Chrysler Valiant VF Series workshop manual

QUICK REFERENCE INDEX: To use, bend manual back to expose black spots on pages of the various groups. Then, by means of the index arrows on this page, locate the corresponding black spots on the pages of the group you you desire to find. VF SERIES Valiant SERVICE MANUAL COPYRIGHT 1969 d~CHRVSLER ~ AUSTRALIA LTD. SERVICE DIVISION CHRYSLER PARK, SOUTH AUSTRALIA PART NO. 3426224 GROUP INDEX GROUP TITLE 1 Lubrication and Maintenance 2 Front Suspension 3 Rear Axle 5 Brakes 6 Clutch 7 Cooling System 8 Electrical 9 Engine 11 Exhaust System 14 Fuel System 16 17 19 21 22 .23 24 Propeller Shaft and Universal Joints Springs and Shock Absorbers Steering Transmissions Wheels and Tyres Body and Sheetmetal Air Conditioning

This manual has been prepared to provide service personnel with service information for Valiant vehicle models shown on the following page. It covers many conditions that may be encountered and their possible causes and remedies. Each section contains practical disassembly, repair and assembly procedures. Included in the manual are numerous illustrations showing the proper service tools in use. Specifications are tabulated at the beginning of each section for quick reference. Chrysler Australia Limited reserves the right to make changes in design or to make additions to, or improvements in its product, without imposing any obligation upon itself to install them on its products previously manufactured.

Lubrication and Maintenance 1 - 1 GROUP 1 LUBRICATION AND MAINTENANCE SERVICE BULLETINS 1 - 2 SERVICE INFORMATION- PROCEDURES 1 - 3 1. ENGINE OIL 1 - 3 2. CAPACITIES 1 - 4 3. OIL FILLER PIPE AIR CLEANER 1 - 4 4. CARBURETTOR AIR CLEANER 1 - 4 5. BATTERY 1 - 5 6. BODY 1 - 5 7. BRAKES 1 - 5 8. CHASSIS LUBRICATION 1 - 5 9. COOLING SYSTEM 1 - 6 10. DISTRIBUTOR 1 - 6 11. ENGINE OIL FILTER 1 - 7 12. FRONT WHEEL ALIGNMENT 1 - 7 13. MANIFOLD HEAT CONTROL VALVE 1 - 7 14. REAR AXLE 1 - 7 15. STEERING 1 - 8 16. TYRES 1 - 8 17. TRANSMISSIONS 1 - 9 18 . UNIVERSAL JOINTS 1 - 10 19. WHEEL BEARINGS 1 - 11 20. CRANKCASE VENTILATOR VALVE 1 -11 21. CARBURETTOR FUEL FILTER 1 - 12 22. CLUTCH TORQUE SHAFT 1 - 12 23. ALTERNATOR 1 - 12 24. RUBBER BUSHINGS 1 - 12 .I 25. SPEEDOMETER CABLE LUBRICATION 1 - 13 26. HOISTING INSTRUCTIONS 1 - 13 LUBRICATION AND MAINTENANCE SCHEDULE 1 - 14 if)

Lubrication and Maintenance 1 - 2 SERVICE BULLETIN REFERENCE DATE NUMBER SUBJECT CHANGES - . ::-

~--------------------- MODEL CODES ----------------------~ SEDAN 6 Cylinder MANUAL TRANSMISSION MANUAL TRANSMISSION PACER MANUAL TRANSMISSION AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION REGAL AUTOMATIC TRANSMISSION REGAL AUTOMATIC TRANSMISSION V.I.P. AUTOMATIC TRANSMISSION 8 Cylinder "318" AUTOMATIC TRANSMISSION REGAL "318" AUTOMATIC TRANSMISSION REGAL "770" "FIREBALL" AUTOMATIC TRANSMISSION V.I.P. "FIREBALL" AUTOMATIC TRANSMISSION STATION 6 Cylinder MANUAL TRANSMISSION WAGON MANUAL TRANSMISSION AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION REGAL AUTOMATIC TRANSMISSION REGAL AUTOMATIC TRANSMISSION 8 Cylinder "318" AUTOMATIC TRANSMISSION REGAL "318" AUTOMATIC TRANSMISSION UTILITY 6 Cylinder MANUAL TRANSMISSION MANUAL TRANSMISSION AUTOMATIC TRANSMISSION WAYFARER MANUAL TRANSMISSION WAYFARER MANUAL TRANSMISSION WAYFARER AUTOMATIC TRANSMISSION VF3-M-41 VF7-M-41 VF7 -S-41 VF4-M-41 VF8-M-41 VF4-H-41 VF8-H-41 VF8-P-41 VF6-M-41 VF6-H-41 VF6-H-41 VF6-P-41 VF3-M-45 VF7-M-45 VF4-M-45 VF8-M-45 VF4-H-45 VF8-H-45 VF6-M-45 VF6-H-45 VF3-L-20 VF7-L-20 VF4-L-20 VF3-M-20 VF7-M-20 VF8-M-20 (A70)

GENERAL SPECIFICATIONS, ENGINE AND BODY NUMBERS ENGINES--------------- 6 CYLINDER 8 CYLINDER Models VF3/VF4 VF7/VF8- (VF7-S) "318"- VF6- FIREBALL" Type In-line OHV 90°V OHV Bore and Stroke 3.400" x 4.125" 3.91" x 3.31" Piston Displacement 225 cu. ins. 318 cu. ins. Compression Ratio 8.4:1 9.2:1 ("Pacer") 9.2:1 B.H.P. @ R.P.M. 145 @ 4000 160 @ 4500 210 @ 4400 230 @ 4400 Torque (lbs./ ft. @ R.P.M.) 215 @ 2400 220 @ 2500 320 @ 2400 340 @ 2400 Taxable Horsepower 27.7 42.2 1--------------- VEHICLE DIMENSIONS -------------1 Wheel-b.ase 108" (all except) V.I.P. 112" Track - Front 57. 9" (all except) Pacer, V.I.P. and Regal "770" -Rear 56.1" (all except) Pacer, V.I.P. and Regal "770" Overall Length Sedan 192.32" (all except) . V.I.P. 196.32" Station Wagon 192.32" Utility Overall Width 69.7" Overall Height Sedan ( 3 pass) 55.0" (all except) Station Wagon 55.0" Utility 55.0" Pacer, V.I.P. and Regal "770" 58.5" 56.6" 54.6"

VEHICLE MODEL CODE IDENTIFICATION ENGINE NUMBERS 6 Cylinder The engine number is stamped on a ground surface located centrally on the left hand side of the cylinder block adjacent to the engine support bracket. The engine number prefixes denote the following engine and transmission equipment combinations. * F30000 * - 225 cu. m. Standard performance, with Manual Transmission. * F40000 * - 225 cu. in. Standard performance, with Automatic Transmission. * F70000 * 225 cu. in. High performance, with Manual Trans- mission. * F7HOOOO * - 225 cu. in. (High compression) High performance, with Manual Transmission. * F80000 * - 225 cu. in. High performance, with Automatic Trans- mission. NOTE that an asterisk is positioned at each end of the complete engine number. 8 Cylinder The engine number is stamped diagonally on the left hand rear horizontal pad positioned above the starting motor mounting face of the engine block extension. The engine number prefixes denote the following engine and transmission equipment. F60000 - 318 cu. in. V8 engine with Automatic Transmission. F6POOOO - 318 cu. in. Fireball V8 engine with Automatic Trans- mission BODY NUMBERS The body number which includes the model type, vehicle serial number and suffix numbers are stamped into the top of the right hand engine compartment splash panel. SUFFIX NUMBERS The suffix numbers, that foll ow the body/ vehicle number, indicate the sales codes which are used to identify the optional equipment built into the vehicle as original equipment and therefore varies from the base model vehicle.

Lubrication and Maintenance 1 - 3 SERVICE INFORMATION- PROCEDURES 1. ENGINE OIL Lubricants are classified and graded according to standards recommended by the Society of Automotive Engineers ( S.A.E.), the American Petroleum Institute (A.P.I.) and the National Lubricating Grease Institute (N.L.G.I.). The S.A.E. grade number indicates viscosity or fluidity of the lubricant, e.g. S.A.E. 30 engine oils may have a dual number, one of which is S.A.E. lOW-40. This marking indicates that the oil is comparable to S.A.E. lOW, S.A.E. 20, and S.A.E. 30 and 40 grades. The A.P.I. designations relate to the type of service for which the oil is recommended. The three designations are MS, MM, and ML. All Valiarit engines require the MS oils, both the S.A.E. number and the MS designation should be marked on the container. The N.L.G.I. makes the recommendation for greases by numbering them from 0 to 6. The numbers refer to the consistency (or stiffness) of the grease. For the best performance and engine protection, Chrysler Australia recommends the following: ( 1 ) An oil which conforms to the requirements of A.P.I. classification for Service MS. (2) An oil with the correct S.A.E. number is recommended for the anticipated temperature shown: Anticipated Temperature Range Above + 32°F As low as + l0 °F As low as - l0°F Viscosity Number S.A.E. 30, lOW-40 20W-40 S.A.E. 20,' lOW-40 S.A.E. lOW, lOW-40 Chrysler Australia Limited does not recommend the use of any lubricant which does not have both S.A.E. designation and MS Service Classification printed on the container. Frequency of Lubrication Engine oil change intervals of 4,000 miles or every two months, whichever occurs first, are recommended. However, unusual or severe operating conditions frequently encountered, can greatly reduce the protective life of oil and necessitate more frequent changes. When a car is operated primarily in city traffic type driving, with some highway use, most trips are less than 10 miles long at slow speeds when the engine often does not warm up enough to resist the formation of condensation and sludge. The recommendation to change the oil every two months will ensure the effects of these harmful materials will be minimised. The oil added to the engine at the factory is a special high quality oil for Service MS. It should be drained after 1,000 miles of vehicle operation. New engines frequently consume some oil during their early life. If it is necessary to add oil during this initial period, an oil for Service MS of the correct viscosity grade should be used. The engine oil level should be checked each time the car is re-fuelled. When the level drops below the "ADD OIL" mark on the engine oil level indicator (dip stick) (See Fig. 1 ), the addition of one quart of oil will usually bring the level within the running range. When adding or changing engine oil use lubricants which have both the S.A.E. designations and the MS Service Classi- fication printed on the container. High quality, well refined engine oils usually have both classifications shown on the containers. Choice of brands should include the reputation of the refiner and the marketer.

Lubrication and Maintenance 1 - 4 Fig. 1 - Engine oil level dip-stick and brake (tandem) master cy Iinder (typical) 2. CAPACITIES (IMPERIAL MEASURES) Cooling System 6 CYLINDER - without heater 18.0 pints -with heater 19.25 pints 8 CYLINDER - without heater 27.0 pints - with heater 28.0 pints Engine Crankcase 6.7 pints - (with filter change) 8.3 pints Fuel Tank 15 .0 galls. Rear Axle 2.3 pints Transmission -Manual 3.1 pints -Automatic (A-904-LA) 13.3 pints -Models A & B 14.25 pints 3. OIL FILLER PIPE AIR CLEANER Engines require ventilation through the cylinder head cover and crankcase to remove combustion products. Air enters the engine through the oil filler cap where any dust is trapped by the oil soaked material in the cap. (Refer Fig. 2). The oil filler pipe air cleaner should be cleaned in kerosene and re-oiled with S.A.E. 30 engine oil every time the engine oil is changed, or more often as operating conditions dictate. In dusty areas as often as each 500 miles, and in extremely dusty areas, daily. 6 CYLINDER 8 CYLINDER Fig. 2 - Engine oil filler cap air cleaner 4. CARBURETTOR AIR CLEANER The carburettor air cleaner paper filter element should be cleaned as often as conditions warrant, but not more than 8,000 mile intervals. For new element replacements periods refer to Maintenance Chart. To Clean Remove the cover and filter element,· clean the housing and the cover with compressed air. Using compressed air, gently clean the paper element by holding the nozzle at least 2" from the inside screen. Examine the paper element for punctures. Discard an element that has even a pinpoint puncture. Also examine the soft plastic sealer on both sides of the element. These sealing surfaces must be smooth and uniform.

63X373 Fig. 3 - Carburettor Air Cleaner (typical view) 5. BATTERY Every month, or more often in hot weather and on long trips, check fluid level of cells. Restore level to i inch above plates, using only water of a known low mineral content. Do not overfill. Check specific gravity, using a reliable hydrometer, every 12 months or 12,000 miles, whichever occurs first, or more often if there is excessive use of water. Clean battery posts and cable terminals and tighten terminals to 18-24 lbs./ in. Protect terminals with light mineral grease. 6. BODY The following parts should be inspected at every oil change and lubricated if necessary. Prior to applying any lubricants, parts should be wiped clean to remove dust and grit. After lubrication, excess oil or grease should be removed. Particular attention should be given to external lock cylinders during winter months to ensure protection from water. Lubricate door latch rotor, door hinges and other parts which are hard to lubricate, with penetrating oil. Lubricate parking brake lever with engine oil. 7. BRAKES All Valiant 6 cylinder models have self-adjusting drum brakes on both front and rear wheels, as standard equipment. 8 cylinder models are power assisted, self-adjusting disc front brakes and Lubrication and Maintenance 1 - 5 standard drum rear brakes as standard equipment. This system is available as optional equipment on the other models. The self-adjusting brakes require no minor adjust- ment. However, periodic checks of the foot and parking brakes should be carried out in accordance with the Maintenance Chart. Disc Brake Equipped Models . Only Every 4,000 miles When rotating the wheels the front disc pads should be inspected visually for abnormal or excessive wear and replaced where necessary. Refer Group 5 Brakes, Part 3. Every 8,000 miles Remove air filter from the hydropower unit and wash filter in soap and water. Dry thoroughly and install in unit. If the vehicle is operated in extremely dusty conditions, service filter more often. All Models: Every 16,000 miles When the front wheel bearings are lubricated as described in Para. 19, also remove the rear brake drums and clean all drums/ disc surfaces and shoe/ pad assemblies, etc., carefully then inspect all components for wear, damaged condition or leaks, etc., remedy if required. Disassemble and disconnect the parking brake cables from the connections to enable them to be cleaned and re-lubricated. Re-assemble and adjust all brakes, refer Brakes, Group 5. Disc Brake Equipped Models Only Remove and discard the hydropower filter element. Install a new replacement element. Replace more frequently where operating conditions warrant. Refer to Brake, Group 5, Part 4, Page 21-26 for filter location. Hydraulic Brake System Clean the reservoir cover before removing to check the fluid in the tandem master cylinder every time engine oil is changed. Replenish with approved Chrysler heavy duty brake fluid to t" from the top of reservoir. (See Fig. 1 ). Check that the reservoir cover diaphragm gasket is correctly "formed" before reinstalling cover and tightening screw to 60 lbs./ in. torque. 8. CHASSIS LUBRICATION All ball joints and the torsion bars are effectively sealed against road splash by tightly fitted balloon type flexible seals.

Chrysler Valiant VF Series workshop manual

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