Chrysler Valiant VC Workshop Manual

CONTENTS ENGINE Speci~caotions 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .. 0 0 .. 0 0 0 0 0 0 0 0 0 0 .... 0 0 0 0 0 .. 0 0 0 .. 0 0 .. 0 0 .. 0 .. Descnptwn Oo ooo oo 000 ooO OO oooo oO ooo.oooo .o.oo ·oo·Oooo ·o· .o.o· ·oo ... 0000 ·o· o .. Engine Assembly 00 .... ooOO· 000000 .. 00 0 •oooooooooooo.oo .... ............. 0 Cylinder Head .. 00 00.00 00.00 ......... 00 ..... .. 00 .. 00 ..... 00 00 .. 0 00 .. 0 00 .. . Rocker Arms & Shaft 00 .. oo .. oo . 00 00 00 .. o ... 00.00 .... 00 00.00 .... 0 Timing Cover & Oil Seal 00 .. .. .. oo ........... 00 00 00 00 .. 00 00 0 Timing Chain & Sprockets 00 ..... 00 00 ... 00 00 .00 .. 00 00 00.00 .. .. Camshaft and Tappets ···· ······ ·oo· · .. ........ . 00 ....... o .. oooo. Pistons & Connecting Rods .. ·oo .......... 00 0000 .. 00 00 00 .... .. Crankshaft & Main Bearings oo·oo .. oo ...... oo .. . oo .... .... oo Engine Sump o .......o oo o.o ...... .......... ...... oo ......... ooooOoo• 0000000 Oil Pump o .... oo .. oo .... oooooo••oo·•oo•oo• .. oo .. oooOoo .............. .... ... .. Flywheel Ring Gear .oo .... oooo ..... oo ... ·······oo .·oo ·oooo ·oooooooo Positive Crankcase Ventilation ....... oo ... ... .... oo ... oo .. .. Manifolds oooooooo ·· ··· ·ooo .. ooo•oo··o·o···oooooooooo ... . oooooooo ·o ·· ···· oo ·· o Engine Fault Diagnosis . ·· oo·· ····oo· .oooo ........ oo. oo oo ·oo·oo ... o COOLING SYSTEM ~~~ifl~~i~~ns .. o :::::::::::::::::::::::::::::::::::::::::::::::: :: :: : ::::: :: :: Radiator .o ...o .oo oooooooooooooo · •·oo•Ooooooo.o.oo .. ooooo ·.o·oo ·o···oooo ·· .. ··o Thermostat .0 0 0. 0000 .. 00 00 oo· 0 00 .. 0. 0. 00 .... 0. 0. 00 .. 0 ... 00. oo· .... 0 0 .. 0 .. 0 ... Water Pump .... oooooooooo.oo ........ ooooooo .... .. ooo ... oo ...... oo .. oooo ... . Fan Belt ..... .. oo· ·· ··oo ·· ·· ······· ···· ··· ·oo·· ···· ···· ·oo ·· ·oooo .oooooo ··oOoo Oil Cooler (Automatic Transmission) ...... oooo·oO·oooOoo Cooling System Fault Diagnosis ... oooo.oo . 00 ooooo ........ oo FUEL SYSTEM Specifications .. .. .. . ooo 00 .. oo ... oo oo ......... oo 00 •oo· 00 00 ... oo .......... .. Carburettor o· ··o 0000. ··o·· o ·· .. .. .... ...... ...... ··o · ·· ·o ·.o· o ·.oooo ·o ·· ··o Carburettor AP5 Models ··oooo••oo·· ·· .. ........ oooooo ....... .. Carburettor AP6-VC Models oo ..... oo .. oo ...... . oo ..... oo ... oo Carburettor - VE-3 - VE-4, VF-3 Carburettor - VF -4 VE-7 - VE-8, VF-7 VF-8 Models ..... ...... . Fuel Pump oooooo .. oo .. oo·· ······oo·· .. oo·oo••oo•oo ··· .. ·oo···. ·oooooooo ·oo Fuel Tank oo.oo.oo•oo····oooooo·oo···oo·oo···· .. ........ ....... o·oo .. ··o .. . Fuel System Fault Diagnosis ... .. ..... ·oo •oooo ..... .... .. . oo CLUTCH Speci~caotions ... 00........... .............. 00 00 .. . Descnptton 00 .oo .. oo 0000 .oo ....... .. . oo .......... .. ... . oo .. . Clutch Unit . . .. oo .... oo .. ... .............. .. .. Clutch Release Fork . Release Bearing ........ ..... . Release Linkage Cross Shaft Bush ... .. Pedal and Linkage Adjustments .. Clutch Housing Alignment oo• .... oo ................ .... ..... .. Hydraulic System (R VI) .. ........ .. oo ... oo .o ooooo .... 00 .. 0 Clutch Fault Diagnosis .... oo .............. . 00 ... 00 ..... ..... ... .. MANUAL TRANSMISSION Specifications ... oo. ·oo· oo·· ... oo .. oo oooo· ... ....... Transmission Assembly (RVI - SVI - AP5 - AP6 Models) 7 12 13 14 17- 18 18 20 21 23 25 26 27 28 29 30 35 35 36 36 37 38 39 39 41 46 53 58 62 71 77 79 80 83 84 84 89 89 90 90 90 94 95 97 99 Transmission Assembly (VC - VE - VF Models) ... . oooooo.oooooooo 0000 oo ..... oooo .. Floor Gearshift RVl and VF Pacer Models OOoOooOO···oooooooo ........ oo ... oooo Column Control Gearshift oooo ..... oo ... .. .... . oooo ..... ooooo0 Propeller Shaft ......... ··oo· ...... oo. 00 .oo . ··oo oooo ... 00 .. oo ...... oo ·o ···. Universal Joint .... ooooo•oo·· ··oooOoo ....... oo .oo .... oooooo ..... .. .. ... oo Engine Fault Diagnosis oooooo. ,oooooo.oo .... oooo·· .. oo .... oo ... oooo AUTOMATIC TRANSMISSION ~e~ifl~~i~~n~ .oo::::::::::::::::::::: ::: :::::::::::::::::::::::::::::::::::::: Hydraulic Fluid ....... ooooooooooooo•o·····oo·· .. O ···o· ··oo .. ooooo o ooo .. Kick down Band .. . 00 .. 00 .. .... 00 .00 0 00 ........ ·oo 0 ... 0 00. oooo. 00 ... oo .. Low and Reverse Band ...... .... ........ .... .... 00 ... . 00 ........ 00 Transmission Shift Linkage ... oo. ·oo· oooo• ...... 00000000000 00 ·· Neutral Starting Switch ......... ·oo·· .... .. .. oo ... oo .. oo ...... .. . 00 Carburettor Throttle & Kickdown Valve Cable /L inkage ·· ·····oo······oo .. oo ... .. oo .... oo.oooo.oo.,oooo Hydraulic Control Pressures - Up to VE Series Hydraulic Control and Air Pressure Tests - VF Models .. ... .... .. oo ... oo.oo·ooooooo .. ooooooooooo ... . oo .... ooooOOoOOOOOoo Transmission Assembly oo · .oo oo. 0000 ... oo ... oooo .. 000000o000o00000 . Transmission Fault Diagnosis oooooooooo ... oo.oooooooooo·oO·oo REAR AXLE Speci~caotions ... 0 .0 0. 00 0 0 0 .0 . 0. 0 00 0 ...... .. .. ... ........ .. 00 0 ... 0. 00 ...... 0 Descnpt10n 000 .... ... ... •oooo ... .o .oo ·oo· ... o ..... .... o .... o.·o····o··o·oOoo. Axle Assembly ... ........... 0000 oooo• ooooooo··oo .. ... .. 0 ....... oooo ... oo .. Axle Shafts 00 ............ 00 oo ... 00. oo· . .. ooOO .. oo ............. 0000 .oo 00 Differential and Final Drive 00 ............... .... ..... . oo .. . Limit (Optional) Slip Differential ··oooooo .. 00 ....... 0000 Rear Axle Fault Diagnosis ... .... ...... 0000 ....... . FRONT SUSPENSION ~~~ifl~~i~~ns ... :::::::::::::::::::::::::::: :::: :::::: : :: : :::::::::::::::::::: Front Hub oooo·· ·oo ... oo.ooooo .. oooo·oo·oo·· ····· ·00 00 ·00° 0000 o0 00 · 00 · .. ··oo Steering Ball Joint - Upper 00o0000000 .... ....... oooooo ... oo Steering Ball Joint - Lower ···oo ···oo·oo .. ··OO ··oo ··oooo ... Steering Swivel .... ... .... .. .. oo. •oo · 00 ..... .. oo ... ··oo· oo ....... .. .. oo . Upper Suspension Arm oo .. .... ... . oo .. oooo ... oooo••OOoo•oo•oo ·· ·· · Torsion Bars .. . .. oo .... .... oo. oo•· .......... .... ... .. .... 00 oo• . Lower Control Arm Strut oo•oo· ··· ···· .. ··oooooo ........ . oooo··· · Lower Control Arm & Shaft .... . oo oo••oo• OOoo• oooooo·oo··· Suspension Crossmember .oo .. oo ...... .... .... .. ... .... .. oo ... ... Suspension Height .... .. oo .......... oo oo ..... oo ...... oo·· 00 Suspension & Steering Angles .......... oo .............. oo··oo Shock Absorbers .oo ... oo. ·····oooo oo·· .... ..... .. .. 0000 ... 00000000· · oo·· Stabiliser Bar .. . ...... 0000 .... ... ... ... .. .... oo .. .. oo ... . Front Suspension Fault Diagnosis .. 00 ..... ........ ... REAR SUSPENSION Specifications .. ... ......... oo .......... .. oo .. 00 ........ 00 ··o ·... Description ... .. ....... 00.00 ................ 00 00 .00 ... .. . Shock Absorbers ...... .... 0000· Springs .... oo .. .... oooo··ooo .... oo.oo .... ... ... . Suspension Fault Diagnosis ... ... ...... .. .. oooo ... oo ......... oo 105 113 115 119 120 123 125 127 128 129 129 130 131 132 135 136 136 138 141 142 142 142 143 148 151 153 154 154 156 157 158 160 161 163 163 165 166 167 168 169 169 171 171 171 172 172

STEERING Speci~c~tions .. ... .......... .. .. .. .. .. .. .. .. .. . .. ........ .... .. .. .. .. .. . .. . 173 Qescnptlon .. .. .. .. .. .. .. .......... .. ..... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ....... 173 Steering Gear Assembly ...... ... ........ .. ..................... 174 Sector Shaft Oil Seal .. .... .. .. .. .. . .. . .... .... .......... .... .. ... .. . 177 Ball Nut Rack and Sector Mesh Adjustment .. .. 177 Worm Shaft Bearing Preload .. .. .............. .............. 177 Steering Column .. .... .... .... .. .. .. .. .. .. ... .. . .. .. .. .. . .. .... .... .. . .. 178 Steering Fault Diagnosis .. ....... .. .. .. ..... .... ................ 185 BRAKES Speci~ca.tions .. . .. .. . .. .. .. .. . .. .. .. .. .. .. ...... .. .. .. .. .. ... .. .. .. . .. .... . 187 Descnptlon ..... .. .. .. ...... ..... ... ..... .......... .......... ... ...... .. ... .. 188 Master Cylinder .. .... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .... . .. . .. 188 Hydraulic System Safety Switch ..... .. .. ........ ........ ... 193 Rear Wheel Cylinder ................................................ 193 Front Wheel Cylinder ........ .. .... ... ... .......................... 194 Hydraulic System ...................................... .. .. .. .......... 195 Front Brake Drum & Shoes .................................... 195 Rear Brake Drum & Shoes .................................... 197 Front Disc Brakes ......... ......... .... .. ... ..... ....... ... :......... 200 Brake Adjustments .. .. .. .. .. .. ... .. .. .. .. . .. .. .. .. . .. ... .. .. .. .. 202 Vacuum Booster Unit ............ ... ........ .. ........... .. ... ... .... 204 Brake Fault Diagnosis ... .. ...... .. ...... .. ... .. .. ........ ... ....... 208 ELECTRICAL SYSTEM Specifications ................................................. ... .. .... .. .. Battery .................................................................... ..... . Alternator & Regulator ....... .. .. ............ .. ......... ..... ... .. Starter Motor ........ ........ .............. .. .. ... .. ....... ........ .... .. .. Distributor ................................................................ .. 211 214 214 222 229 Spa.r~ Plu~s ~ High Tension Cables .................... 234 Igmtlon Clrcmts ............................................. .. ... .. .... 235 Direction Indicator Switch ...... .............................. 236 Windscreen Wiper .... ..... ...... ...... .. .. .. .. .... ...... .. .... ... ... ... 237 Headlamps ............. ............. ....... .. .. ......... ..... .... ........... 239 Electrical Fault Diagnosis ..... ................... .. ............. . 241 BODY Specifications .................................... ......... ..... ... ... ... ... 255 Lifting and Jacking Points ...................................... 255 Windscreen and Rear Glass ..... .. .. .. ........ .. .. .. ..... .. .. .. 256 Front and Rear Doors .......... ........ .... .... .. . .. .. ........ ... 257 Engine Bonnet, Lock and Hinges ........ .. .... . .. .. .. . .. 262 Radiator Grille .. . .. .. .. . .. .. .... . .. .. .. .. .. .. .. .. .... .. .. ..... .. .. ... . .. 264 Front Fenders ...... ... ........ .... ....................................... 264 Luggage Compartment ..... ......................................... 265 Station Sedan Tail Gate ........ ..... .. .......... .. .... ............. 266 Head Lining .. . .. .. .. .. .. .. .. .. .. .. ... .. .. .... .... .. . .. . .... .. ............. 269 WHEELS AND TYRES Specifications ....... .. ..... ............ .............. ... ...... .. .... ....... 271 Tyre and Wheel Assembly .... .... ........ .. ......... ..... .. 272 Tubeless Tyres ............................................................ 272 Tyre Wear Fault Diagnosis .... ....... .. .......... ... .... ...... 275 LUBRICATION AND MAINTENANCE Specifications .. .. ... .. ........ ..... ...... .. ... .... .. .......... ...... ... ... . ~~;~~~i~~i~~·· ··::::::::::::::::::::::::: : : ::::::::::::::::::::::::::::::::::: Suspension and Steering ........................................ .. Miscellaneous ........... .. ... ... ... .. .. .. ........ ...... ......... ... ... .. . 277 278 278 278 279

Type .... Bore diameter Stroke ... . Capacity .. . Compression ratios Compression pressure at cranking speed Maximum variation between cylinders Maximum bhp at engine rpm : 8.2: I cr 8.4: I cr 9.2: I cr RAC rating Maximum torque (8.2: I and 8.4: I cr) 9.2: I cr . Firing order Type .......... . Combustion chamber type Valve seat angle Valve seat width: Inlet Exhaust . .. Valve seat run-out, maximum Cylinder head gasket compressed thickness Head diameter: Inlet · ... Exhaust .. Stem diameter: Inlet Exhaust Stem to guide clearance: Inlet Exhaust ENGINE SPECIFICATIONS CYLINDER HEAD VALVES 7 6 cyl-in line-ohv 3.401" 4.125" 225 cu in 8.2: 1 early, 8.4:1 later. VF SERIES 8.4: 1 Standard 9.2 : 1 High compression 7.5:1 Low compression 110-140 psi at 130 rpm 125-155 psi at 130 rpm (9 .2: 1 engines) 20 psi 145 at 4,400 145 at 4000 160 at 4500 27.7 hp 215 ft/lb at 2400 rpm 220 ft/lb at 2500 rpm 1-5-3-6-2-4 Cast iron with integral valve guides Wedge shape 45° .080" ± .01 0" .050" ± .0 I 0" .002" .022" 1.62 0" ± .005" 1.360" ± .005" .373" + .000" .001" .372" + .000" .001 "" .001" + .002" .000" . 002'' + .002" . .000"

2-Engine Valve face angle: Inlet Exhaust . . . Valve lift - inlet : RV-SV-AP5-AP6 VC-VE-VF ... Valve lift - exhaust: RV-SV-AP5-AP6 VC-VE-VF ... Valve timing - RV-SV-AP5 Models : Inlet 6pens . . Inlet closes . . Exhaust opens Exhaust closes Valve timing- AP6-VC-VE3-VE4-VF3-VF4 Models: Inlet opens . . Inlet closes . . Exhaust opens Exhaust closes Valve timing - VE7-VE8-VF7-VF8 Models: Inlet opens . . Inlet closes .. Exhaust opens Exhaust closes Rocker arm to valve stem clearance (hot): Inlet Exhaust . .... . .... .. · . . . . Type .... . .. . Free length: RV-SV-AP5-AP6 VC-VE-VF . ... Length and load, valve closed: RV-SV ........ . AP5-AP6-VC-VE-VF .. Length and load, valve open: RV-SV ...... . AP5-AP6-VC-VE-VF .. Cylinder bore - standard Bore out of round -maximum Bore taper - maximum Permissible oversize - maximum Tappet bore diameter ... .. VALVE SPRINGS CYLINDER BLOCK 8 45° 47° , 43° (VF Series) .375" .395" .360" .395" 8° btdc 44° abdc 48° bbdc tdc 10° btdc 50° abdc 50° bbdc 6° atdc 12° btdc 52° abdc 50° bbdc 14° atdc .0 I 0" .020" Single 2" 1.92" 1.687" at 68-76 lb 1.687" at 49-57 lb 1.312" at 160-172lb 1.312"at 137-1501b 3.40" .005" .0 I 0" . 040" .9053" + .0005" . 003" A '

Type ............. . Overall length . . . . . . . . . Clearance in bore at top of skirt Oversizes available . . . . Piston weight . . . . . . Number of piston rings: .Compression Oil control ..... Ring land clearance, overall Type .. Diameter Length . Clearance in piston Interference fit in rod Gudgeon pins available Offset in piston Number of rings: Compression Oil control Width of rings: Compression Oil control- RV-SV-AP5-AP6 Oil control- VC-VE-VF Ring gap : Compression Oil control Side clearance in piston groove: Compression . . . . . Oil control - RV Oil control - SV-AP5-AP6 Oil control - VC-VE-VF . tr PISTONS GUDGEON PINS PISTON RINGS 9 Engine--3 Tin plated aluminium alloy, steel strut 3.51" .0005" + .001" .000" .005", .020", .040" 16 oz 2 I .025" + .005" .000" Press fit in rod .9009" + .000" 2.960" ± .00045" + .0012" + Standard only .0002" .01 5" .0003" .000" .000" .0005" To right side of engine 2 .078" + .1865" + .000" . 0005" .000" . 0005" .025" Steel segments .010" + .01 5" + .0015" + .001 5" + .010" . 000" .045" . 000" .001 5" .000" . oor5" .000" . 009" maximum .0002" + . 004" . 000"

4-Engine Main bearing journal diameter Cr ankpin di ameter . . . . . . Permissible journal out of round Crankshaft end float End float taken at . Number of main bearings Bearing running clearance Und ersize bearings available Be aring wear limit ..... Type of rod .. .... . Length between centres . Side clearance on crankpin Small end bore diameter Big end bearing type Bearing diameter Bearing length . Bearing clearance Bearing wear limit Bearing bore diameter Bearing crush . .... Undersize bearings available Journal diameter: 1\ o 1 No 2 No 3 No 4 End thrust taken at Bearing bore diameter, fitted: No I No 2 CRANKSHAFT AND MAIN BEARINGS CONNECTING ROD AND BEARINGS CAMSHAFT AND BEARINGS 10 2.7505" + 2.1875" + .000" .001" . 000" .001" .001" maximum .002" + . .005" . 000" No 3 main bearing 4 .0005" + . 001" .000" . 001 " , .002", . 003", .010", .012" . 003" H section forging 6.699" ± .002" . 009" ± . 003" .8995" + . 0005" .000" Steel backed babbit 2.187" 1:015" .0005" + . 001" . 0025" 2.3125" + .002" + .000" .0003" .0000" . 004" . 000" .001 ", .002", .003" , .010", .012" 1.999,., + .000" .001 " 1.983" + .000" . 001" 1.968" + .000" . 001" 1.952" + .000" .001" Front of crankcase 2.000" + . 001" .000" 1.984" + .001" .000"

' No 3 No4 Bearing clearance Bearing wear limit Camshaft drive . . Number of chain links Chain pitch . Chain width .. ... Tappet type Bore in block Tappet outer diameter Tappet to bore clearance Rocker arm type . . . . Rocker to valve stem clearance {hot): Inlet Exhaust ..... ....... . . TAPPETS AND ROCKERS LUBRICATION Oil pump type .. . .. ............. . Relief valve spring length: Standard, colored red . Light, colored grey .. Heavy, colored brown Operating pressure at 45 mph Filter type ......... . Sump refill capacity .... . Sump capacity with filter change Engine oil grade: Above 32°F l0°F to 32°F Below l0°F . Cylinde( head bolts Main bearing bolts . Connecting rod nuts Camshaft sprocket bolt Rocker cover bolts . . . .. Rocker shaft pedestal bolts Starter mounting bolts ... Front engine mounting to frame nut Front engine mounting to block screw Front engine mounting to bracket nut Rear engine mounting bolts . . . . . TORQUE WRENCH SETTINGS 11 1.970" + 1.054" + .001" + . 005" .000" .001" .000" . 001" .002' . 000" Chain and sprockets 50 lh" .880" Solid cylindrical .9053" + .0005" .9045" + . 0012" + Steel stamping .01 0" .020" .0003" .000" .0005" .0013" .000" Eccentric rotor 2.296" 2.19.0" 2.390" 45-65 psi Replaceable element 6.66 Imp pt 8.33 Imp pt SAE 30 or 10W-30 SAE 20 or 10W-30 SAE 10 or lOW-30 65 ft/lb 85 ft/lb 45 ft/lb 35 ft/lb 40 in/lb 30 ft/lb 50 ft/lb 75 ft/lb 50 ft/lb 35 ft/lb 35 ft/lb Engine--5

6-Engine I. DESCRIPTION The engine is a six cylinder in-line, over-head valve type and is inclined 30 degrees from the vertical to the right. A chrome alloy cast iron cylinder head has wedge shaped combustion chambers and integral valve guides. Aluminium tubes in the cylinder head serve as gaskets for the spark plugs. Poppet type valves, with single springs are installed on the cylinder head. The valves are operated by stamped rocker arms in conjunction with push rods and tappets actuated by the camshaft. The rocker arms are positioned on the one piece rocker shaft by hardened steel spacers used between pairs of rocker arms and seven rocker shaft brackets on the cylinder head. The rocker shaft is located in position by bolts and stamped steel retainers attached to the brackets. A cast iron cylinder block and integral crankcase is line bored for the crankshaft main bearings and the camshaft bearings. A water pump housing is cast in the forward end of the block. Bores in the block are provided for the solid cylindrical tappets. A counter-weighted balanced crankshaft runs in four main bearings. End thrust is taken at No 3 bearing. The front end of the crankshaft carries a vibration damper, valve timing sprocket and pulley for fan and alternator belt drive. The flywheel is bolted to the flanged rear end. The camshaft has integral oil pump and distributor drive gear, and fuel pump eccentric, carries the valve timing sprocket at its forward end and runs in four bearings. End thrust is taken on the rear face of the timing sprocket bearing directly on the front face of the cylinder block. End thrust of the camshaft occurs only to the rear on account of the drive reaction at the oil pump and distributor drive gear and the taper on the cam lobes. The camshaft and the crankshaft sprocket are coupled by an endless chain. The cam ground pistons are tin plated aluminium alloy with steel strut and have two compression rings and one oil control ring each. Oil control rings on VC, VE and VF series are steel segment type. Bushings in the piston bosses provide bearings for the gudgeon pins which are a press fit in H section forged connecting rods. The gudgeon pins are offset to the right side of the engine. Big end bearings are steel backed babbit shell type. An eccentric rotor type oil pump is mounted Engine Assembly (Right Hand Side) .' 12

Engine--7 Engine Assembly (Left Hand Side) .' externally on the lower right side of the cylinder block. The pump draws oil through a screen in the sump and delivers it via a full flow, replaceable element oil filter to the oil gallery from where it is distributed to the crankshaft main bearings, the camshaft bearings and the overhead rocker and valve mechanism. The pump incorporates a pressure relief valve. Induction and exhaust manifolds are both on the left of the engine. They are bolted together at a central connection permitting exhaust heat, controlled by a thermostatic heat control valve, to be directed to a heat chamber in the induction manifold below the carburettor. A choke thermostatic control is located in a pocket in the exhaust manifold. Air is filtered through a gauze in the oil filler cap and is drawn out with crankcase fumes through a ventilation valve on the rocker cover and thence by a hose to a connection on the induction manifold. This provides positive crankcase ventilation. Early engines have a compression ratio of 8.2: I. Later engines have a ratio of 8.4 : I. Pacer engine h~ a compression ratio of 9.2: I. 2. ENGINE ASSEMBLY TO REMOVE AND INSTAL (I) Mark around the bonnet hinges with a pencil to facilitate replacement and remove the bonnet. (2) Drain the cooling system at the cock at the bottom of the radiator and the plug on the side of the cylinder block. (3) Disconnect the battery leads and remove the battery from the car. (4) Disconnect the upper and lower radiator hoses and heater, hoses and remove the radiator. 13 NOTE: On automatic transmission models it will be necessary to disconnect the oil cooler lines before the radiator is removed. Plug the ends of the line. (5) Remove the crankcase ventilation valve hose from the rocker cover and remove the carburettor air cleaner. On RV-1 Series disconnect the oil filter lines. ( 6) Disconnect the fuel line from the tank at the fuel pump. Disconnect all electrical leads to the engine. (7) Disconnect the carbure ttor linkage and remove the accelerator and shaft from the engine bulkhead.

8-Engine (8) Disconnect the exhaust pipe from the manifold and remove the exhaust pipe and silencer assembly. (9) Jack up the car and support on stands. (10) On manual transmission rnodels - Drain the transmission, remove the clutch torque shaft and remove the transmission as outlined in MANUAL TRANSMISSION - TO REMOVE AND INSTAL (II) On automatic transmission models - Drain the convert -e r and transmission and remove the assembly as outlined in AUTOMATIC TRANSMISSION - TRANS- MISSION ASSEMBLY- TO REMOVE. NOTE: Procedures (I 0) or ( 11) as described will cover removal of all associated connections, linkages and components. (12) Support the rear of the engine using the special fixture and remove the engine rear support crossmember. (13) Lower the vehicle and remove stands. (14) Using a suitable sling and lifting tackle take up the weight of the engine and remove the special engine support fixture used at (12) above. (15) Remove the front engine mounting bolts and raise the engine at an angle with the front higher than the rear and manoeuvre it clear through the bonnet opening. Installation is a reversal of the removal procedure with attention to the following points: The front engine mounting bolts should be torqued to 85 ft/lb after the full weight of the engine and transmission is taken on the mountings. Check the procedures for installing manual or automatic transmission, as applicable, in the appropriate sections. 3. CYLINDER HEAD TO REMOVE AND INSTAL (1) Drain the cooling system at the lower radiator tank cock and the plug on the side of the cylinder block. (2) Remove the air cleaner, disconnect the choke control cable and accelerator linkage at the carburettor. (3) Disconnect the fuel pipes at the carburettor and fuel pump, and the vacuum pipes at the carburettor and distributor. (4) Remove the high tension wires from the distributor and coil and remove the distributor cap. Remove the plugs. 13 9 5 10 6 2 (5) Disconnect the heater hose and the clamp holding the by-pass hose. (6) Disconnect the water temperature sending unit lead. (7) Disconnect the exhaust pipe from the exhaust manifold, undo the nuts securing the manifolds to the cylinder head and remove both manifolds and carburettor as an assembly. (8) Remove the crankcase ventilation valve hose from the rocker cover and remove the rocker cover. In order to remove the rocker cover proceed as follows when an air conditioner is installed : 3 7 11 4 12 Cylinder Head Tightening Sequence. 14

Chrysler Valiant VC Workshop Manual

You're Reading a Preview

Recently Viewed