The oil holes in camshaft bearings and cylinder

block must be in exact alignment to insure proper

lubrication (Fig. 77).

Camshaft bearing index can be checked after in-

stallation by inserting a pencil flashlight in the bearing shell. The camshaft bearing oil hole should be perfectly aligned with the drilled oil passage from the main bearing. Another oil hole in the camshaft bearings should be visible by looking down on the left bank oil hole above and between No. 6 and No. 8 cylinders to No. 4 camshaft bearing and on the right bank above and between NoL 5 and 7 cylinders to No. 4 camshaft bearings. If the; camshaft bearing shell oil holes are not in exact Alignment, remove and reinstall them correctly. Use| Tool C-897 to install a new welch plug at the reajr of camshaft. Be sure this plug does not leak.

plugs are installed, coat the edges of plug and core

hole with a suitable sealer and drive plugs in place

with driver, Tool C-897. Examine block for cracks

or fractures. Remove the top ridge of cylinder bores with a reliable ridge rearmer before removing the

pistons from cylinder block. Be sure to keep the tops

of pistons covered during this operation.

NOTE: Pistons and connecting rods must be removed from the top of cylinder block. When removing pis-

ton and connecting rod assemblies from the engine,

rotate crankshaft so each connecting rod is centered in the cylinder bore.

Remove connecting rod cap. Install Tool C-3221 on one connecting rod bolt and protector over the other bolt and push each piston and rod assembly out of the cylinder bore. After removal, install bearing cap on mating rod.

a. Checking Cylinder Bores

The cylinder bores should be checked for

out-ofround and taper with Tool CM-119. If the cylinder bores show more than .005 inch out-of-round or a

taper of more than .010 inch the cylinder block

should be rebored and honed, and new pistons and rings fitted.

b.

Honing Cylinder Bores

To remove light scoring, scuffing, or scratches from

the cylinder walls, use Tool C-823. Usually a few

strokes will clean up a bore and maintain the required

limits.

The cylinder walls should be deglazed, using

cylinder surfacing hone Tool C-3501 equipped with 280 grit stones, prior to installation of the new rings or to smooth down the cylinder walls after rough

honing. A satisfactory finish can be obtained by

PISTON RING

FEELER GAGE

RING GROOVE

x

CYLINDER BLOCK |

The cylinder block is of the deep lj>lock design which eliminates the need for a torque converter housing adapter plate. Its sides extend three inches below the crankshaft centerline.

Cleaning and Inspection j

Clean cylinder block thoroughly ^nd check all core

hole plugs for evidence of leaking. If new core hole

Fig.

78

— Measuring Piston Ring Clearance

58x165

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—63

giving each cylinder wall with

the

hone

so

that a cross hatch pattern will

20

strokes

obtained.

After honing, cleaned again to prevent excessive wear may

be

safely used

inch

and as

it is

to

remove

high

as .010 to

necessary that

all

traces

of

engine parts. The hone

for

removal

.015 inch

enced operator.

CAUTION

Be sure after honing.

soap oughly dried. gine

all

and

water

oil and

abrasives

It is

If

are

removed from engine parts

recommended that a solution

be

used with a brush

this

is

impossible,

CLEAN cloth. When

wiped with a clean white cloth

clean,

the

bore

is

clean.

c. Cylinder Walls Cylinder walls which

scratched,

or

worn beyond specified limits should be rebored. Whatever type used, boring operation should with

the

fitting

of

specified clearance

are

pistons

may be

badly scored, scuffed,

of

boring equipment

be

and

maintained.

d. Fitting Pistons

of

metal

in 20

abrasives,

and

seconds

the

block

up to .005

by an

experi-

then thor-

and

use SAE 10 en-

the

bore

can be

and be

withdrawn

closely coordinated

rings

in

order that

be

of

is

NUT CTOOl)

CONNECTING

58x195A

Fig.

79 — Tool Arrangement of Removing Piston Pin

This measurement

ure

the

side clearance between piston ring

land.

The

clearance should

for

the top

compression ring, .001

the intermediate ring,

ANVIL (TOOL)

PISTON

ROD

GUIDE-LARGE (TOOL)

is the

same

and control ring. Starting with place expander ring install

oil

control ring. Install

in middle

C-3629

3628

NOTE:

sion ring

and top

for the

Be

MC-3

sure

is to the top of

in the

grooves.

MC-1

and

the

mark "Top"

MC-2 engine

MY-1 engine.

piston when

stalled.

PISTON

PILOT (TOOL)

MAIN SCREW (TOOL)

GUIDE-SMALL

(TOOL)

for all

rings. Meas-

and

be .0015 to .003

to

.0025 inch

.001

to .003 for the oil

the oil

ring expander,

lower ring groove

the

compression rings

Use

ring installer, Tool

and

Tool

on

each compres-

the

ring

ring inch

for

and

C-

is in-

The piston The specified clearance between cylinder wall

The piston diameter should

top

of

bores

down

and

cylinder wall must

is

.0005

skirt 90°

on

used engines should

the

to the

cylinder bore

to

.0010 inch.

piston

and

transverse

be

clean

the

piston

be

measured

axis.

The

be

measured halfway

to the

and dry.

and the

at the

cylinder

engine

crankshaft centerline.

NOTE: Pistons ured

at

normal room temperature

All service pistons include pins,

in standard

and

and the

cylinder bores should

be

70° F.

and are

available

following oversizes, .005,

meas-

.020

and .040 inch. e. Fitting Rings

Measure from bottom fitted. (An inverted piston rings down

the

piston ring

of

to

gap

about

cylinder bore

can be

in

two (2)

which

used

inches

it is to be

to

push

insure positioning rings squarely

the

in

the cylinder wall before measuring.) Insert the feeler

stock

in

gap (Fig.

The ring gap should

78). be

between .013

to

.025 inch.

REMOVAL OF PISTON PIN Arrange Tool C-3624 parts

pin,

as

shown

screw. Install

anvil over small

end of

in

Figure 79. Install pilot

the

screw through piston

the

threaded

anvil against

Fig.

80 —

end of the

Removing Piston

for the

the

piston boss.

MAIN SCREW

(TOOL)

removal

of

on the

pin.

piston

main

Install

main screw with

PRESS

PISTON

[58x166

MyMopar.com

64—ENGINE

CHRYSLER SERVICE MANUAL

-«*>^—-—-

58x196 A GUIDE-LARGE (TOOL)

Fig.

81 —

ANVIL (TOOL)

- SPRING

Tool Arrangement

PILOT (TOOL)

PISTON

MAIN SCREW

for

Installing Piston

(TOOL)

GUIDE-SMALL

(TOOL)

NOTE: Be sure spring is removed from the anvil.

Install nut loosely on the main screw and place the

assembly on a press, as shown in Figure 80. Press

the piston pin out of connecting rod.

NOTE: When the pin falls free from connecting rod, stop the press to prevent damage to bottom of the anvil.

Remove the tool from the piston.

INSTALLATION OF PISTON PIN

Check the piston pin fit in the piston. It should be

a sliding fit in the piston at 70

°F.

Piston pins are supplied in standard sizes only. Lubricate piston pin holes in the piston and connecting rod.

Arrange the tool parts for installation of piston pin, as shown in Figure 81. Install the spring inside the pilot and install the spring and pilot in the anvil. Install the piston pin over main screw. Place piston, with "front" up, over pilot so that the pilot extends

Fig.

(TOOL)

83

— Testing

NUT

Fit on

TORQUE WRENCH

SOCKET

ANVfL (TOOt)

MAIN SCREW

(TOOL)

Piston

Pin in

58x168

A

Connecting

Rod

through the piston pin hole. Position connecting rod

over the pilot which extends through the piston hole. NOTE: Assemble rods to pistons of the right cylinder

bank (2, 4, 6, and 8) with the indent on the piston head opposite to the larger chamfer on the large bore end of connecting rod. Assemble the rods to pistons of the left cylinder bank (1, 3, 5, and 7) with the indent on the piston head on the same side as the large chamfer on the large bore end of connecting rod.

Install the main screw and piston pin in the pis-

ton, as shown in Figure 81.

Install the nut on puller screw to hold assembly together. Place assembly on a press, as shown in Figure 82. Press in the piston pin until piston pin bottoms on the pilot properly positioning the pin in the connecting rod. Remove the tool and arrange tool parts and piston assembly in the same manner, as shown in Figure 79.

PISTON

Fig.

PIN «-

82 —

Installing Piston

*

-

PRESS

:

lV>A:N

i

'L*-

-

*• f TOOL)

•• - ANVIL ITOOU

SCREW

PISTON

"58x16?

58x169

Fig.

84

— External Identification

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—65

Place the assembly in a vise, as shown in Figure

83. Attach the torque wrench to nut and check torque

up to 15 foot-pounds torque. If the connecting rod moves downward on piston pin, reject this connecting rod and piston pin combination. Obtain a connecting rod with proper small end bore diameter and repeat the installation, and checking procedure.

If connecting rod does not move under 15 foot-

pounds torque, the piston pin and connecting rod interference is satisfactory, the tool may be removed.

CONNECTING RODS

IMPORTANT

A Maltese Cross stamped on the engine numbering

pad (Fig. 84) indicates that engine is equipped with a crankshaft which has one or more connecting rods and main bearing journals finished .001 inch undersize.

The position of the undersize journal or journals will be stamped on machined surface of No. 3 counterweight (Fig. 85).

Connecting rod journals will be identified by the letter "R" and main bearing journals by the letter "M."

Thus "M-l" indicates that No. 1 main bearing

is .001 inch undersize.

INSTALLING CONNECTING ROD BEARINGS

NOTE: Fit all rods on one bank until completed. Do not alternate from one bank to another, because when the rods are assembled to pistons correctly, they are

not interchangeable from one bank to another.

Each bearing cap has a small "V" groove across the

parting face. When installing the lower bearing shell,

make certain that the "V" groove in shell is in line with "V" groove in cap. This allows lubrication of

the cylinder wall. The bearing shells should always be installed so that small formed tang fits into ma-

LETTERS

( 4

chined grooves of rods. The side play should be from

.009 to .017 inch (two rods).

Limits of taper or out-of-round on any crankshaft journals should be held to .001 inch. Bearings are available in

.001,

.002, .003, .010 and .012 inch under-

size. NOTE: 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. CHECKING THE CONNECTING ROD BEARING

CLEARANCE (PLASTIGAGE METHOD)

Connecting rod bearing clearance measurements can be made by the use of Plastigage with the engine in the chassis. After removing the connecting rod cap, wipe off the oil from the journal and inserts. Place the Plastigage on bearing parallel with crankshaft. Reinstall the cap and tighten attaching nuts alternately to specified torque.

Remove cap and measure the width of the compressed material with the graduated scale to determine the bearing clearance. Allowable clearance is

from .0005 to .0015 inches. If taper of the com-

pressed material is evident, measure with the grad-

uated scale. If the taper appears to exceed .005 inch,

the journal should be checked with micrometers. INSTALLING PISTON AND CONNECTING ROD

ASSEMBLY IN CYLINDER BLOCK Before installing the pistons, rods, and rod assem-

blies in bore, be sure that compression ring gaps are

diametrically opposite one another and not in line with oil ring gap. The oil ring expander gap should be toward the outside of the "V" of the engine. The oil ring gap should be turned toward the inside of the "V" of engine. Immerse the piston head and rings in clean engine oil, slide the ring compressor, Tool C-385, over the piston and tighten with the special wrench (part of Tool C-385). Be sure the position of rings does not change during this oper-

ation. Screw the connecting rod bolt protector (part

of Tool C-3221) on one rod bolt, and insert the rod

and piston into cylinder bore. NOTE: Rotate the crankshaft so that connecting rod

journal is on center of the cylinder bore.

Fig.

85 — Internal Identification

55x162

Attach the puller part of Tool C-3221 on the other bolt, and guide the rod over the crankshaft journal, as shown in Figure 86.

Tap piston down in the cylinder bore, using the

MyMopar.com

66—ENGINE

CHRYSLER SERVICE MANUAL

CRANKSHAFT JOURNAL

Fig.

86 — Removing and Installing Connecting Rod

handle of a hammer. At the same time, guide connecting rod into position on crankshaft journal. The notch or groove on the top of the piston must be pointing toward front of the engine and the larger chamfer of the connecting rod bore must be installed

toward crankshaft journal fillet. Install the rod caps,

tighten nuts to 45 foot-pounds torque.

CRANKSHAFT MAIN JOURNALS

The crankshaft journals should be checked for excessive wear, taper and scoring. Journal grinding should not exceed .012 inch under the standard journal diameter. DO NOT grind the thrust faces of No. 3 main bearing. DO NOT nick the crankpin or main bearing fillets. After regrinding, remove the rough edges from crankshaft oil holes and clean out all oil passages.

CRANKSHAFT MAIN BEARINGS

The lower main bearing halves of 1, 2, 4 and 5 numbers are interchangeable, as shown in Figure 87. The

upper main bearing halves of 1, 2, 4 and 5 numbers

are interchangeable. Upper and lower bearing halves

are not interchangeable because the upper bearing

is grooved and the lower is not.

The upper and lower No. 3 bearing halves are flanged to carry the crankshaft thrust loads and are not interchangeable with any other bearing halves in the engine.

NOTE: Bearings that are not badly worn or pitted must be reinstalled in the same position.

The bearing caps are not interchangeable and should be marked at removal to insure correct assembly. Bearing shells are available in standard and the following undersizes: .001, .002, .003, .010 and .012 inch. Never install an undersize bearing shell

that will reduce the clearance below specifications. REMOVAL AND INSTALLATION OF THE

MAIN BEARINGS

a. Removal Remove the oil pan and mark bearing caps before

removal. Remove bearing caps one at a time. Remove upper half of bearing by inserting Tool C-3059 (Fig.

88) into the oil hole of crankshaft. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.

Checking the Main Bearing Clearance

Plastigage Method. Use the same technique as described in "Checking the Connecting Rod Bearing Clearance."

CAUTION

If bearings are measured with the engine in the chas-

BEARING

m m m.

Fig.

87 — Main Bearing Identification

>THRUST BEARING

UPPER

LOWER

x!72

INSTALLING •[51x93A

Fig.

88 — Removing and Installing Main

Bearing Upper Shell

MyMopar.com

CHRYSLER SERVICE MANUAL

sis,

the

crankshaft must

take

up

clearance between

and

the

crankshaft journal. This

snugging bearing caps

.005

to .015

shell

and

done

to

or bearings,

inch cardboard between lower bearing

journal.

Use

avoid unnecessary strain

or

false reading may

rotate crankshaft while plastigage

be

supported

the

upper bearing insert

can be

of the

adjacent bearings with

extreme caution when this

on the

be

obtained. Do

is

installed.

to remove cardboard before reinstalling

It

is

permissible

bearing shell with

.002 inch bearing shell. Always ameter bearing half bearing with a used bearing

bearing half more than

lower bearing

to use one .001

one

standard bearing shell

as the

.001

half.

inch undersize

use the

upper. Never

and

never

inch smaller than

in

order done

crankshaft

Be

oil pan.

or one

smaller

use a new

use an

to

by

is

not

sure

di-

upper

the

PLUG

GASKET

|CHN»

SPRING

RELIEF VALVE

PLUNGER

58x173

Fig.

SEAL RING

89 — Oil

GASKET

"O"

Pump

BOLTS

AND

RING

and

Filter Assembly

ENGINE—67

WASHERS

OIL FILTER

INNER ROTOR

AND SHAFT

BODY

DRIVE SHAFT

AND GEAR

b.

Installation of the Upper Main Bearing

NOTE: slightly chamfer

the

the crankshaft counter-clockwise sliding into position. After tighten shaft

OIL

When installing

Start bearing

oil

hole

of

all

caps

end

play should

PAN

(ALL MODELS)

a new

the

sharp edge from

in

place,

and

crankshaft

all

bearings have been fitted,

to 85

foot-pounds torque.

be .002 to .007

upper bearing shell,

the

plain side.

insert Tool C-3059 into

(Fig. 88).

Slowly rotate

the

bearing

The

inch.

crank-

a. Removal

Drain

the oil and

steering linkage from steering

steering linkage system, Be sure supported.

the

exhaust crossover pipe must

the

It

located across

allow enough clearance pan attaching bolts only. Disconnect throttle linkage

remove dipstick. Disconnect

arm to

to be

rest

may

the

lowered.

of

exhaust system

be

necessary

to

On

pull

crossmember slightly forward

and

for pan

lower

removal. Remove

the oil pan on MC-1

at

transmission and

the

allow

the

single exhaust

be

removed.

is

sufficiently

the

brake line

to

oil

at carburetor. Rotate the crankshaft until the center-

line

of the position. Remove and raise

b.

Installation

front counterweight

the

front engine mounting nuts

the

engine

one

inch. Remove

is in the 10

the oil pan.

o'clock

attaching bolts. Tighten bolts torque. Lower

mounting nuts

the

and

engine

tighten

to 15

and

install front engine

to 85

foot-pounds torque.

foot-pounds

Connect exhaust pipes (if removed) and steering, throttle and carburetor linkage. Refer to Transmission Section in this manual. Refill the crankcase.

OIL

PUMP

a. Removal

Remove oil pump attaching bolts and remove pump and filter assembly from bottom side of the engine.

b.

Disassembly

Remove the filter base and oil seal ring. Remove pump rotor and shaft and lift out the outer pump rotor. Remove oil pressure relief valve plug and lift out spring and plunger (Fig. 89).

c.

Inspection and Repair

Clean all parts thoroughly. The mating face of oil

IfRAIGHT

/

EDGE

NOTE:

bottom

machined surface

Check

of

the

strainer must

alignment

be on a

of the

cylinder block.

strainer should touch bottom

pan thoroughly

and

install

new

of the oil

strainer.

horizontal plane

The

of the oil pan.

gasket,

oil pan and

The

foot

Clean

of

FEELER

GAUGE

Fig.

90 —

Checking

Oil

Pump Cover Flatness

MyMopar.com

68—ENGINE

CHRYSLER SERVICE MANUAL

STRAIGHT EDGE

FEEIER GAUGE

Fig.

93 — Measuring Clearance over Rotors

51x66A

Fig.

91 —Measuring Outer Rotor Thickness

DIAMETER

pump cover should be smooth. Replace cover if it is scratched or grooved.

Lay a straight edge across the oil pump cover sur-

face (Fig. 90). If a .0015 inch feeler gauge can be

inserted between the cover and straight edge, the cover should be replaced. If outer rotor length meas-

ures less than .943 inch (Fig. 91), and diameter less

than 2.469 inches, replace outer rotor.

If the pump inner rotor length measures less than

.943 inch (Fig. 92) a new pump rotor should be in-

stalled.

Slide outer rotor and inner rotor into pump body and place a straight edge across the face (between the bolt holes), as shown in Figure 93.

If a feeler gauge of more than .004 inch can be

inserted between rotors and straight edge, replace pump body. Remove pump inner rotor and shaft leaving the outer rotor in pump cavity. Press the outer rotor body to one side with fingers and measure the clearance between outer rotor and pump body (Fig. 94). If measurement is more than .012

inch replace the oil pump body. If clearance between inner rotor and outer rotor (Fig. 95) is more than .010 inch, replace the inner and outer rotors.

Check the oil pump relief valve plunger for scoring and for free operation in its bore. If the plunger is scored, replace the plunger. The spring should conform to specifications on chart. If, for any reason, the spring has to be replaced, the same color spring should be used. An exception is where oil

pressure is either above or below specifications.

When assembling oil pump, be sure to use new oil

seal rings between filter base and body. Tighten the attaching bolts to 35 foot-pounds torque.

Installation

Install the oil pump on engine.

OUTER ROTOR

58x176

Fig.

92 — Measuring Inner Rotor Thickness

51x67A

Fig.

94 — Measuring Outer Rotor Clearance

.,- OUTER ROTOR

-INNER ROTOR

FEELER

GAUGE

Fig.

95 — Measuring Clearance Between Rotors

MyMopar.com

58x1,77

CHRYSLER SERVICE MANUAL

OIL FILTER ASSEMBLY

TOOL

58x239

Fig.

96 — Removing

RELIEF VALVE SPRING CHART

Oil

Filter with Tool

ENGINE—69

*

58x238

Fig.

98 — Trimming Rear Main Bearing

Lower Oil Seal

Free Loaded

Color

Gray(Lt.) Red (Std.)

2.19 1.60

2.29 1.60

Brown (Hvy.)....

REMOVAL AND INSTALLATION OF OIL FILTER

Length Length

2.39 1.60

The oil filter should be replaced every coincide with

Use care so as not to damage transmission

an

engine oil change

Compression

Pounds

11.85

14.85

17.9

5,000

as

follows:

to

12.85

to

15.85

to 18.9

miles

oil

cool-

to

er lines. Using Tool C-3654, unscrew the filter from base on bottom side on engine and discard. Wipe the base clean. Screw

new

filter

on

base,

as

shown

in Figure 96, until gasket on filter contacts base. Tighten

y2 turn more by hand. Start engine and check

for

leaks.

BRIDGE

(PART

OF

TOOL)

REPLACEMENT OF THE REAR MAIN BEARING OIL SEAL (Crankshaft Removed)

Remove Allen screws and seal retainer. Install a new rear main bearing

oil

seal

in the

cylinder block

so that both ends protrude. Tap seal down into position, using Tool C-3625 until the tool bore.

Hold tool in this position and cut

seal that extends above the block

NOTE:

Be

sure

the

Install a new seal

bridge

in

the seal retainer so that

ends protrude (Fig. 97). Install bridge

is

seated

on

is

removed from tool.

in

off

portion of

both sides.

on

bearing

the

tool

and

tap the seal down into position with Tool C-3625 un-

til tool is seated. Trim

protrudes above side seals

tainer

in

grooves

and

tighten screws

off

the cap

in

seal retainer. Install seal

OUTER

the portion

of

the seal that

(Fig. 98). Install

to 30

foot-pounds torque.

CUP

INSTALL INDEX MARK TOWARD ENGINE

the two

re-

SEAL

SEAL RETAINER

SIDE GROOVES

Fig.

97 — Installing Rear Main Bearing

Lower Oil Seal

58x237

INSULATOR BOLT ASSEMBLY

58x33

AND

FRAME BRACKET

Fig.

99 — Right Front Engine Support

-.' •£

LOCKWASHER

L- PLATE

NUT

MyMopar.com

70—FUEL

AND

EXHAUST SYSTEM

CHRYSLER SERVICE MANUAL

FRONT ENGINE MOUNTS a. Removal Disconnect throttle linkage at transmission and at

carburetor. Remove the nuts, washers, plates from front engine mounts and raise the engine sufficiently

enough to remove the insulator and stud assembly.

b.

Installation

Install the insulator and stud assembly with the index mark on the insulator facing toward the engine, as shown in Figure 99.

Lower the engine aligning the stud with the slots

in frame brackets.

CAUTION

Be sure

bottom

engine, and tighten nuts to 85 foot-pounds torque.

Connect throttle linkage to transmission and to car-

buretor. Refer to Transmission Section in this manual for adjustment.

the

insulator stud does

of the

Install plates, washers and nuts. Neutralize the

slot

in the

not

frame bracket.

Section VIII

FUEL

Model

FUEL PUMP

Make Carter Model M-2769S Type Mechanical Driven Pump Pressure (pounds)

By

Camshaft

AND

DATA

5 to 7

AND

EXHAUST SYSTEM

SPECIFICATIONS

interfere with

MG-1

the

CARBURETOR

Type Dual Throat Downdraft Model BBD-2795S-2872S

ADJUSTMENTS

Idle Mixture (both screws) One full turn open Idle Speed. . 500 Fast Idle Fast Idle

Choke Unloader

Accelerator Pump Travel 1 in.

Float Setting

CHOKE

Control Cross over type Setting Fast Idle Speed Setting 1375

FUEL PUMP

Make Model

Type

Driven Pump Pressure (pounds)

.017" Cam On

On

Model

By

J

%2 + or —%

34

MG-2,

rpm

Index

inch

+ or

Index

to

1425

MG-3

and MY-1

Carter

M-2769S

Mechanical

Camshaft

5

to 7

—l{i

rpm

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—41

(b) Remove the two screws and remove bezel by

lifting bezel outward and upward (to clear metal retaining tabs).

(c) Expose internal mechanism of mirror assem-

bly by lifting top portion of back cover up-

ward (to clear metal retaining tabs) and

moving back cover rearward over mirror support. Move back cover rearward only far enough to provide access to potentiometer adjusters (Fig. 38).

(d) To increase sensitivity of the "City" position,

turn the arm of the potentiometer marked "City" in the direction indicated by the arrow.

(e) To increase sensitivity for "Hi-way" driving,

turn the arm of the potentiometer marked

"Hi-way" in the direction indicated by the

arrow.

Section VII

ENGINE

DATA AND SPECIFICATIONS

NOTE: To decrease sensitivity of either or both the

potentiometers, turn potentiometer arms in the di-

rection opposite to direction indicated by arrow.

(f) Replace back cover by positioning back cover

over the two metal tabs and aligning screw holes in bottom of cover with threaded holes in mirror support.

(g) Install bezel by aligning slots at top of bezel

with metal tabs and aligning screw holes in bottom of bezel with threaded holes in mirror support replace screws (Fig. 36) and

tighten securely. (h) Replace plastic switch knob. (i) Adjust mirror to desired position and test

operation of unit.

ENGINE

Type Number of Cylinders Bore—MC-1,

Stroke Piston Displacement—MC-1, MC-2

Compression Ratio Compression Pressure at 150 rpm (plugs removed) Wide Open Throttle Maximum Variation Between Cylinders (any one engine) Firing Order

CYLINDER NUMBERING

Left Bank Right Bank

CRANKSHAFT

Type Bearings Journal Diameter

Crank Pin Diameter

Maximum Out-of-Round Permissible Number Main Bearings

Diametral Clearance Desired End Play Thrust Taken By

Finish at Rear Seal Surface

Interchangeability of Bearings

MC-3,

MC-2 MY-1

MC-3,

MY-1

90° V

8

4.031"

4.188"

3.750"

383 cu. in.

413 cu. in.

10.0 to 1

150 to 180 lbs.

25 lbs.

1-8-4-3-6-5-7-2

1-3-5-7

2-4-6-8

Fully Counter-Balanced

Steel Backed Babbitt

2.7495 to 2.7505"

2.374 to 2.375" .001"

5

.0005 to .0015"

.002 to .007"

No.

3 Main Bearing

Diagonal Knurling Upper Nos. 1, 2, 4, 5 Lower Nos. 1, 2, 4, 5

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42—ENGINE

CHRYSLER SERVICE MANUAL

ENGINE (Cont'd)

MAIN BEARINGS (Service) All Available in Standard and the following

Undersizes .001, .002, .003, .010, .012"

CONNECTING RODS AND BEARINGS

Type Drop Forged "I" Beam Length (Center to Center) 6.766—.770" Weight (less bearing shells) 29.4 oz. Bearings Steel-Backed Babbitt Diameter and Length 2.375 x .927" Diametral Clearance Desired .0005 to .0015" Maximum Allowable before Reconditioning .0025" Side Clearance .009 to .017" Bearings for Service Standard .001, .002, .003,

.010,

.012" U.S.

Piston Pin Bore Diameter

CAMSHAFT

Drive Chain Bearings Steel Backed Babbitt Number 5 Thrust Taken by Cylinder Block Diametral Clearance .001 to .003" Maximum Allowable before Reconditioning .005"

1.0925

to 1.0928"

CAMSHAFT BEARING JOURNALS

Diameter

No.

1 1.998 to 1.999" No. 2 1.982 to 1.983" No. 3 1.967 to 1.968" No. 4 1.951 to 1.952" No. 5 1.748 to 1.749"

CAMSHAFT BEARINGS

Diameter (after reaming)

No.

1 2.000 to

No.

2 1.984 to

No.

3 1.969 to

No.

4 1.953 to

No.

5 1.750 to 1.751"

TIMING CHAIN

Adjustment None Number of Links , 50 Pitch .50" Width .88"

TAPPETS

Type Hydraulic

Clearance in Block .0005 to .0015"

Body Diameter .9040 to .9045"

Clearance Between Valve Stem and Rocker Arm Pad Dry Lash

.060 to .210"

2.001"

1.985"

1.970"

1.954"

PISTONS

Type Horizontal Slot w/Steel Struts Material Aluminum Alloy Tin Coated

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—43

ENGINE (Cont'd)

Land Clearance (diametral) Clearance at Top of Skirt Weight (std. through .040 oversize)

MC-1,

MC-2

MC-3,

MY-1 Piston Length (overall) Ring Groove Depth

No.

1—MC-1

No.

2—MC-1

No.

3—MC-1

Pistons for Service

PISTON PINS

Type Diameter Length Clearance in Piston Interference in Rod Piston Pins for Service. . . Direction Offset in Piston

PISTON RINGS

Number of Rings per Piston. Compression Oil Width of Rings (Compression)

(Oil)

Piston Ring Gaps (all)

& MC-2

MC-3 & MY-1

&MC-2

MC-3 & MY-1

& MC-2

MC-3 & MY-1

.041 to .047"

.0005 to .0010"

724 gms.

780 gms.

3.95" .213"

.216" .213" .216" .195" .200"

Std. .005, .020, .040" O.S.

Press Fit in Rod

1.0935

to

1.0937"

3.4440

to 3.450"

.00045 to .00075"

.0007 to .0012" Standard Only

Toward Right Side of Engine

3 2

1

.0775 to .0780" .1860 to .1865"

.013 to .025"

RING SIDE CLEARANCE

(Compression)

Upper Intermediate

(Oil)

VALVES—Intake

Material Head Diameter

Length (to top of valve face) Stem Diameter Stem to Guide Clearance

Maximum Allowable Before Reconditioning. Angle of Seat Adjustment

Lift

VALVES—Exhaust

Material

Head Diameter.

MC-1,

MC-3,

MC-2 MY-1

.0015 to .0030" .0015 to .0030"

.0010 to .0030"

Silicon—Chromium Steel

1.95"

2.08"

4.79"

.372 to .373"

.001 to .003"

.004"

45°

None

.389"

Nitrogen Treated Manganese

Chromium—Nickel Steel

1.60"

MyMopar.com

44—ENGINE

CHRYSLER SERVICE MANUAL

ENGINE (Cont'd)

Length (to top of valve face) 4.79" Stem Diameter .371 to .372" Stem to Guide Clearance .002 to .004"

Maximum Allowable Before Reconditioning .006" Angle of Seat 45° Adjustment None

Lift .389"

VALVE SPRINGS

Number 16

Free Length 2.34"

Load when Compressed to (valve closed)

Load when Compressed to (valve open)

Valve Springs I.D 1.010 to

CYLINDER HEAD

Number Used 2

Combustion Chamber Wedge Type

Valve Seat Runout (maximum) .002'

Intake Valve Seat Angle 45 Seat Width (finished) .060 to .085" Exhaust Valve Seat Angle 45° Seat Width (finished) .040 to .060" Cylinder Head Gasket Compressed (thickness) .022"

1.860"

1.470"

@ 95 —105 lbs. @ 188—252 lbs.

1.030"

C

•o

ENGINE LUBRICATION

Pump Type Rotary, Full Pressure

Capacity (qts.) 5* Pump Drive Camshaft Operating Pressure at 40 to 50 mph 45 to 70 lbs. Pressure Drop Resulting from Clogged Filter 7 to 9 lbs.

*When Filter Element is Replaced, add 1 qt.

TIGHTENING REFERENCE

Torque Thread

Foot-Pounds Size

Connecting Rod Nut—Plain Connecting Rod Nut—CST (Black) Cylinder Head Bolt Main Bearing Cap Bolt Spark Plug

Camshaft Lockbolt Carburetor to Manifold Nut Chain Case Cover Bolt Torque Converter Housing Bolt Clutch Housing Bolt Crankshaft Rear Bearing Seal Retainer Crankshaft Bolt Cylinder Head Cover Stud and Nut Distributor Vacuum Line Tube Nut Distributor Clamp Bolt

45 40

70 85 30

35

7

15 30 30 30

135

40 in.-lbs.

95 in.-lbs.

15

^8-24 ^-24

%-14

J4-13

14 mr %>—14 %-24

5

/i6-18

•HJ-16

^-16

%~1Q

%-W

J4-28

^-24 ^fi-18

MyMopar.com

CHRYSLER SERVICE MANUAL

TIGHTENING REFERENCE (Cont'd)

Engine Front Mounting to Frame Nut 85 Engine Front Mounting to Block Nut „ 45 Exhaust Manifold Bolt „ 30 Exhaust Pipe Flange Nut 40 Exhaust Pipe Clamp Bolt 20 Exhaust Pipe Support Clamp Bolt 20 Fan Attaching Bolt 15-18 Fan Belt Idler Pulley Nut . 45 Fan Belt Idler Pulley Bracket Bolt 30 Flywheel Housing to Cylinder Block Bolt 50 Flywheel Housing Cover Bolt , 7 Fuel Pump Attaching Bolt 30 Generator Bracket Bolt 50 Generator Mounting Nut 20 Generator Adjusting Strap Bolt . 15

Generator Adjusting Strap Mounting Bolt 30 Intake Manifold Bolt 40 Manifold Heat Control Counterweight Bolt 50 in.-lbs. Oil Pan Drain Plug 35 Oil Pan Bolt 15 Oil Pump Cover Bolt 15 Oil Pump Attaching Bolt 35 Oil Filter Attaching Stud 30 Rocker Shaft Bracket Bolt 30 Starter Mounting Bolt 50 Vibration Damper Bolt 15 Valve Tappet Cover End Bolt 8 Water Pump to Housing Bolt 30 Water Pump Housing to Cylinder Block Bolt 30 A/C Compressor to Engine Bolt 30

ENGINE—45

#10-32

56-16

ENGINE

The new V-8 Engine, as shown in Figure 39, 40 and

41,

ia one of the finest, most efficient engines to be

designed by Chrysler Engineering. It contains many weight reducing features.

Some of the new features, as shown in Figures

42,

43 and 44, are in-line overhead valves, wedge

shaped combustion chambers, full length cylinder

water jackets, rigid crankshaft and series flow cool-

ing system. In addition, the volume of coolant in the engine has been reduced to improve engine warm up.

The ignition distributor is located at the upper

front end of the engine for easier servicing.

The lubrication system consists of an externally mounted rotor type oil pump of greater capacity, full flow oil filter and a series of passages where the oil is delivered to the engine. The oil filter can be installed by hand.

The engine has 10:1 compression ratio, is equipped

with a dual carburetor on the Windsor Model

(MC-1),

els,

tional smoothness and performance throughout the

entire speed range.

MINOR TUNE UP

A periodic engine tune up will assure maximum engine performance and fuel economy. The following procedures should be followed when performing minor engine tune up.

sary and clean and tighten battery connections. Clean and adjust the spark plugs (.035 inch gap). Tighten to 30 foot-pounds torque with Tool C-3054. Adjust the distributor contact points (.015 to .018

and a 4-barrel carburetor on all other mod-

and uses premium fuel. The engine has excep-

Check battery specific gravity, add water if neces-

MyMopar.com

46—ENGINE

CHRYSLER SERVICE MANUAL

Fig.

39 — Chrysler Engine Assembly

59x151

Fig.

40 — Engine End Sectional View

59x54

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—47

inch gap). Install new points if necessary. Check the distributor cap for cracks and corrosion,. Inspect the rotor, rotor spring and plunger. Inspect the distributor to spark plug wires for brittle, cracked or frayed insulation. Inspect small lead wires for tightness,

or damaged insulation. Check for excessive play in distributor vacuum advance plate bearing. Install a new plate if necessary. Reset the ignition timing. Inspect accessory belt drives referring to "Accessory Belt Drives," for proper adjustments.

Tighten the carburetor flange nuts to 7 foot-pounds torque. Set carburetor idle mixture adjustment. Ad-

just the throttle stop screw so engine idles at 450 to

500 rpm. Check manifold heat control valve in the right exhaust manifold for proper operation and

apply Manifold Heat Control Valve Solvent Part

Number 1879318 to the bushing and shaft, as shown in Lubrication Section.

MAJOR

TUNE

UP

Perform all the steps of a "Minor Tune Up" and in addition, the following procedures should be followed when performing Major Engine Tune Up.

Tighten the manifold nuts. Perform the cylinder compression test. Compression pressures can be read from the top side of engine without interference using a 30 degree bend extension on, the gauge. The compression should not vary more than 25 pounds between cylinders.

Refer to specifications for compression pressures. Test the coil, and condenser. Inspect the primary and secondary wires. Service the air cleaner — DO NOT WASH OR OIL. Service more frequently under severe dusty conditions. Replace air cleaner filter cart-

ridge every 15,000 miles. Test fuel pump for pressure and vacuum. Refer to Fuel Section Specifications. Perform a combustion analysis. Adjust the

carburetor. Road test the car as a final check.

REMOVAL OF

THE

ENGINE ASSEMBLY (From Car)

Drain the cooling system and remove the battery. Remove the fan shroud and radiator. Scribe the outline of hinge brackets on hood to assure proper adjustment when installing. Remove the hood. Disconnect fuel lines and wires attached to engine units.

Fig.

41 —

Engine Side Sectional View

58x135

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48—ENGINE

CHRYSLER SERVICE MANUAL

O>

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CHRYSLER SERVICE MANUAL

Fig.

42 — Engine External Parts

1.

Carburetor Air Cleaner

2.

Coil

3. Vacuum Line

4.

Wiring Harness (bracket)

5. Fuel Line

6. Tappet Chamber Cover and Intake Manifold Gasket

7. Reinforcement, silencer and

Retainer

8. Wiring Harness (brackets)

9. Oil Filler Cap

10.

Rocker Cover L

11.

Rocker Cover Gasket L

12.

Spark Plug Heat Shield

13.

Cylinder Head L

14.

Oil Level Indicator

15.

Exhaust Manifold L

16.

Oil Level Indicator Tube

17.

Cylinder Head Gasket

18.

Distributor Clamp

19.

Water Pump Housing Gasket

20.

Oil Pump Housing Gasket

21.

Outlet Elbow

22.

Outlet Elbow Gasket

23.

Thermostat

24.

Temperature Sending Unit

25.

Water Pump Housing

26.

Water Pump Body Gasket

27.

Water Pump Body

28.

Hub

29.

Water Pump Pulley

30.

Bolt

31.

Washer

32.

Crankshaft Pulley

33.

Vibration Damper

34.

Oil Filter

35.

Oil Pump

36.

Chain Case Cover

37.

Chain Case Cover Gasket

38.

Oil Pan Gasket

39.

Oil Pan

40.

Chain Case Cover Oil Seal

41.

Cylinder Block

42.

Oil Screen Suction Pipe

43.

Fuel Pump

44.

Fuel Pump Gasket

45.

Exhaust Manifold

46.

Starter

47.

Solenoid

48.

Torque Converter Housing Dust Shield

49.

Generator Bracket

50.

Ring Gear

51.

Torque Converter

52.

Torque Converter Housing

53.

Manifold Heat Control Valve

54.

Spark Plug

55.

Spark Plug Heat Shield

R

ENGINE—49

56.

Cylinder Head R

57.

Crankcase Vent Tube

58.

Rocker Cover Gasket

59.

Rocker Cover

60.

Wiring Harness (brackets)

61.

Crankcase Vent Tube Cap

62.

Generator

63.

Distributor Gasket

64.

Distributor

65.

Wires

66.

Reinforcement

67.

Generator Adjusting Strap

68.

Intake Manifold

69.

Automatic Choke

70.

Control Spring Bracket

71.

Carburetor Gasket

72.

Carburetor

73.

Carburetor Air Cleaner Gasket

R

Remove the air cleaner and carburetor. Attach the engine lifting fixture Tool C-3466 to carburetor flange studs on the intake manifold and attach a

chain hoist to the fixture eyebolt. Disconnect the pro-

peller shaft, wires and linkage at transmission. Disconnect exhaust pipes at manifolds. Be sure the exhaust system is sufficiently supported while the en-

gine is removed. Remove rear crossmember to transmission support attaching bolts.

NOTE: Place a roUaway jack under the transmission

RIGHT BANK

LUBRICATION

NO.

4 CAMSHAFT

BEARING

to relieve weight from the crossmember. Place a wood block between jack and transmission to avoid

damaging transmission oil pan.

The jack supports the weight of rear of engine and must be able to roll with the power plant as it is removed from the chassis. Remove rear crossmember engine support. Remove front engine mounting nuts.

Raise the engine with chain hoist and work

the engine out of the chassis. Remove transmission.

Place the engine in repair stand C-3167 and Adapter

ROCKER SHAFT

ROCKER ARM

RIGHT MAIN OIL GALLERY

OIL FILTER

Oil PUMP RELIEF VALVE

Fig.

OIL PRESSURE

43 — Engine Oiling System

LEFT ROCKER SHAFT

59x24

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50—ENGINE

CHRYSLER SERVICE MANUAL

WASHER

CAMSHAFT

BOLT\

RETAINER

SPACER

ROCKER

BRACKET

GEARAND SHAFT

SPROCKET

CHAIN

BOLT

(SERVICED IN PACKAGE)

OIL SEAL

RETAINER -

SCREW

CAP

SCREW

NUT

CAP

Fig.

44 — Engine Internal Parts

BEARING

CRANKSHAFT

SPROCKET OIL SLINGER

_~-—~—SCREW

CAP {SERVICED IN ROD)

59x53

MyMopar.com

CHRYSLER SERVICE MANUAL

3662 for disassembly using the transmission mounting bolts.

INSTALLING THE ENGINE ASSEMBLY (In Car)

Remove the engine from repair stand and install transmission. Install the engine lifting fixture Tool

C-3466 and attach the chain hoist to fixture eyebolt. Raise the engine. Lower the engine carefully into the car until front and rear of engine are approxi-

mately positioned. Place a rollaway jack under the

transmission to support the weight of rear of the engine. Install the engine rear support crossmember. Position the engine and install the nuts at front en-

gine mounts. Position and install rear engine sup-

port bolts and remove the jack, hoist and engine

lifting fixture.

Install the carburetor, fuel lines, wiring and link-

age.

Install the radiator, fan shroud and radiator

hoses.

Connect exhaust pipes, using new gaskets. Install the hood, being sure to align hood by the scribe marks placed on the inside of hood at disassembly. Connect the propeller shaft at the transmission. Connect linkage and wires. Be sure all drain cocks are closed, and fill cooling system. Fill the engine crankcase and transmission. Refer to the lubrication Section for quantities and lubricants to use. Check the entire system for leaks and correct as necessary.

NOTE: Whenever an engine has been rebuilt and a

new camshaft and/or new tappets have been installed, add one quart of factory recommended oil additive

to engine oil to aid break-in (MoPar Engine Oil Additive, Part No. 1643234). The oil mixture should

be left in engine for a minimum of 500 miles, and

drained at the next normal oil change.

INTAKE VALVES

&&^5>-

k:a

EXHAUST

VALVES

ENGINE—51

58x137

Fig.

46 — Tightening Sequence

Start the engine and run until normal operating" temperature is reached. Check the timing and adjust carburetor as necessary. Road test the car.

CYLINDER HEADS

The chrome alloy cast iron cylinder heads as shown in Figure 45 are held in place by 17 bolts. The spark

plugs enter the cylinder head horizontally and are

located at the wide edge of the combustion, chambers.

a. Removal

Drain the cooling system. Remove generator, carburetor air cleaner and fuel line. Disconnect the accel-

erator linkage. Remove the vacuum control tube at carburetor and distributor. Disconnect the distrib-

utor cap, coil wires and heater hose. Disconnect the

heat indicator sending unit wire. Remove spark plugs located under the manifolds. Remove the in-

take manifold, ignition coil and carburetor as an assembly. Remove the tappet chamber cover. Remove cylinder head covers and gaskets.

NOTE: On air conditioned cars, number eight cyl-

inder exhaust valve must be open to allow clearance

between the right bank cylinder head cover and the heater housing.

Remove the generator. Remove exhaust manifolds. Remove the rocker arms and shaft assembly. Remove the push rods and place them in their respective slots in holder Tool C-3068. Remove the 17 head bolts from each cylinder head and remove cylinder heads.

Place cylinder head in holding fixture Tool

C-3626.

Fig.

45 — Cylinder Heads

58x136

b.

Installation

Clean the gasket surfaces of cylinder block and cyl-

inder head. Check all surfaces with a straight edge

if there is any reason to suspect leakage. Coat the

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52—ENGINE

CHRYSLER SERVICE MANUAL

EXHAUST MANIFOLD - RiGHT

, TOOL

mam*

V> X 1

M

Fig.

47 — Checking Cylinder Head Bolt Torque

new gaskets with a suitable sealer, MoPar Part

Number 1122893. Install

heads.

Install cylinder head bolts. Starting

center, tighten

pounds torque

all

cylinder head bolts

in

sequence, and using Tool C-3666 Figure 47.

Repeat

the

procedure, retightening to 70 foot-pounds torque. Inspect push rods place worn small ends rod,

as

or

in

shown

bent rods. Install push rods with tappets maintaining alignment using in

Figure 48.

Install the rocker arm and shaft assembly starting

each push

rod

into

its

NOTE: Use extreme care pounds torque,

so the

down to their operating length. Bulged tappet bodies,

CYLINDER HEAD INTAKE PUSH RODS ASSEMBLIES

the

gaskets

as

shown

to

check torque,

and

in

all

respective rocker

in

tightening bolts

tappets have time

cylinder

at top

to 70

Figure

as

shown

head bolts

and re-

arm

socket.

30

to

bleed

foot-

46,

in

the

foot-

LOCATING ARROW ROCKER ARMS-RIGHT

;

• . ROCKER ARMS-RIGHT

58xl?9

Fig.

bent push rods, may result

if

the tappets are forced down too rapidly.

LOCATIMOARROW

49 — Rocker Arms Installed

and

permanently noisy operation

i

Place the new cylinder head cover gaskets in posi-

tion

and

install cylinder head covers. Tighten

the bolts to 40 inch-pounds torque. Install exhaust manifolds and tighten the bolts Adjust spark plugs plugs,

and

tighten

to

to 30 Tool C-3054. Install tighten end bolts

to 8

Install intake manifold, carburetor

coil

as an

assembly and tighten manifold bolts

to

30 foot-pounds torque.

.035 inch

gap and

install

foot-pounds torque with

the

tappet chamber cover

foot-pounds torque (Fig.

and

the

and

49).

ignition

to 40

food-pounds torque. Install the distributor cap. Con-

nect

the

coil wire, heat indicator sending unit wire, accelerator linkage, spark plug cables and insulators. Install

the

vacuum tube from carburetor

to

distributor. Install generator and tighten generator bracket bolts to 50 foot-pounds torque, and generator mounting nut to 20 foot-pounds torque. Install the fuel line and carburetor Adjust belt tensions Drives"

in

air

cleaner. Fill

as

outlined

this supplement.

the

cooling system.

in

"Accessory Belt

INSTALLING

ROD

EXHAUST PUSH RODS "58x138

Fig.

48 — Push Rods Installed

-BRACKETS-

OIL FEED GROOVE THIS SIDE

58x140

Fig.

50 — Rocker Arms & Shaft Assembly

OIL FEED GROOVE THIS SIDE

SPACERS-

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CHRYSLER SERVICE MANUAL

ENGINE—53

ROCKER ARMS The rocker arms

AND

SHAFT ASSEMBLY

are of

stamped steel

and are arranged on one rocker arm shaft, per cylinder head. The push rod angularity tends

to

force the pairs of

rocker arms toward each other where oilite spacers

carry the side thrust

ets attach each rocker shaft

at

each rocker arm. Five brack-

to

the cylinder head.

a. Removal Remove cylinder head cover and gasket. Remove the

bolts that attach rocker

arm

support brackets

to cylinder head and remove the rocker arms, brackets and shaft as an assembly.

If the rocker arm assemblies have been disassem-

bled

for

cleaning, inspection,

to Figure 49 and 50 b.

Installation

NOTE: The right and left rocker arms must be in-

stalled on rocker shaft, as shown in Figure 49. The

stamped arrow on rocker shaft must be on top and the arrow must point toward the push rod socket of

the rocker arm. This is necessary to provide proper lubrication to the rocker assemblies. The two wide brackets must be installed with the oil feed grooves facing the push rod side of rocker arm, as shown in Figures 49 and 50.

Install

the

rocker arms, brackets,

for

or

replacement, refer

proper reassembly.

and

shaft

as-

sembly.

NOTE: Use extreme care

in

tightening the bolts

so

"OOU

58x142

Fig.

52 —

Using Sleeve Tool

in

Checking Wear

that tappets have time to bleed down to their operating length. Bulged tappet bodies, bent push rods and

permanent noisy operation may result

if

the tappets

are forced down too rapidly.

Tighten the bolts

VALVES

AND

to

30 foot-pounds torque.

VALVE SPRINGS

Valves are arranged in-line in the cylinder heads and

inclined 30° outward from vertical. Intake and

ex-

haust valves operate in guides that are integral with

the heads. a. Removal

With

the

cylinder head removed, compress valve

springs using

Tool.

C-3422, as shown in Figure 51.

CYLINDER HEAD

ASSEMBLY

Fig.

51

— Compressing Valve Spring

TOOL

REPAIR" STAND

(TOOL)

58x141

Remove

the

valve retaining locks, valve spring retainers, valve stem cup seals and valve springs. Remove the burrs from valve stem lock grooves to pre-

vent damage

to

the valve guide when valves are re-

moved.

b.

Valve Inspection

Clean

the

valves thoroughly,

and

discard burned, warped and cracked valves. Measure valve stems for wear. Intake valve stem diameter should measure .372

to

.373 inch

should measure .371 to .372 inch.

and

exhaust valve stem diameter

If

the wear exceeds .002 inch, replace the valve. Remove carbon and varnish deposits from

the

inside

of

valve guides with

cleaner, Tool C-756.

Measure

the

valve stem guide clearance

as fol-

lows : Install sleeve Tool C-3026 over the valve stem,

as shown in Figure 52, and install valve.

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54—ENGINE

CHRYSLER SERVICE MANUAL

VALVE

58x143

Fig.

53 — Measuring Guide Wear

The special sleeve places the valve at the correct height for checking with a dial indicator. Attach the dial indicator Tool C-3339 to cylinder head and set it at right angle of the valve stem being measured

(Fig. 53).

Move valve to and from the indicator. The total dial indicator reading should not exceed .010 inch on intake valves, and .014 inch on exhaust valves. Ream

the guides for valves with oversize stems if dial indi-

cator reading is excessive or if the stems are scuffed

or scored.

Service valves with oversize stems are available in .005,

.015 and .030 inch oversizes. Reamers to accom-

modate the oversize valve stem are as follows: Ream-

er Tool C-3433 (.379 to .380 inch) Reamer Tool C3427 (.404 to .405 inch). Slowly turn reamer by hand

and clean guide thoroughly before installing new

valve.

CAUTION

Do not attempt to ream the valve guides from standard directly to .030 inch. Use step procedure of .005,

MARGIN

FACE

VALVE

MAXIMUM MEASUREMENT 58x144A

Fig.

55 — Measuring Valve Stem Length

TOOL

^MINIMUM MEASUREMENT

.015 and .030 inch so the valve guides may be reamed true in relation to the valve seat.

c. Referring valves

and

valve seats

The intake and exhaust valve faces have a 45° de-

gree angle. Always inspect the remaining margin

after the valves are refaced (Fig. 54). Valves with less than 3/64 inch margin should be discarded.

The angle of both valve and seat should be identi-

cal.

When refacing the valve seats with Tool MTH-

80,

it is important that the correct size valve guide

pilot be used for reseating stones. A true and com-

plete surface must be obtained. Measure the concentricity of valve seat using a dial indicator. The total runout should not exceed .002 inch (total indicator

reading). When the seat is properly positioned, the width of intake seats should be 1/16 to 3/32 inch. The width of exhaust seats should be 3/64 to 1/16 inch.

When the valves and seats are reground, the position of the valve in the cylinder head is changed, shortening the operating length of hydraulic tappet. This means that the plunger is operating closer to its bottomed position, and less clearance is available for thermal expansion of valve mechanism during

STEM-

VALVE SPRING RETAINER

LOCK GROOVES

Fig.

54 — Intake and Exhaust Valve

54x33CC

VAtve

SPRiNG

Fig.

56 — Checking Valve Spring Squareness

MyMopar.com

CHRYSLER SERVICE MANUAL

high speed driving. The design of the valve mechanism includes a safety factor to allow for a limited amount of wear, and the refacing of valves and seats.

To insure that the limits have not been exceeded, the dimension from valve spring seat in head to valve tip should be measured with Gauge, Tool C-

3648,

as shown in Figure 55.

The end of the cylindrical gauge and the bottom of slotted area represent the maximum and minimum allowable extension of valve stem tip beyond the spring seat. If the tip exceeds maximum, grind the stem tip to within gauge limits. Clean tappets if tip grinding is required.

Fig.

58 — Installing Valves and Cup Seals

ENGINE—55

d. Testing Valve Springs

Whenever the valves have been removed for inspection, reconditioning or replacement, the valve springs should be tested. To test a spring, first determine the length at which the spring is to be tested. As an example, the compressed length of the spring

to be tested is C-647 until surface is in line with the

1-15/32

inches. Turn the table of Tool

1-15/32

inch mark on the threaded stud and the zero mark to the front. Place spring over stud on table and lift the compressing lever to set the tone device. Pull on torque wrench until a ping is heard. Take the reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at the

test length. Fractional measurements are indicated

on the table for finer adjustments. The valve springs should test 183 to 202 lbs. when compressed to 115/32 inch. Discard springs that do not meet these

specifications.

Inspect each valve spring for squareness with a

RETAINER

steel square and surface plate, as shown in Figure

56. If the spring is more than 1/16 inch out of square,

install a new spring.

e. Installation

Coat the valve stems with lubricating oil and insert

them in position in cylinder head. Install the cup

seals on intake and exhaust valve stems and over valve guides, as shown in Figure 57 and 58 and install valve springs and retainers.

Compress the valve springs with Tool C-3422. In-

stall locks and release tool.

NOTE: measure the installed height of springs. Make sure

measurement is taken from the bottom of the spring seat in cylinder head to the bottom surface of spring

retainer. (If spacers are installed, measure from the

top of spacer.) If height is greater than inches, install a 1/16 inch spacer in head counterbore to bring spring height back to normal to

If the valves and/or seats are reground,

1-57/64

inch.

1-57/64

1-53/64

EXHAUST

VALVE

INTAKE VALVE

Fig.

57 — Valve Assembly

SPRING

59x51

HYDRAULIC TAPPETS

a. Preliminary to Checking Hydraulic Tappets

Before disassembling any part of engine to correct

tappet noise, read the oil pressure at gauge and

check the oil level in the oil pan. The pressure should be between 45 and 70 pounds at 2000 rpm. The oil level in the pan should never be above "full" mark

on dip stick, or below "add oil" mark. Either of these two conditions could be responsible for noisy tappets.

Oil Level Too High — If oil level is above "full" mark on dip-stick, it is possible for the connecting

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56—ENGINE

CHRYSLER SERVICE MANUAL

rods to dip into oil while the engine is running and create foam. Foam in the oil pan would be fed to the hydraulic tappets by the oil pump causing them to go flat and allowing the valves to seat noisily.

Oil Level Too Low — Low oil level may allow the oil

pump to take in air which, when fed to tappets,

causes them to lose length and allows the valves to

seat noisily. Any leaks on intake side of the pump through which air can be drawn will create the same tappet action. When tappet noise is due to aeration,

it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and

leaks have been corrected, the engine should be op-

erated at fast idle for sufficient time to allow all of

air inside of tappets to be bled out.

b.

Tappet Noises

To determine the source of tappet noise, operate the

engine at idle with the cylinder head covers re-

moved. Feel each valve spring or rocker arm to de-

tect the noisy tappet. The noisy tappet will cause

the affected spring and/or rocker arm to vibrate or

feel rough in operation.

NOTE:

sometimes mistaken for noisy tappets. If such is the

case, noise may be dampened by applying side thrust on valve spring. Inspect rocker arm push rod sockets and push rod ends for wear. If noise is not apprecia-

bly reduced, it can be assumed the noise is in the tappet.

heavy click. A light noise is usually caused by exces-

Worn valve guides or cocked springs are

Valve tappet noise ranges from a light noise to a

CYLINDER HEAD

ASSEMBLY

HYDRAULIC TAPPET

f 7*-PLUNGER RETAINING SPRING CLIP

v—'

y%+

-PLUNGER

VALVE SPRING-

VALVE RETAINER*

PLUNGER SPRING-

52x389B

Fig.

TAPPET BODY

60 — Hydraulic Tappet Assembly

CAP

TAPPET PLUNGER

FLAT VALVE

sive leakdown around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet check valve not seating, or by foreign particles becoming wedged between the plunger and tappet body, causing plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between valve stem and rocker arm as valve closes. In either case, the tappet assembly should be removed for inspection and cleaning.

c. Removal of Tappets

Tappets can be removed without removing the intake manifold by following this recommended procedure: remove the cylinder head covers. Remove rocker arms and shaft assembly. Remove the push rods and place them in their respective holes in Tool

C-3068. Slide puller Tool C-3661 through push rod

opening in cylinder head and seat tool firmly in the

head of tappet. Pull tappet out of bore with a twist-

ing motion, as shown in Figure 59.

Fig.

59 — Removing Tappet

If all tappets are to be removed, remove the hydraulic tappets and place them in their respective holes in tappet and push rod holder, Tool C-3068. This will insure installation of the tappets in their

original locations.

NOTE: engine numbering pad indicates that all tappet bodies are .008 inch oversize, see Figure 84.

Do not disassemble a tappet on a dirty work bench. 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 tap-

A diamond shaped marking stamped on the

CAUTION

MyMopar.com

CHRYSLER SERVICE MANUAL

3160,

in the

Engage ger. Check leakdown ger collapses almost instantly plied, disassemble tappet, clean tappet still does cleaning, install

groove

jaw of

of

tappet body

pliers with

by

not

operate satisfactorily after

a new

tappet assembly.

top of the

compressing pliers.

as

and

h. Installation Lubricate

the

tappets. Install tappets in their original positions. Install and shaft assembly. Start Warm

up to

normal operating temperature.

and

operate

ENGINE—57

(Fig. 61).

tappet plun-

If

pressure

test again.

and

the

is ap-

push rods

rocker

the

engine.

plun-

If the

arm

51x971D

Fig.

61 — Testing Tappet

pet

at a

time

to

avoid mixing

are

not

compatable.

d.

Disassembly

Pry

out

plunger retainer spring clip. Clean nish deposits from the plunger

plunger

cap,

(Fig.

60)

the

inside

cap.

Invert

the

plunger, flat check valve, check valve spring, check valve retainer Separate valve spring. Place

in

the

e. Cleaning

Clean all varnish unfit semble

f.

Inspection

If

the

scuffed,

the

plunger, check valve retainer

all

parts

tappet holder Tool C-3068.

and

Assembly

all

tappet parts

and

carbon. Replace

for

further service with

the

tappets,

tappet

or

shows signs

as

bore

in a

shown

in

of next oversize, using Tool C-3028. signs

of

scoring

the valve seat

or

wear

on end of

plunger indicates

of

parts. Mixed parts

the var-

of

tappet body above

tappet body

and

in

their respective place

and

remove

plunger spring.

and

check

solvent that will remove

the

tappets that

new

assemblies.

in

Figure

cylinder block sticking, ream

and

valve

56.

is

scored,

the

bore

If

plunger shows

is

pitted,

any

or if

condi-

are

As-

to

tion that would prevent valve from seating, install

a

new

tappet assembly.

NOTE: engine must hydraulic tappets have filled with

To

prevent damage

not be run

to

valve mechanism,

above fast idle until

oil and

come quiet.

CHECKING

Turn crankshaft until full open

Insert

pad

and the ond valve so that er

as spring load a solid tappet. Zero

Turn direction) until intake valve The timing

VALVE

and the

a *4

stern

on the

the

plunger contacts

nearly perpendicular

to

the

crankshaft clockwise (normal running

on the

TIMING

the No. 1

No. 1 piston

exhaust valve

is on TDC.

inch spacer between

tip of the No. 1

intake valve

left bank). Install a dial indicator

the

valve spring retain-

as

possible. Allow

bleed

the

tappet down giving

the

indicator.

has

lifted

timing indicator, located chain case cover, should read from 2° ATDC. limits:

timing chain

the

DC shaft counter-clockwise until remove

If the

Check

mark

the

spacer.

reading

the

sprocket index marks, inspect

for

wear,

on the

is not

and

within

check

timing indicator. Turn crank-

the

valve

-CHAIN CASE COVER

- - TIMING INDICATOR

- -CYLINDER BLOCK

- TIMING MARK

VIBRATION DAMPER

the

10°

the

have

rocker

in

.013

on the

BTDC

the

specified

accuracy

is

closed

the

all of

be-

is

arm

(sec-

the

effect

inch.

to

the

of

and

g. Testing

Fill

a pan

plunger

with clean kerosene. Remove

and

completely submerge

upright position.

Allow tappet and replace position

and

the cap.

insert

cap

the

tappet

to

fill with kerosene, remove tappet,

Hold

the

lower

tappet

jaw of

in an

upright

pliers, Tool

from

in an

C-

^

Fig.

62 — Removing Vibration Damper Assembly

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58x149A

58—ENGINE

CHRYSLER SERVICE MANUAL

CAUTION

Do not turn crankshaft any further clockwise as the valve spring might bottom and result in serious damage.

TIMING SPROCKETS AND CHAIN

The timing chain has 50 links of i/2 inch pitch and is %

inch wide. Chain stretch is reduced because of

fewer joints to wear.

a. Removal Drain the cooling system. Remove the radiator and

water pump assembly. Remove the bolt holding vibration damper on crankshaft. Remove two of the

pulley bolts, install Tool C-3033, and pull the damper assembly off the end of crankshaft, as shown in Figure 62.

Remove the chain cover and gasket. Slide the

crankshaft oil slinger off end of crankshaft. Remove the camshaft sprocket attaching bolt. Remove timing chain with crankshaft and camshaft sprockets.

b.

Installation

Place both the camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. Place the timing chain around

both sprockets. Turn the crankshaft and camshaft to line up with the keyway location in crankshaft sprocket and the dowel holes in the camshaft sprocket.

Lift the sprockets and chain, (keep sprockets

tight against the chain in position as described).

Slide both sprockets evenly over their respective shafts.

Use a straight edge to check alignment of

the timing marks (Fig. 63). Install the washer and

TORQUE WRENCH

58x151

Fig.

64

— Measuring Chain Stretch

camshaft sprocket bolt and tighten to 35 foot-pounds torque.

c. Checking Timing Chain for Stretch

Place a scale next to timing chain so that any move-

ment of the chain may be measured. Place a torque wrench and socket over the camshaft sprocket attaching bolt and apply torque in the direction of

crankshaft rotation to take up the slack; 30 foot-

pounds torque (with cylinder heads installed) or

15 foot-pounds torque (cylinder heads removed).

Holding a scale with dimensional reading even with edge of a chain link, apply torque in the reverse di-

rection 30 foot-pounds (with cylinder heads in-

stalled) or 15 foot-pounds (cylinder heads removed),

and note the amount of chain movement, as shown in Figure 64. Install a new timing chain, if its movement exceeds 11/64 inch.

CAMSHAFT SPROCKET

CRANKSHAFT SPROCKET

Fig.

63

— Alignment

of

Timing Marks

58x150

NOTE:

With a torque applied to camshaft sprocket

bolt, the crankshaft should not be permitted to move.

It may be necessary to block the crankshaft to pre-

vent rotation.

If chain is satisfactory, slide the crankshaft oil

slinger over shaft and up against the sprocket

(flange away from sprocket.)

TIMING CHAIN

CASE

COVER OIL SEAL

REPLACEMENT a. Removal

Position puller screw of Tool C-3506 through case cover, the inside of case cover up. Position the puller blocks directly opposite each other, and force the angular lip between neoprene and flange of the seal retainer. Place washer and nut on puller screw.

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CHRYSLER SERVICE MANUAL

ENGINE—59

PULLER BLOCKS (TOOL)

CHAIN CASE COVER

V

'. "

'.V-*.-

Fig.

65 — Puller Blocks Expanded to Pulling Position

/ '•

'^.?!^^T

>--•

LIP

OF

SEAL

RETAINER

58x152

Tighten the nut as tight as possible by hand, forcing

blocks into tainer only positioned retainer

into sleeve. Place

screw. Hold to remove seal (Fig.

b.

Installation of Oil Seal

gap to a

lip (Fig. 65).

at

this point). Place sleeve over

and

place removing

the

center screw

point

of

This

is

flat washer

66).

distorting

the

seal

important (puller and

installing plate

and nut on

and

tighten lock

puller

re is

the

nut

Insert puller screw through removing and installing plate

so

that

the

thin shoulder will

Insert puller screw with plate through

opening (inside

the seal

in

of

chain case cover facing up). Place

cover opening, with neoprene down. Place

be

facing

the

up.

seal

the seal installing plate into the new seal, with pro-

tective recess toward

Install the flat washer and

screw

and

tighten

The seal

is

properly installed when neoprene tight against the face inch feeler gauge between neoprene and cover

69).

If

the seal is installed properly, the feeler gauge

lip of

the nut

of

cover. Try

seal retainer (Fig.

nut

on puller screw, hold

(Fig.

68).

to

insert a .0015

67).

is

(Fig.

cannot be inserted.

PULLER SCRFW (TOOL) REMOVING

INSTALLING PLATE (TOOL)

AND

•- \

INSTALLING PLATE (TOOL)

SEAL"

ASSEMBLY

Fig.

67 — Positioning Installer Plate on New Seal

NOTE: collected between oil slinger after

It is

normal

the

to

find particles

seal retainer

seal has been

c. Installing Chain Case Cover

Be sure the mating surfaces cylinder block

PULLER SCREW (TOOL)

SEAL' RETAINER

SEAL

are

clean and free from burrs. Using

7

-: 58x155

Fig.

68 — Installing New Seal

FEELER GAUGE?

PULLER SCREW (TOOL)

CHAIN CASE COVER

58x154

of

neoprene

and

crankshaft

in

operation.

of

chain case cover and

INSTALLING PLATE (TOOL)

CHAIN CASE COVER

SLEEVE (TOOL)

^ "••*'

Fig.

66 — Removing Oil Seal

CHAIN CASE

COVER

58x153

CHAIN CASE

Fig.

69 — Checking Seal for Proper Seating

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60—ENGINE

CHRYSLER SERVICE MANUAL

A

CHAIN CASE COVER

TIMING INDICATOR

CYLINDER BLOCK

TIMING MARK

VIBRATION DAMPER

/

TOOL

58x157A

Fig.

70 — Installing Vibration Damper Assembly

a new gasket slide the chain case cover over the locating dowels and tighten bolts to 15 foot-pounds torque.

d. Installing Vibration Damper

Place the damper hub key in slot in crankshaft, and

slide hub on crankshaft. Place the installing tool,

part of Puller set Tool C-3033 in position and press damper hub on the crankshaft (Fig. 70). Slide the pulley over the shaft and attach with bolts and lockwashers. Tighten the bolts to 15 foot-pounds torque. Install damper hub retainer washer and bolts. Tighten to 135 foot-pounds torque.

CAMSHAFT

The camshaft has an integral oil pump and distributor drive gear and fuel pump eccentric, as shown in Figure 71.

Rearward camshaft thrust is taken by the rear face of the cast iron camshaft sprocket hub, bearing directly on the front of the cylinder block, eliminating the need for a thrust plate. The helical oil pump and distributor drive gear and the camshaft lobe taper both tend to produce only a rearward thrust.

58x159

Fig.

72 — Removing Distributor Drive Shaft Bushing

tor drive shaft. Remove the fuel pump to allow the

push rod to drop away from the cam eccentric. Re-

move the camshaft being careful not to damage the

cam bearings with the cam lobes.

DISTRIBUTOR DRIVE SHAFT BUSHINGS a. Removal

Insert Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 72). Hold the puller screw and tighten puller nut until bushing is re-

moved.

b.

Installation

Slide new bushing over burnishing end of Tool C3053 and insert the tool and bushing into bore, as shown in Figure 73.

Drive bushing and tool into position, using a soft hammer. As the burnisher is pulled through bushing by tightening puller nut, the bushing is expanded tight in block and burnished to correct size, as shown in Figure 74. DO NOT REAM THIS BUSHING.

Removal

With the tappets and timing sprockets removed, remove distributor and lift out oil pump and distribu-

BOIT

WASHER

Fig.

CAMSHAFT SPROCKET CAMSHAFT

-DISTRIBUTOR DRIVE GEAR (CAMSHAFT;

FUEL PUMP ECCENTRIC (CAMSHAFT)

LOCATING DOWEL

71 — Camshaft and Sprocket Assembly

BUSHING

TOOL

Fig.

73 — Installing Distributor Drive Shaft Bushing

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'•**?*

58x160

A*v

CHRYSLER SERVICE MANUAL

ENGINE—61

^58x161

Fig.

74

— Burnishing Distributor Drive Shaft Bushing

c. Camshaft Installation Lubricate the camshaft lobes and camshaft bearing

journals and insert the camshaft to within 2 inches of its final position in the cylinder block. Modify Tool C-3509 by grinding off the index lug holding

upper arm on the tool and rotate arm 180°. Install Tool C-3509 in place of distributor drive gear and shaft, as shown in Figure 75. Hold the tool in posi-

tion with distributor lock plate screw. This tool will restrict the camshaft from being pushed in too far and prevent knocking out the welch plug in the rear

of

the

cylinder block.

stalled until

the

The

camshaft

tool should remain

and

crankshaft sprockets

in-

and timing chain have been installed.

NOTE:

new camshaft and/or stalled,

tive should in.

minimum next normal

Whenever

one

The oil

TOOL

an

engine

quart

of

factory recommended

be

added

to

mixture should

of 500

miles. Drain

oil

change.

has

been rebuilt

new

tappets have been

the engine

be

left

oil to

in the

the oil

oil

aid

in

engine

mixture

ARM (TOOL)

and a

in-

addi-

break-

for a

at the

DISTRIBUTOR

CENTER LINE

Fig.

NOTE:

Whenever

the tappet faces must straight edge. served,

the

AND OIL

PUMP DRIVE

GEAR

OF

CRANKSHAFT

76

— Distributor Drive Gear Installation

the

camshaft

be

inspected

If any

tappet must

negative crown (dish)

be

d. Distributor (Basic) Timing

Before installing

shaft, time engine until

No. 1

stroke. When

the

as

cylinder

in

this position,

distributor follows: Rotate

is at top

the vibration damper should timing indicator. Coat shaft gine

oil.

Install rals into place, that

the

slot

center line

e. Installation

Hold distributor over block with center

of

ward

and to the tower terminal utor gasket

the

shaft

so

it

will index with

in

top

of

drive gear will

of

crankshaft

of

Distributor

the

vacuum chamber pointing toward

engine. Turn

as

the

mounting

approximate location

in the

in

position. Lower distributor

distributor cap. Place distrib-

is

replaced,

for

replaced.

and oil

dead center

the

straight line

be

under

and

drive gear with

that after

oil

be

shown

in

pad on

rotor until

all of

crown with

is ob-

pump drive

the

crankshaft

on

firing (DC) on the the

gear

pump shaft,

parallel with

Figure

76.

cylinder

it

points

for-

of the No. 1

and en-

a

on

en-

spi-

so

the

DISTRIBUTOR DRIVE GEAR (CAMSHAFT)

Fig.

75

— Camshaft Holding Tool

-C

58x162

Fig.

CRANKSHAFT MAIN BEARING

BEARING

77 —

OIL

HOLE]

Removing Camshaft Bearing

OIL

HOLE

58x164

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62—ENGINE

CHRYSLER SERVICE MANUAL

gage shaft in slot of distributor drive shaft gear.

Turn distributor clockwise until the breaker contacts

are just separating and install hold down clamp.

REMOVAL AND INSTALLATION OF CAMSHAFT BEARINGS (Engine Removed from Car)

a. Removal

With the engine completely disassembled, drive out

the rear cam bearing welch plug. Install proper size

adapters and horse shoe washers (part of Tool C3132A) at back of each bearing shell to be removed and drive out the bearing shells.

b.

Installation

\

Install the new camshaft bearings with Tool C-3132A by sliding the new camshaft (bearing shell over the proper adapter. Position bearing in the tool. In-

stall horse shoe lock and by reversing removal pro-

cedure, carefully drive bearing sliell into place, as

shown in Figure 77. Install remaining shells in like

manner.

NOTE: Install the No. 1 camshaft bearing 1/32" inward from front face of the cylinder block.

The oil holes in camshaft bearings and cylinder

block must be in exact alignment to insure proper

lubrication (Fig. 77).

Camshaft bearing index can be checked after in-

stallation by inserting a pencil flashlight in the bearing shell. The camshaft bearing oil hole should be perfectly aligned with the drilled oil passage from the main bearing. Another oil hole in the camshaft bearings should be visible by looking down on the left bank oil hole above and between No. 6 and No. 8 cylinders to No. 4 camshaft bearing and on the right bank above and between NoL 5 and 7 cylinders to No. 4 camshaft bearings. If the; camshaft bearing shell oil holes are not in exact Alignment, remove and reinstall them correctly. Use| Tool C-897 to install a new welch plug at the reajr of camshaft. Be sure this plug does not leak.

plugs are installed, coat the edges of plug and core

hole with a suitable sealer and drive plugs in place

with driver, Tool C-897. Examine block for cracks

or fractures. Remove the top ridge of cylinder bores with a reliable ridge rearmer before removing the

pistons from cylinder block. Be sure to keep the tops

of pistons covered during this operation.

NOTE: Pistons and connecting rods must be removed from the top of cylinder block. When removing pis-

ton and connecting rod assemblies from the engine,

rotate crankshaft so each connecting rod is centered in the cylinder bore.

Remove connecting rod cap. Install Tool C-3221 on one connecting rod bolt and protector over the other bolt and push each piston and rod assembly out of the cylinder bore. After removal, install bearing cap on mating rod.

a. Checking Cylinder Bores

The cylinder bores should be checked for

out-ofround and taper with Tool CM-119. If the cylinder bores show more than .005 inch out-of-round or a

taper of more than .010 inch the cylinder block

should be rebored and honed, and new pistons and rings fitted.

b.

Honing Cylinder Bores

To remove light scoring, scuffing, or scratches from

the cylinder walls, use Tool C-823. Usually a few

strokes will clean up a bore and maintain the required

limits.

The cylinder walls should be deglazed, using

cylinder surfacing hone Tool C-3501 equipped with 280 grit stones, prior to installation of the new rings or to smooth down the cylinder walls after rough

honing. A satisfactory finish can be obtained by

PISTON RING

FEELER GAGE

RING GROOVE

x

CYLINDER BLOCK |

The cylinder block is of the deep lj>lock design which eliminates the need for a torque converter housing adapter plate. Its sides extend three inches below the crankshaft centerline.

Cleaning and Inspection j

Clean cylinder block thoroughly ^nd check all core

hole plugs for evidence of leaking. If new core hole

Fig.

78

— Measuring Piston Ring Clearance

58x165

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CHRYSLER SERVICE MANUAL

ENGINE—63

giving each cylinder wall with

the

hone

so

that a cross hatch pattern will

20

strokes

obtained.

After honing, cleaned again to prevent excessive wear may

be

safely used

inch

and as

it is

to

remove

high

as .010 to

necessary that

all

traces

of

engine parts. The hone

for

removal

.015 inch

enced operator.

CAUTION

Be sure after honing.

soap oughly dried. gine

all

and

water

oil and

abrasives

It is

If

are

removed from engine parts

Chrysler Imperial 1959, New Yorker 1959, Saratoga 1959 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual