Chrysler Imperial 1959 Owner's Manual

Below you will find brief information for Windsor MC-1, Saratoga MC-2, New Yorker MC-3, Imperial MY-1. This supplement provides advanced service information for the 1959 Chrysler and Imperial models, covering changes & improvements. Refer to the 1958 models manual for unchanged procedures, related to suspension, axle, brakes, engine, fuel system & others.

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Document

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 GENERAL SPECIFICATIONS—1

SERVICING THE 1959 CHRYSLER AND IMPERIAL

This supplement contains advanced service information on the new 1959 Chrysler^ and Imperial Models. Only changes and improvements affecting the servicing of the new models are included. If the information desired cannot be found in this supplement the servicing procedures will remain the same as those for corresponding models covered in the 1958

Chrysler and Imperial Service Manual D-16350.

In order to use this supplement to best advantage with the previous Chrysler and Imperial

Service Manual D-l 6350, the corresponding or superseding car models must be understood.

The supersedence of these models is as follows:

Chrysler Models:

Windsor

Saratoga

New Yorker

Imperial Models

Custom, Crown, and LeBaron

1958

LC-1

LC-2

LC-3

1958

LY-1

1959

MC-1

MC-2

MC-3

1959

MY-1

The service tools referred to in this manual are available through the Miller Manufacturing

Company, 17640 Grand River, Detroit 27, Michigan, U.S.A., unless otherwise specified.

Extra copies of this Supplement are available at $2.00 each, under part number D-l6798.

Order from Chrysler Division, P.O. Box 1658, Detroit 3 1 , Michigan.

CHRYSLER DIVISION

Chrysler Corporation

DETROIT 3 1 , MICHIGAN

Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its product without imposing any obligations upon itself to install them on its products previously manufactured.

LITHO IN U.S.A.

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

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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 SPECIFICATIONS—3

GENERAL DATA AND SPECIFICATIONS

Item Body Style

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 Los Angeles

M511-100,001

M531-100,001

M551-100,001

M617-100,001

M637-100,001

M657-100,001

M514-100,001

M534-100,001

M554-100,001

MC-1

Windsor

216.6

215.9

216.6

79.3

59.8

60.9

122

2.93

8.00x14

8.50x14

8.00x14

1959 Models

MC-2 MC-3

Saratoga

126

60.9

59.8

220.6

79.3

2.93

8.50x24

8.50x14

MY-1

New Yorker

61.2

126

Imp. Custom

Imp. Crown

Imp. Lebaron

129

61.8

220.9

220.1

220.9

60.0

79.5

61.8

62.4

226.3

81.0

2.93

81.0

2.93

9.00x14

2.93

9.50x14

9.00x14

9.50x14

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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, MC-3..

MY-1

.iy

"+or

• 2Vs"+0T

CASTER AND CAMBER WITH MANUAL STEERING

Caster

~H° ± H°

Camber

0° ± M° (right)

+ H° ± H° (left)

Steering Axis

Inclination

5° to 7°

At 0° Camber

Toe-In

y% ± w

(Vs" Preferred)

Caster

WITH POWER STEERING

Camber

0°± M° (right)

Ji°.± M°(left)

Steering Axis

Inclination

5° to 7°

At 0° Camber

Toe-In

± W

Preferred)

Type

Length

Width

Number of Leaves—Std. Susp

Rate—Std. Susp

Number of Leaves—True-Level. . .

Rate—True-Level

REAR SUSPENSION

MC-1

REAR SPRINGS

MC-2

Sedans &

Coupes

Town &

Country

Sedans &

Coupes

Sedans &

Coupes

MC-3

Town &

Country

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

57"

2.5"

57"

2.5"

60"

2.5"

60"

2.5"

60"

2.5"

95 # per in.

125 # per in.

90 # per in.

135 # per in.

80 # per in.

95 # per in.

75 # per in.

100 # per in.

MY-1

Sedans &

Coupes

Semi-Elliptic

60"

2.5"

90 # per in.

83 # per in.

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CHRYSLER SERVICE MANUAL

FRONT PIVOT

REAR

TYPE

SUSPENSION—5

REAR SUSPENSION (Cont'd)

Silent Block Rubber' Bushings

Shackle with Rubber Bushing

SHOCK ABSORBERS

Oriflow, Double Acting Hydraulic

TRUE-LEVEL TORSION AIRE

CAR REAR HEIGHT (Axle Housing to Frame)

Imperial Models Only 4% + or —y% inch

MC-1, MC-2, MC-3 Models Only 4% + or — y

inch

HEIGHT CONTROL VALVE

Make Midland-Ross

Type Bleed-Feed

AIR PRESSURE

High Pressure Tank 220 + or —20 psi

Low Pressure Volume Tank (1 pass, load) 20 psi approximately

(6 pass, load) 70 psi approximately

(9 pass, load) 90 psi approximately

COMPRESSOR

Make Tecumseh

Type Balanced Head

TORQUE SPECIFICATIONS

Pounds Torque

AIR LINE

Elbow Mounting Screw 100 in. lbs.

High Pressure Tank to Low Pressure Tank Height Control Valve Tube Nuts (4) 85 in. lbs.

Air Hose Assembly to High Pressure Tank Tube Nut 125 in. lbs.

Compressor Check Valve to Air Hose Assembly Tube Nut 90 in. lbs.

Compressor to Air Line Check Valve 130 in. lbs.

AIR SPRING

Retainer Bolt Nut 10 ft. lbs.

COMPRESSOR

Adjusting Strap Bolts 30 ft. lbs.

Adjusting Strap to T-Nut Bolt 15 ft. lbs.

Bracket to Support Bolt 30 ft. lbs.

Bracket to Air Conditioning Compressor Bolt Nut 30 ft. lbs.

Cylinder Head Bolt 155 in. lbs.

Front Bearing Housing Bolt

17 in. lbs.

Oil Inlet Connector 130 in. lbs.

Rear Cover Plate Bolt 17 in. lbs.

Strap Bolt Nut 35 ft. lbs.

Suction Muffler Retaining Screw 17 in. lbs.

Support Bracket to Water Pump Body (or Cylinder Block or Cylinder Head Bolt) 30 ft. lbs.

Support to Cylinder Head Bolt 70 ft. lbs.

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6—SUSPENSION CHRYSLER SERVICE MANUAL

TORQUE SPECIFICATIONS (Cont'd)

Pounds Torque

HEIGHT CONTROL VALVE

Axle Housing Link Bracket Bolt Nut 30 ft. lbs.

Minimum Pressure Valve 130 in. lbs.

Mounting Nuts 100 in. lbs.

HIGH PRESSURE TANK *

Drain and Charging Valve 140 in. lbs.

Mounting Bolts (%>) 10 ft. lbs.

Mounting Bolts (%) 100 in. lbs.

LOW PRESSURE VOLUME TANK

Mounting Bracket Screw 100 in. lbs.

TOOL LIST

C-3128 Snap Ring Pliers

C-3293 300 lb. Pressure Gauge

C-3569 Detector Torch

C-3670 Air Spring Height Gauge

C-3677 Crankshaft Support Stand

C-3680 Front Oil Seal Protector

C-3693 Adapter—used with Tool C-3293, 300 lb. pressure gauge

C-3694 Hold-Down Straps (Pr.)

PO-11 Pulley Puller

Section I

SUSPENSION (FRONT SUSPENSION)

The new upper control arm and frame brackets simplify the method of adjusting caster and camber.

Tool C-3669 is required for installation of upper control arm bushings.

OPERATION (FIG. 1)

The upper control arms attach to brackets which are welded to the frame. Each bracket has cam retainers welded to its front and rear faces, around the slotted openings for the attaching bolts. Each of the four bolts have an integral cam at the head of the bolt. A matching removable cam is installed at the threaded end.

Cams can be adjusted only by turning the head end of the bolt. Turning one bolt will move the upper ball joint fore or aft to affect the caster (more than camber). Turning both bolts on one side an equal amount in the same direction will move the upper ball joint in or out to affect camber. Full bolt travel is 180°, therefore it may be necessary to reverse the direction of rotation of the bolts in order to attain specifications on both caster and camber.

ADJUSTMENT

Apply MoPar solvent, Part No. 1879318, after wire brushing dirt to expose bolt threads. In addition to

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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.

All Chrysler Models with True-Level Torsion Aire must maintain the specified rear height of 4% inches

-f or — i/

inch, the Imperial (MY-1), rear height if

4% + or — % inch while setting the front end, with engine running (see True-Level Torsion Aire).

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.

NOTE; Turning both cams in the same direction an 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.

REAR SPRINGS

REAR SUSPENSION

els. Refer to the 1958 Chrysler and Imperial Man-

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.

ual, D-16350, for information on the removal and installation of the Oriflow shock absorbers.

CAUTION

SHOCK ABSORBERS

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

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.

TRUE-LEVEL TORSION AIRE

The True-Level Torsion Aire System (Figs 2 and 3) valve assembly, air springs and valve (actuating) rubber linkage.

available as optional equipment on the 1959 Chrysler and Imperial cars consists of an engine driven balanced head compressor, compressor drive belt, check valve, high pressure air lines, high pressure reservoir tank, low pressure volume tank, height control

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

HIGH PRESSURE TANK

COMPRESSOR

CHRYSLER SERVICE MANUAL

HEIGHT CONTROL VALVE

LOW PRESSURE

VOLUME TANK

AIR SPRING

PISTON.

SPRING PLATE

Fig. 2 - True-Level Torsion Aire System (Models M C - 1 , 2 and 3)

HEIGHT CONTROL VALVE

LOW PRESSURE

VOLUME TANK

59 x 70

SPRING PLATE

COMPRESSOR

HIGH PRESSURE TANK

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

59x67

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CHRYSLER SERVICE MANUAL

SUSPENSION—9

CYLINDER HEAD

OIL INLET LINE

VALVE PLATE

CONNECTION

CHECK VALVE

PRESSURE LINE

SUCTION MUFFLER

59x75

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

LOW PRESSURE

VOLUME TANK

HIGH PRESSURE

VALVE

CAP

WASHER

LOCKWASHER

NUT

FRONT OF CAR

ADJUSTING

C A M

LOCKWASHER

NUT

BRACKET O N

DIFFERENTIAL HOUSING

•NUT O N CARRIER

Fig. 5 —Height Control Valve

59x64

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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 pressure valve to maintain 8-15 psi in the air springs 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.

MAINTENANCE

SERVICE PROCEDURES

engine. Operate the car engine until normal operating pressure of 200 + or — 20 psi is obtained.

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.)

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

TESTING FOR LEAKS (Liquid Soap Method)

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

With the engine running, apply a diluted liquid soap solution at the following locations where leaks would cause bubbles: air springs and seats, height control 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)

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.

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

CHECKING AND ADJUSTING SUSPENSION HEIGHT

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 specified vertical distance between, the top of the axle housing and highest part under the axle bumper straps, to the rear of the rubber bumpers on both 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.

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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.

DISCHARGING THE SYSTEM

CAUTION

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

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 exceed */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 — y

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-

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 remove 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

CHRYSLER SERVICE MANUAL

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.

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 piston 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 excessive 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

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.

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 housing is removed by pulling the linkage off the pivot pins.

Before installing, apply water or soap solution

BOLT

NUT

AIRSPRING

59 x 66

Fig. 9 — Body to Frame Hold Down Straps

PISTON

WASHER

LOCKWASHER

NUT

Fig. 10 — Installing Air Spring and Piston Assembly

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CHRYSLER SERVICE MANUAL SUSPENSION—13 around pivot pin holes. Position linkage with rounded end up toward actuator arm and stop boss to the left side of car. Push linkage on pivot pins.

HEIGHT CONTROL VALVE (Fig. 5) a. Removal

Refer to paragraph "Discharging the System." Remove high pressure line from valve end cap. Remove valve mounting nuts and remove valve assembly.

NOTE: Height control valves are serviced only as an assembly.

The " 0 " ring valve to low pressure volume tank seal is serviced separately.

b. Installation

Apply diluted liquid soap to " 0 " ring on housing boss. Install valve assembly on low pressure volume tank, inserting the boss in tank without damaging the "O" ring. Install adjusting cam in housing at the lower mounting stud.

Install mounting nuts finger tight. Connect air line to valve end cap. Start the engine and check the valve for operation.

Tighten mounting nuts to 100 inch pounds torque.

Connect actuator arm to rubber linkage. Check for leaks, refer to paragraph "Testing for Leaks." Check car height, paragraph "Checking and Adjusting

Suspension Height" and adjust as necessary.

LOW PRESSURE VOLUME TANK (Fig. 11) a. Removal

Discharge the system. Remove air springs from tank by pulling top of springs downward and outward.

Disconnect air line at valve end cap. Disconnect actuator arm at rubber linkage. Loosen and lower

HEIGHT CONTROL VALVE

DIFFERENTIAL HOUSING

LOW PRESSURE VOLUME TANK 59 x 61

Fig. 11 — Low Pressure Volume Tank

GASKET

SCHRADER

VALVE

HIGH PRESSURE TANK

AIR OUTLET

'FLAT WASHER

LOCKWASHER

NUT

59x63

Fig. 12 - High Pressure Tank (Models M C - 1 , 2 and 3) right tail pipe only.

Support axle and remove right rear wheel. Remove self-tapping screws (two each side) holding tank to frame side rails. Remove tank from right side of car. Remove height control valve assembly and adjusting cam.

b. Installation

Install new " 0 " ring on height control valve air spring boss. Coat ring with diluted liquid soap solution. Install valve assembly and adjusting cam.

Tighten nuts to 100 inch pounds torque. Install tank making sure that insulating pads are in position between frame and tank mounting flanges. Tighten mounting screws to 100 inch pounds torque.

Connect air line to control valve. Install air springs paragraph "Air Springs and Pistons." Position and tighten right tail pipe. Install right rear wheel. Check system for leaks. Adjust car rear height.

HIGH PRESSURE AIR TANK (Figs. 12 and 13) a. Removal

Discharge the system. Disconnect both air lines at tank. Remove bolts holding tank cradle to the car.

Remove tank and bracket assembly.

GASKET

SCHRADER VALVE

HIGH PRESSURE TANK

AIR OUTLET

AIR INLET

BOLT

FLAT WASHER

LOCKWASHER

NUT

MOUNTING BRACKET

59x74

Fig. 13 - High Pressure Tank (Model MY-1)

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14—SUSPENSION

CHRYSLER SERVICE MANUAL

SUCTION

MUFFLER

FELT

CYLINDER

BLOCK

SCREW C3)

BOLT (6)

CYLINDER HEAD

^ ^

GASKET

REED VALVE

VALVE PLATE

ASSY.

GASKET

CRANK SHAFT

GASKET

BOLT (4)

FRONT SEARING HOUSING ASSY. S E A L ' * *

59x90

Fig. 14 — A i r C o m p r e s s o r (Disassembled V i e w ) b. Installation

Position tank and bracket assembly and install bolts.

Tighten 14 i n c n

bolts to 100 inch pounds torque, and

5/16 inch bolts to 130 inch pounds torque. Connect air lines to tank. Check for leaks.

AIR COMPRESSOR (Fig. 14) a. Testing Compressor

Discharge the system. Disconnect air line from compressor 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

ADAPTER o

SUPPORT

ADJUSTING STRAP i ^ L O C K W A S H E R

« ^ - SCREW

WASHER

LOCKWASHER

WASHER

LOCKWASHER

SCREW

59x72

Fig. 16 — Compressor Mounting (with Air Conditioning

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

With engine running at 1800-2000 rpm, gauge reading should be 220 psi +

o r

— 20 psi. Remove gauge and install air line.

b. Removal

Remove oil pressure line at rear of compressor. Remove air line from check valve. Remove oil return line at engine end. Loosen belt adjusting bolt in generator and remove belt from compressor. Remove compressor bracket bolt. Remove bolts holding compressor support to engine and remove compressor assembly from car.

COMPRESSOR ASSEMBLY

MOUNTING BRACKET I I

SUPPORT

ADJUSTING STRAP

WASHER

LOCKWASHER

SCREW

LOCKWASHERO^

SCREW

LOCKWASHER

SCREW

OCKWASHER

SCREW 59x65

Fig. 15— Compressor Mounting (with Air

Conditioning — Model MC-1)

GASKET

MOUNTING BRACKET

WASHER

SCREWS ^ V i ^

L O C K W A S H E R

J S C R E W

* LOCKWASHER

'SCREW 59x76

Fig. 17 — C o m p r e s s o r M o u n t i n g ( w i t h o u t A i r

C o n d i t i o n i n g — A l l M o d e l s )

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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

PULLEY COMPRESSOR

TOOL 59x91

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

18).

Remove front bearing, housing and oil seal assembly. 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

SERVICE DIAGNOSIS

CAR DOES NOT MAINTAIN CORRECT HEIGHT

POSSIBLE CAUSES a. Leaks in System b. Incorrect Rear Height Adjustment c. Incorrect Front Height Adjustment

UNABLE TO OBTAIN CORRECT HEIGHT

POSSIBLE CAUSES a. Broken or Pinched Air Line b. Leak in Air Spring c. Leak in Height Control Valve

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16—AXLE—REAR d. Fast Leak in Low Pressure Volume Tank e. Height Control Valve Out of Adjustment f. Rubber Linkage Loose or Broken at Differential g. Broken Height Control Actuator Arm

LOW AIR PRESSURE

POSSIBLE CAUSES a. Leak in Air Line b. Compressor Belt Broken or Out of Adjustment c. Slipping Drive Belt d. Plugged Check Valve

CHRYSLER SERVICE MANUAL 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 Piston Ring Wear

EXCESSIVE AIR PRESSURE

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

Section II

REAR AXLE

DATA AND SPECIFICATIONS

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 8B Country Models

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

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

Axle and Sure Grip Differential as specified in the

1958 Chrysler and Imperial Service Manual, D-

16350.

Section III

BRAKES

DATA AND SPECIFICATIONS

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

TYPE Total Contact (Floating Shoe) Hydraulic

DRUM DIAMETER . . . , 11 in. 12 in.

LINING

Type Moulded Asbestos

Attachment Cyclebond

Width 2Y

in.

Thickness

%i i n

BRAKE SHOE RETURN SPRING TENSION USING

FISH SCALE HOOKED AT TOE OF SHOE 35 to 45 lbs. required to break contact between shoe and push rod

BRAKE PEDAL FREE PLAY % in. to J^ in.

(in models with Power Brakes)

WHEEL CYLINDER BORE

Front—Upper and Lower 1% in.

Rear 1K

MASTER CYLINDER BORE V/

in.

PISTON CLEARANCE .003 in. to .0065 in.

HAND BRAKE

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

TYPE Internal Expanding

LOCATION Propeller Shaft at Rear of Transmission

DRUM DIAMETER. 7 inch

LINING TYPE , Moulded and Compressed Asbestos

Length 13.06 inch

Width 2 in.

Thickness %

Clearance .015 in. to .020 in.

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18—BRAKES

CHRYSLER SERVICE MANUAL

TOTAL CONTACT SERVICE BRAKES (Figs. 19 and 20)

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.

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.

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.

MASTER CYLINDER

Removal — While holding retainer pin in dust shield, push retainer toward brake shoe, turning the retainer to unlock it from the pin.

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

Remove retainer, spring and washer from pin.

Remove retainer pin from dust shield.

Installation — Insert retainer pin through the dust

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

UPPER CYLINDER

ADJUSTING C A M

DUST SHIELD-v.

SHOE RETURN

SPRING

S U P P O R T - ^

SHOE RETAINE

.- SHOE AND UNING

— SHOE RETAINER

SHOE RETURN

SPRING

-ADJUSTING CAM

CONNECTING

TUBE

LOWfi? CYLINDER

Fig. 19 —Total Contact Brake Assembly (Front)

CYLINDER ASSEMBLY ADJUSTING CAMS

SHOE RE'

SPRINGS

SUPPORT

DUST SHIELD

SHOE RETAINERS

ANCHORS

SHOE AND ^**z~~-

LINING

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 making 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

VACUUM HOSE VACUUM CHAMBER

VACUUM TUBE / VALVE PASSAGE /

RETURN SPRING

GASKET

SPRING

SEAL

VALVE ROD

RETURN SPRING

AIR

CLEANER

ATMOSPHERIC

CHAMBER

ATMOSPHERIC VALVE

(PORT CLOSED)

VACUUM

VALVE

(PORT OPEN)

VALVE OPERATING £

ROD

DIRECTION

Fig. 2 1 — P o w e r Brake Unit (Sectional V i e w )

57x176

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20—BRAKES

ARBOR f-<

(TOOL) ^

CHRYSLER SERVICE MANUAL

GAUGE

BLOCK

(TOOL)

57x17

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

Fig. 22 - Power Brake Unit (Exploded View) 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 of triangular hole in pedal bracket, to prevent trigger arm from extending beyond extremities of bracket.

NOTE: If pedal linkage is allowed to extend through hole in dash panel the trigger arm may be damaged.

Disconnect vacuum hose at power unit. Remove attaching bolts at dash panel and carefully remove power unit assembly.

NOTE: Use care to prevent loss of the pedal linkage cross pin.

b. Disassembly

Scribe across flange of cylinder and end plate as a guide to correct assembly (Fig. 23).

NOTE: Do not clamp yoke in vise during any operation.

Remove the cylinder shell and gasket, disconnecting the vacuum hose from the air cleaner cover.

CAUTION

The vacuum tube must be in the lowest quadrant

(Fig. 4 ) . Make certain the bead at outer diameter of diaphragm is in the annular groove of the tube and plate assembly.

Install valve rod poppet and applying diaphragm.

NOTE: Before installing the vacuum cylinder, make the following test.

Depress the valve rod and at the same time, try to blow through the vacuum hose. Failure to blow through the hose indicates the poppet assembly is properly seated.

VACUUM CYLINDER NUT (4)

AIR CLEANER

COVER

AIR CLEANER

HAIR

END PLATE

MATING MARKS

GASKET

END PLATE SPRING ROD END

RETAINER PLATE

POPPET DIAPHRAGM

APPLYING

DIAPHRAGM

VALVE ROD

APPLYING PIN

TUBE AND

PLATE

ASSEMBLY

VALVE

ROD

SEAL

SPRING

RETAINER

WASHER

PISTON

SPRING VALVE ROD

SCREW (4) VACUUM HOSE 57x201

Fig. 24 — Disassembly of Tube and Plate Assembly

Install a new vacuum cylinder gasket and connect vacuum hose. Align vacuum cylinder and end plate scribe marks and assembly.

c. Installation

Position the power brake unit on dash panel of car so that its axis inclines down toward front of car.

(Fig. 28)

NOTE: As yoke passes through dash panel, be sure that it engages pedal linkage correctly by sliding over nylon bushings on power brake lever cross pin. Install and connect master cylinder.

Replace four hex nuts and lockwashers, tighten nuts securely, and release pedal. Install vacuum hose and hose clips, operate engine and check pedal free play. Refer adjustment on "pedal free play." d. Lubrication

The power unit will require no lubrication under normal use. If the unit is disassembled for overhaul or repair, all oil seals and " 0 " rings must be suitably coated with silicone grease before assembly.

RETAINING PINS STOP WASHER

PISTON ROD

END PLATE

BOLT AND

LOCKWASHER (4)

57 x 200 SCREWS (3)

Fig. 23 — Removal of Air Cleaner and

Vacuum Cylinder)

57x202

Fig. 25 — Removal of Vacuum Piston, Spring and Piston Rod

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22—BRAKES

LEATHER PACKING

EXPANDER SPRING

RETAINER PLATE

COTTON WICK

PISTON

CHRYSLER SERVICE MANUAL

INSPECTION PORT SCREW

GASKET

PISTON ROD SEAL

SCREW AND SEAL WASHER (4)

PISTON PLATE

EXPANDER SPRING

SCREW (6)

57x203

Fig. 26 — Disassembly of Vacuum Piston

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.

MOUNTING RING

SPRING

GASKET

END PLATE

57x204

Fig. 27 — Removal of Mounting Ring, Seal and Washer

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,

POWER BRAKE

CYLINDER ASSEMBLY

PEDAL TRIGGER ARM

RETURN SPRING \

PEDAL MOUNTING

BRACKET

POWER LEVER PIN

•——YOKE

POWER LEVER

TRIGGER

*~^" PIVOT BOLT

MASTER CYLINDER W

ASSEMBLY

PUSH ROD

END PIN

FRONT OF DASH PANEL

^ . MASTER CYLINDER PUSH ROD

TRIGGER

ADJUSTING

SCREW

BRAKE PEDAL

SHAFT

Fig. 28 — Power Brake Unit Installed

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CHRYSLER SERVICE MANUAL 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 silicone grease to outer face of gasket around center hole. Position the piston rod seal and retainer and retaining spring. Coat the bearing surface of mounting

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

ACCESSORY BELT DRIVES—23 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 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."

LACK OF POWER ASSISTANCE (WHEN COLD)

NOTE: This condition only occurs when the car has been setting for a long period of time ( storage ). Unit must be disassembled, cleaned of all old lubricants, seals and diaphragm must be softened with silicone grease before unit will function properly.

DELAY IN APPLICATION (NOTED DURING FAST

BRAKE APPLICATION)

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

LEAKS IN BOOSTER (Whistle when Brake is Applied) a. Air leaks in vacuum lines.

b. Leaks in power cylinder. Recondition complete power cylinder assembly.

Section IV

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 maintained, 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 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:

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

ACCESSORY BELT DRIVES—23 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 easily damaged.

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."

LACK OF POWER ASSISTANCE (WHEN COLD)

DELAY IN APPLICATION (NOTED DURING FAST

BRAKE APPLICATION)

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

LEAKS IN BOOSTER (Whistle when Brake is Applied) a. Air leaks in vacuum lines.

b. Leaks in power cylinder. Recondition complete power cylinder assembly.

Section IV

ACCESSORY BELT DRIVES

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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 servicing 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. W P - W a t e r Pump

3. G—Generator

4. PS—Power Steering

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

5 9 x l l 8

Fig. 29 — Belt Deflection Location

5. I—Idler

6. A C - A i r Conditioning

7. SC—Suspension Compressor

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CHRYSLER SERVICE MANUAL ACCESSORY BELT DRIVES—25

BELT TENSION SPECIFICATIONS

TORQUE METHOD

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

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 IN USE

NEW BELT

BELT DEFLECTION METHOD

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

ACCESSORY BELT IN USE N E W BELT

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

Vs

SERVICE DIAGNOSIS

Insufficient Accessory Output Due to Belt Slippage c. Non-uniform belt—replace belt.

Check belt tension and belt condition. If belt is excessively glazed or worn, install new belts and adjust d. Dirt and paint imbedded in belt—replace belt.

e. Belt too loose—retighten.

as specified.

Belt Squeal when Accelerating Engine f. Belts glazed—install new belts and tighten to specified tension.

a. Belts too loose—retighten.

b. Belts glazed—install new belts.

Belt Rolled Over in Groove

Broken cord in belt—replace belt.

Belt Squeak at Idle a. Misaligned pulleys—align accessories (file brackets or use spacers as required).

b. Non-uniform groove or eccentric pulley—replace pulley.

Belt Jumps Off a. Belt too loose—retighten.

b. Misaligned pulleys—align accessories.

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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 2 l

A inch

*MC-1 with Air Conditioning have box shroud six blade fan with 234 inch radiator.

*MC-2, 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.

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

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 procedure.

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 proof, the gauge reading will remain constant.

Testing for Leaks

Remove the two oil cooler lines at the radiator. Connect a pressure gauge to one cooler outlet. Connect a source of air pressure with a shut-off valve (closed

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.

Section VI

ELECTRICAL SYSTEM

DATA AND SPECIFICATIONS

BATTERY

MG-1, MG-2, MG-3, MY-1

78 Plate 70 Amp Hour

Negative

Voltage

Capacity

Terminal Ground

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 procedure.

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 proof, the gauge reading will remain constant.

Testing for Leaks

Remove the two oil cooler lines at the radiator. Connect a pressure gauge to one cooler outlet. Connect a source of air pressure with a shut-off valve (closed

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.

Section VI

ELECTRICAL SYSTEM

DATA AND SPECIFICATIONS

BATTERY

MG-1, MG-2, MG-3, MY-1

78 Plate 70 Amp Hour

Negative

Voltage

Capacity

Terminal Ground

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)

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28—ELECTRICAL SYSTEM

Solenoid Switch

Pull-in Coil

Hold-in Coil

STARTER (Cont'd)

CHRYSLER SERVICE MANUAL

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

4001

4002

1034

1004

1073

1891

1003

C.P. or Chrysler

Watts Part No.

37J^ W

5 0 - 3 7 ^ W

32-4

1753435

1753436

127934

151567

142450

127934

151578

127934

151578

142453

142456

127934

151577

CIRCUIT PROTECTORS

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.

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Gar Model

Generator Model

Standard

With Air Conditioning

Front Unit Only

Dual Air Conditioning

Front and Rear

Gas Heater

Heavy Duty

MC-1

GJM-8001A;

GHM-8005B;

GENERATORS

MC-2, MC-3

1842801

1889400

GGA-6003E; 1842603

Heavy Duty True-Level Torsion Aire..

Generator Model

Rotation

GGA-6001N

GGA-6003E

Clockwise at

Drive End

Voltage

Rated Output

Control

Ground Polarity

Poles '..

Brushes

40 Amperes

Vibrating Regulator

Negative

GHM-8001A

Clockwise at

Drive End

30 Amperes

Vibrating Regulator

Negative

Brush Spring Tension

Bearings

End Play

Field Coil Draw (Arm. to field term.)

Motoring Draw

34 to 41 ounces

Ball—Both Ends

.003"-.010"

1.2 to 1.3 Amps at 10 Volts

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

35 to 53 ounces

Ball—Both Ends

.003"-.010"

1.2 to 1.3 Amps at 10 Volts

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

GJM-8001A; 1842801

GJM-8002A; 1842797

GHM-8001A; 1842774

GHM-8005A; 1842778

GGA-6003E; 1842603

GGA-6001N; 1658863

GHM-8005A

GHM-8006B

Clockwise at

Drive End

30 Amperes

Vibrating Regulator

Negative

35 to 53 ounces

Ball & Sleeve

.003"-.010"

1.2 to 1.3 Amps at 10 Volts

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

GHM-8005A; 1842778

GHM-8001A; 1842774

Clockwise at

Drive End

35 Amperes

Vibrating Regulator

Negative

18 to 36 ounces

Ball & Sleeve

.003'

-.010'

1.4 to 1.7 Amps at 10 Volts

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

MY-1

GHM-8001A; 1842774

GHM-8005A; 1842778

GGA-6003E; 1842603

GGA-6001N; 1658863

GJM-8001A GJM-8002A

Clockwise at

Drive End

35 Amperes

Vibrating Regulator

Negative

18 to 36 ounces

Ball—Both Ends

.003"-.010"

1.6 to 1.7 Amps at 10 Volts

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

Car Model MC-1, MC-2, MC-3, MY-1

Regulator Model VRX-6301A-1842798

(For 35 Amp Generators)

VRX-6201A-1642333

(For 30 Amp Generators)

Volts

Ground Polarity

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 ohms 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

Current Limiting Regulator

Armature Air Gap

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

.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

50°

60 c

70°

80°

90°

100°

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

Min. Setting....

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

Min. Setting....

Cut-Out Relay:

Voltage Winding Resistance

Air Gap (contacts open)

(Measure gap as near to hinge as possible)

107 to

.031 to

VAT-6201-1662137

(For 40 Amp Generators)

121 ohms

.034 inch

Point Gap (Minimum)

Contacts Close (Volts)

Contacts Open (after charge of 10 amperes)

Discharge Amperes

.015 inch

12.6 to 13.6 Volts

8.2 to 9.3 Volts to 6 amperes (discharge)

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CHRYSLER SERVICE MANUAL

Car Model

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.

DISTRIBUTOR

MC-1, MG-2

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

Vacuum Advance

Distributor Degrees and Inches of Vacuum

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"

ELECTRICAL SYSTEM—31

MC-3, MY-1

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° @ 2300

0°@7.5to9.1"

6.0° to 9° @ 13"

11.5° to 14.5°© 18.2"

SPARK PLUGS AND COIL

MC-1, MC-2 CAR MODEL

Spark Plugs

Type

Size

Gap...

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, MY-1

A-42

14 mm

.035 inch

MyMopar.com

32—ELECTRICAL SYSTEM CHRYSLER SERVICE MANUAL

SPARK PLUGS AND COIL (Cont'd)

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

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 1 j/£ amps at 66 to 75 rpm

Low Speed 3 amps at 35 to 40 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

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CHRYSLER SERVICE MANUAL ELECTRICAL SYSTEM—33

SPEEDOMETER REMOVAL

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.

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.

Chrysler—Disconnect battery. Disconnect speedometer cable housing. Remove the two nuts and washers from the rear of the speedometer. Slide speedometer out the rear of panel.

CONTROL CIRCUITS

Power is supplied to the motor relay from the circuit breaker. Three wires go to the switch from the motor relay.

Imperial—Disconnect battery. Disconnect speedometer cable housing. Remove 7 screws from the rear of speedometer and pull out speedometer from rear of panel.

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

(white and blue) are used for directional control of the motor.

SIX-WAY ELECTRIC POWER SEAT — OPTIONAL

The six-way electric power seat is driven by a twoway electric motor which operates through a solenoid and clutch assembly that supplies power through

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

[Red

Connect Wires<j White

[Green

For Rearward Horizontal fRed

Connect Wires^j Blue

Green

For Forward Tilt

[Red

Connect Wires*) White

[Yellow

For Rearward Tilt fRed

Connect Wires^j White

[Brown

REMOVAL AND INSTALLATION OF FLEXIBLE

CABLES — POWER SEAT

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

CAUTION:

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. Remove the two nuts holding the motor to the drive unit. Remove the motor from drive unit and rubber coupling.

For Straight Up fRed

Connect Wires J White

I Yellow

[Brown

For Straight Down

[Red

Connect Wires j Blue

I Yellow

[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 solenoid assembly. Be careful not to lose the three springs under the solenoid when removing the solenoid 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.

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RT. PARK & T/SIG. LAMP

IGNITION DISTRIBUTOR

GLOVE BOX SW.

RT. AUTO. DOOR I

RADIO

LAMP

| 9* C A 18

YELLOW

18 YELLOW-

p * < *

18 ORANGE

.RT. MAP LP.

-CIGAR LIGHTER FUSE BLOCK

•-C/LITER

- D O M E

CLOCK

WIPER MOTOR

RT.

DUAL HEADLAMP

SP. EQ. HORN t=Q

OIL GAUGE

FUEL GAUGE

,RT. T/SIG. LP.

18 WHITE-

••RR. A / C

-RADIO

*B/UP LP

RR. DEFR

IGNITION COIL

COIL RESISTOR

LUE

RADIO CONDENSER

18D

HORNS

TEMP. GAUGE

SENDING UNIT LAMP^ ITCH-

16 DK. GREEN

LT.

DUAL HEADLAMPS

18 VIOLET

GENERATOR

0«

12 RED

16 B R O W N -

HORN RELAY

NOTE: 18-BLACK CIRCUIT

WITHOUT POWER STEERING

SER

STARTER MOTOR &

STARTER SOLENOID

12 BROWI

tfpPIp

— 1 8 BLACK-

18 DK. BLUE

LT.

PARK & T/SIG. LAMP

"18 TAN"

-16 RED-

-16 BLACK

18 LT. GREEN"

18 YELLOW

18 DK. GREEN

BATTERY

S T A R T E I

RELAY

VIOIET_

1 0

RED

GRD.

t — 1 2 BLACK

BATT.

GENERATOR REGULATOR/GRD.

A R M

NEUTRAL SAFETY SWITCH

-2I T/SIG. SW.

DISCONNECT

TO HORN

BUTTON

REAR W I N D O W

DEFROSTER SW.

LT. MAP LP.

HI BEAM IND. LP.

CLOCK LP.

HANDBRAKE IND. LAMP

LT. T/SIG. LP.

¥ * * * SIGNAL LAMP SWITCH

TAN TO W/LIFT SW.

TO SEAT ADJ. SW.

REAR OF FRONT SEAT

CIGAR LIGHTER MC3

4 DR. SEDAN 4 DR. HT.

4 DR. SUB.

PUSH

BUTTON

"GEAR

SHIFT LP.

r-18 YELLOWfT8 PINK

I—LJ 18 VifrlTE

18 LT. BLUE

BACK UP LP. SW.

LT. AUTO. DOOR SWITCH

-18 BLACK-^

14 LT. GREEN-

59x58

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

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RT. PARK & T/SIG. LAMP

TRIAD HORN

IGNITION DISTRIBUTOR

RT. DOOR SW.

"YELLOW

GLOVE BOX

LAMP MAP

SWIT

2 4 6 8

SPARK PLUGS

1 3 5 7 ,

RADIO CONDENSER

IGNITION COIL

COIL RESISTOR

BLUE

TURN SIG.

..AUTO. SW TURN

SIG.

AUTO.

SW.

TEMPERATURE GAUGE

TURN SIGNAL RELAY

LT. PARK & r/SIG. LAMP

A / C & HTR.

RR. A / C

RADIO REAR W I N D O W

INSTRUMENT PANEL

REAR W I N D O W

DEFROSTER MOTOR

REAR SHELF PANEL

16 LT. GREEN

R O W N - 0 * -

- I B — I NEUTRAL

R O W N SAFETY

12BLXCK SWITCH

FOOT DIMMER

SWITCH

A D

. , HAND BRAKE

A R M

- LAMP FLASHER

BATT.

R D

W I N D O W LIFT,

„ ' SEAT ADJUSTER

E L D

CIGAR LIGHTER

CIRCUIT BREAKERS

MYI-L CLOTH TRIM 4

1 REQ'D. 2 REQ'D

LEATHER TRIM

14 LT. GR

- 1 8 BRO

HAND BRAKE SW.

•TO REAR SEAT

CIGAR LIGHTER

LT. DOOR SW.

FO SEAT ADJ.

LT. f'/SIG. LP.

DO. LAMP

BUTTON

R SHIFT LP.

MANUAL T/SIG.

CANCELING SW

Fig. 31 —Chassis and Instrument Panel Wiring Diagram — Model MY-1 w/s

WASHER

SWITCH

16 YELLOW

6 RED

BLUE

6 BLACK

59x59

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36—ELECTRICAL SYSTEM CHRYSLER SERVICE MANUAL

LOCK RELAY

- 1 4 YELLOW

RT. FRT. SW. &

PINK

14 VIOLET

•VIOLET-L-T

14 VIOLET-

PINK

GRAY-

RT. FRT. DOOR LOCK SW

14 WHITE-

16 ORANGE-pn—UNLOCK

12 LT. BLUE+M—FEED

16 PINK 1£*—LOCK

12 ORANGE

^ ^ - - - R T . RR. SW. & MTR fff— G R A Y - * GRAY-foj rtsJ DK. G R E E N L

14 WHITE

14 LT. GREEN

RT. FRT. DOOR LOCK SOLENOID

RT. RR. CIGAR LIGHTER

RT. RR. DOOR

LOCK SOLENOID

BATTERY

LT. RR. CIGAR LIGHTER

14 LT. GREEN-

LT. RR. DOOR

LOCK SOLENOID

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 O N 4 D'RS

& C/LT'R. C/B O N 2 D'RS.

ORANGE

LT. FRT. DOOR LOCK SOLENOID

LT. FRT. DOOR LOCK SW.

14 DK. BLUE p [_

14 BROWN-|o f>T

LT. FRT. DR. MASTER SW. & MTR.

BLACK-

ORANGEff=] ORANGE rty RED

\ T .

RR. DR.

J SW.

O R A N G E F ~ ~ |

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 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.

POWER SEAT SERVICE DIAGNOSIS

ENTIRE UNIT INOPERATIVE does not light, check for continuity in #10 red feed

Remove all wires from seat switch and connect together as shown in the chart for the six various controls operations, if the operation is normal, by connecting wires. Replace switch.

MOTOR INOPERATIVE 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. Repair.

(b) Possible seized solenoid armature in coil. Replace coil.

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

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 synchronization.

(d) Remove seat slave unit from seat track slide

(C).

(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

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 welding.

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.

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 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.

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 is required to remove it from the spark plug.

The cables should never be removed by giving them a quick jerk. Doing so can stretch the core and cause a high resistance or open circuit. If a damaged core is suspected, a resistance check with an ohmmeter should be made. The resistance of the various plug cables will vary because of the different lengths, see chart below: specified, check to be sure the terminals are in contact with the pin and the pins is in full contact with the core. If the terminals and pins are properly installed and the cable resistance is still more than specified, the cable should be replaced with a new 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 not be maintained with the core. This will result in arcing and burning of the core which will cause engine malfunctioning and radio interference.

SPARK PLUG 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

If any cable has appreciably more resistance than

CAUTION

Resistor type spark plugs are never to be used with the new resistance type cable. The added resistance of the spark plugs may cause malfunctioning of the ignition system. When replacing a spark plug, be sure to use the correct type specified for the particular engine.

If the radio develops excessive noise or if there is a pronounced engine miss, check for faulty or broken cables.

SERVICE DIAGNOSIS

THE AUTOMATIC BEAM CHANGER

The automatic beam changer is an automatic headlight control unit which senses the headlight intensity from other vehicles and automatically adjusts the headlights (of the vehicle in which it is mounted,) to the upper or lower beam position.

A0JUSTIN8 KNOB

—LOCKING-SCREW

SCANNER

A scanner and base assembly (Fig. 33), is mounted on top of the instrument panel, directly in front of the steering column. The control unit Fig. 33 is 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 an oncoming car is approached at a distance of approximately 1200 feet.

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. If the unit has an "upper beam" setting and the driver feels that

CONTROL UNIT

Fig. 33 — Scanner and Control Unit

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CHRYSLER SERVICE MANUAL

"SCANNER"

INSTRUMENT

PANEL

Fig. 34 — Location of Beam Changer Control Unit

ELECTRICAL SYSTEM—39 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).

AIMING 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.

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.

"SCANNER'

BASE

LOCKING

SCREW

Fig. 35 — Mounting Scanner Aimer Tool

MyMopar.com

40—ELECTRICAL SYSTEM CHRYSLER SERVICE MANUAL line. (Figure 35). Tighten locking screw (Fig. 33) securely and then recheck position of bubble. If position of bubble has changed, loosen locking screw slightly and make necessary correction to bring bubble once more into desired position. Retighten locking screw securely and remove "scanner" aimer Tool.

THE ELECTRONIC REAR VIEW MIRROR

("MIRROR-MATIC")

The electronically operated rear view mirror (mirror-matic), as shown in Fig. 36 is a self-dimming rear view mirror which provides maximum rear-

SILVERED MIRROR

LIGHT-SENSITIVE CELL / SURFACE

BRIGHT REFLECTION ward vision at night, since the bright reflection surface of the mirror is in use except when glaring light strikes its surface.

NON-GLARE

DIM REFLECTION

FRONT SURFACE

OF MIRROR

The electronic glare detecting mechanism is housed entirely within the mirror case. Sensitivity is selected by a three-position switch on the front of the mirror bezel (Fig. 36). "Off" locks the mirror in the normal "bright" position. Selection of either

"City" or "Hi-way" switch position permits the mirror to respond to glare conditions. It is less light-sensitive when "City" has been selected and therefore response to neon signs, streetlights, etc. is held to a minimum.

"OFF" POSITION

"CITY" OR "HI-WAY" POSITION

MIRROR-MATIC ELECTRONIC REARVIEW MIRROR

Fig. 37 — Positioning Mirror in Operation OPERATION (FIG. 37)

The heart of the automatic tripping mechanism is a tiny photo-electric cell which "sees" through a small aperture in the silvered mirror surface (Fig. 36).

Light striking the cell generates a small voltage which increases with increasing light intensity.

When the light intensity becomes high enough to cause annoying glare, the voltage is enough to activate a miniature amplifier and solenoid assembly which pulls the prism mirror a few degrees upward to reflect a dim image off the front surface of the glass and into the driver's eyes. As long as glare is present, the mirror will remain in its "dim" position, returning immediately to its normal "bright" position when the glare drops below a pre-set level.

DRIVER ADJUSTMENT (POSITIONING MIRROR)

When adjusting the position of mirror-matic for best

I BRIGHT

\ LIGHT

RAYS visibility, first turn off the headlights (headlight circuit energizes mirror system) and set the mirror for brightest image.

When adjustment for best visibility is obtained, lock mirror -in position by turning lock nut (clockwise) at the mirror support base.

SERVICE ADJUSTMENTS

If a glare condition exists with the switch (Fig. 37) set either in the "City" or "Hi-way" position, it is an indication that the sensitivity in either or both of these positions is too low.

Sensitivity can be raised by making an internal adjustment at the mirror assembly as follows:

(a) Remove plastic knob from 3-position switch

(Fig. 36) by carefully pulling outward on plastic knob.

LIGHT SENSITIVE

CELL

POTENTIOMETERS

Fig. 36 — Mirror-Matte Rear View Mirror Fig. 38 — Mirror-Matic Back Cover

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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 assembly by lifting top portion of back cover upward (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.

NOTE: To decrease sensitivity of either or both the potentiometers, turn potentiometer arms in the direction 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.

Section VII

ENGINE

DATA AND SPECIFICATIONS

ENGINE

Type

Number of Cylinders

Bore—MC-1, MC-2

MC-3, MY-1

Stroke

Piston Displacement—MC-1, MC-2

MC-3, MY-1

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

90° V

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"

.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 1.0925 to 1.0928"

CAMSHAFT

Drive Chain

Bearings Steel Backed Babbitt

Number 5

Thrust Taken by Cylinder Block

Diametral Clearance .001 to .003"

Maximum Allowable before Reconditioning .005"

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 2.001"

No. 2 1.984 to 1.985"

No. 3 1.969 to 1.970"

No. 4 1.953 to 1.954"

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"

PISTONS

Type Horizontal Slot w/Steel Struts

Material Aluminum Alloy Tin Coated

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CHRYSLER SERVICE MANUAL

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 & MC-2

MC-3 & MY-1

No. 2—MC-1 &MC-2

MC-3 & MY-1

No. 3—MC-1 & MC-2

MC-3 & MY-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)

RING SIDE CLEARANCE

(Compression)

Upper

Intermediate

(Oil)

VALVES—Intake

Material

Head Diameter MC-1, MC-2

MC-3, MY-1

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.

ENGINE—43

.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

.0775 to .0780"

.1860 to .1865"

.013 to .025"

.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"

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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) 1.860" @ 95 —105 lbs.

Load when Compressed to (valve open) 1.470" @ 188—252 lbs.

Valve Springs I.D 1.010 to 1.030"

CYLINDER HEAD

Number Used 2

Combustion Chamber Wedge Type

Valve Seat Runout (maximum) .002'

•o

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"

E N G I N E 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

135

40 in.-lbs.

95 in.-lbs.

^8-24

^ - 2 4

%-14

J4-13

14 mr

%>—14

%-24

/i6-18

•HJ-16

^ - 1 6

%~1Q

%-W

J4-28

^ - 2 4

^ 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.

The engine has 10:1 compression ratio, is equipped with a dual carburetor on the Windsor Model

(MC-1), and a 4-barrel carburetor on all other models, and uses premium fuel. The engine has exceptional smoothness and performance throughout the entire speed range.

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 cooling 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.

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.

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.

Check battery specific gravity, add water if necessary 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

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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. Adjust 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 cartridge 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

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CHRYSLER SERVICE MANUAL ENGINE—49

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

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 propeller shaft, wires and linkage at transmission. Disconnect exhaust pipes at manifolds. Be sure the exhaust system is sufficiently supported while the engine is removed. Remove rear crossmember to transmission support attaching bolts.

NOTE: Place a roUaway jack under the transmission

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 R

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

56. Cylinder Head R

57. Crankcase Vent Tube

58. Rocker Cover Gasket R

59. Rocker Cover R

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 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

RIGHT BANK

LUBRICATION

ROCKER

SHAFT

ROCKER ARM

NO. 4 CAMSHAFT

BEARING

RIGHT MAIN OIL GALLERY

LEFT ROCKER SHAFT

OIL FILTER

OIL PRESSURE

Oil PUMP RELIEF VALVE

Fig. 43 — Engine Oiling System

59x24

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50—ENGINE

WASHER

BOLT\

CAMSHAFT

CHRYSLER SERVICE MANUAL

RETAINER

SPACER

ROCKER

BRACKET

GEARAND SHAFT

SPROCKET

CHAIN

BOLT

OIL SEAL

(SERVICED IN PACKAGE)

BEARING

CRANKSHAFT

SPROCKET

OIL SLINGER

RETAINER -

SCREW

CAP

SCREW

_~-—~—SCREW

CAP {SERVICED IN ROD)

NUT

CAP

Fig. 44 — Engine Internal Parts

59x53

MyMopar.com

CHRYSLER SERVICE MANUAL ENGINE—51

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 approximately 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 engine mounts. Position and install rear engine support bolts and remove the jack, hoist and engine lifting fixture.

Install the carburetor, fuel lines, wiring and linkage. 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

EXHAUST

VALVES

&&^5>k:a

Fig. 45 — Cylinder Heads

58x136

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 accelerator linkage. Remove the vacuum control tube at carburetor and distributor. Disconnect the distributor cap, coil wires and heater hose. Disconnect the heat indicator sending unit wire. Remove spark plugs located under the manifolds. Remove the intake 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 cylinder 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.

b. Installation

Clean the gasket surfaces of cylinder block and cylinder head. Check all surfaces with a straight edge if there is any reason to suspect leakage. Coat the

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52—ENGINE

EXHAUST MANIFOLD - RiGHT

, TOOL mam*

CHRYSLER SERVICE MANUAL

LOCATING ARROW ROCKER ARMS-RIGHT

V> X 1 M

Fig. 47 — Checking Cylinder Head Bolt Torque new gaskets with a suitable sealer, MoPar Part

Number 1122893. Install the gaskets and cylinder heads. Install cylinder head bolts. Starting at top center, tighten all cylinder head bolts to 70 footpounds torque in sequence, as shown in Figure 46, and using Tool C-3666 to check torque, as shown in

Figure 47.

Repeat the procedure, retightening all head bolts to 70 foot-pounds torque. Inspect push rods and replace worn or bent rods. Install push rods with the small ends in tappets maintaining alignment using rod, as shown in Figure 48.

Install the rocker arm and shaft assembly starting each push rod into its respective rocker arm socket.

NOTE: Use extreme care in tightening bolts 30 footpounds torque, so the tappets have time to bleed down to their operating length. Bulged tappet bodies,

CYLINDER HEAD INTAKE PUSH RODS

ASSEMBLIES

58xl?9

• . ROCKER ARMS-RIGHT ; i

LOCATIMOARROW

Fig. 49 — Rocker Arms Installed bent push rods, and permanently noisy operation may result if the tappets are forced down too rapidly.

Place the new cylinder head cover gaskets in position and install cylinder head covers. Tighten the bolts to 40 inch-pounds torque. Install exhaust manifolds and tighten the bolts to 30 foot-pounds torque.

Adjust spark plugs to .035 inch gap and install the plugs, and tighten to 30 foot-pounds torque with

Tool C-3054. Install the tappet chamber cover and tighten end bolts to 8 foot-pounds torque (Fig. 49).

Install intake manifold, carburetor and ignition coil as an assembly and tighten manifold bolts to 40 food-pounds torque. Install the distributor cap. Connect 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 air cleaner. Fill the cooling system.

Adjust belt tensions as outlined in "Accessory Belt

Drives" in this supplement.

-BRACKETS-

OIL FEED

GROOVE

THIS SIDE

OIL FEED GROOVE

THIS SIDE

INSTALLING ROD

EXHAUST PUSH RODS "58x138

Fig. 48 — Push Rods Installed

S P A C E R S -

58x140

Fig. 50 — Rocker Arms & Shaft Assembly

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CHRYSLER SERVICE MANUAL ENGINE—53

ROCKER ARMS AND SHAFT ASSEMBLY

The rocker arms 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 at each rocker arm. Five brackets attach each rocker shaft 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 disassembled for cleaning, inspection, or replacement, refer to Figure 49 and 50 for proper reassembly.

b. Installation

NOTE: The right and left rocker arms must be installed 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, and shaft assembly.

NOTE: Use extreme care in tightening the bolts so

CYLINDER HEAD

ASSEMBLY

TOOL

REPAIR" STAND

(TOOL)

Fig. 51 — Compressing Valve Spring

58x141

" O O U

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 to 30 foot-pounds torque.

VALVES AND VALVE SPRINGS

Valves are arranged in-line in the cylinder heads and inclined 30° outward from vertical. Intake and exhaust 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.

Remove the valve retaining locks, valve spring retainers, valve stem cup seals and valve springs. Remove the burrs from valve stem lock grooves to prevent damage to the valve guide when valves are removed.

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 and exhaust valve stem diameter should measure .371 to .372 inch. 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 follows : Install sleeve Tool C-3026 over the valve stem, as shown in Figure 52, and install valve.

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54—ENGINE

VALVE

CHRYSLER SERVICE MANUAL

TOOL

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 indicator 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 accommodate the oversize valve stem are as follows: Reamer Tool C-3433 (.379 to .380 inch) Reamer Tool C-

3427 (.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

^MINIMUM MEASUREMENT

MAXIMUM MEASUREMENT 58x144A

Fig. 55 — Measuring Valve Stem Length

.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° degree 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 identical. 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 complete 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

VAtve

SPRiNG

STEM-

VALVE SPRING RETAINER

LOCK GROOVES

Fig. 54 — Intake and Exhaust Valve

54x33CC

Fig. 56 — Checking Valve Spring Squareness

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CHRYSLER SERVICE MANUAL

ENGINE—55

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.

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 1-15/32 inches. Turn the table of Tool

C-647 until surface is in line with the 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 1-

15/32 inch. Discard springs that do not meet these specifications.

Inspect each valve spring for squareness with a

RETAINER

EXHAUST

VALVE

SPRING

INTAKE VALVE

Fig. 57 — Valve Assembly

59x51

Fig. 58 — Installing Valves and Cup Seals 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. Install locks and release tool.

NOTE: If the valves and/or seats are reground, 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 1-57/64 inches, install a 1/16 inch spacer in head counterbore to bring spring height back to normal 1-53/64 to 1-57/64 inch.

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 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 operated 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 removed. Feel each valve spring or rocker arm to detect the noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation.

NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on valve spring. Inspect rocker arm push rod sockets and push rod ends for wear. If noise is not appreciably reduced, it can be assumed the noise is in the tappet.

Valve tappet noise ranges from a light noise to a heavy click. A light noise is usually caused by exces-

CYLINDER HEAD

ASSEMBLY

HYDRAULIC TAPPET

Fig. 59 — Removing Tappet

CHRYSLER SERVICE MANUAL

f 7*-PLUNGER RETAINING SPRING CLIP v—' y%+ -PLUNGER CAP

TAPPET PLUNGER

FLAT VALVE

VALVE SPRING-

VALVE RETAINER*

PLUNGER SPRING-

TAPPET BODY

52x389B

Fig. 60 — Hydraulic Tappet Assembly 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 twisting motion, as shown in Figure 59.

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: A diamond shaped marking stamped on the engine numbering pad indicates that all tappet bodies are .008 inch oversize, see Figure 84.

CAUTION

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-

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CHRYSLER SERVICE MANUAL ENGINE—57

51x971D

Fig. 61 — Testing Tappet pet at a time to avoid mixing of parts. Mixed parts are not compatable.

d. Disassembly (Fig. 60)

Pry out plunger retainer spring clip. Clean the varnish deposits from the inside of tappet body above the plunger cap. Invert the tappet body and remove plunger cap, plunger, flat check valve, check valve spring, check valve retainer and plunger spring.

Separate the plunger, check valve retainer and check valve spring. Place all parts in their respective place in the tappet holder Tool C-3068.

e. Cleaning and Assembly

Clean all tappet parts in a solvent that will remove all varnish and carbon. Replace the tappets that are unfit for further service with new assemblies. Assemble the tappets, as shown in Figure 56.

f. Inspection

If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize, using Tool C-3028. If plunger shows signs of scoring or wear and valve is pitted, or if the valve seat on end of plunger indicates any condition that would prevent valve from seating, install a new tappet assembly.

g. Testing

Fill a pan with clean kerosene. Remove cap from plunger and completely submerge the tappet in an upright position.

Allow tappet to fill with kerosene, remove tappet, and replace the cap. Hold the tappet in an upright position and insert the lower jaw of pliers, Tool C-

3160, in the groove of tappet body (Fig. 61).

Engage jaw of pliers with top of the tappet plunger. Check leakdown by compressing pliers. If plunger collapses almost instantly as pressure is applied, disassemble tappet, clean and test again. If the tappet still does not operate satisfactorily after cleaning, install a new tappet assembly.

h. Installation

Lubricate the tappets. Install tappets and push rods in their original positions. Install the rocker arm and shaft assembly. Start and operate the engine.

Warm up to normal operating temperature.

NOTE: To prevent damage to valve mechanism, the engine must not be run above fast idle until all of hydraulic tappets have filled with oil and have become quiet.

CHECKING VALVE TIMING

Turn crankshaft until the No. 1 exhaust valve is full open and the No. 1 piston is on TDC.

Insert a *4 inch spacer between the rocker arm pad and the stern tip of the No. 1 intake valve (second valve on the left bank). Install a dial indicator so that the plunger contacts the valve spring retainer as nearly perpendicular as possible. Allow the spring load to bleed the tappet down giving in effect a solid tappet. Zero the indicator.

Turn the crankshaft clockwise (normal running direction) until intake valve has lifted .013 inch.

The timing on the timing indicator, located on the chain case cover, should read from 10° BTDC to

2° ATDC. If the reading is not within the specified limits: Check the sprocket index marks, inspect the timing chain for wear, and check the accuracy of the DC mark on the timing indicator. Turn crankshaft counter-clockwise until the valve is closed and remove the spacer.

- C H A I N CASE COVER

- - TIMING INDICATOR

- -CYLINDER BLOCK

- TIMING MARK

VIBRATION DAMPER

58x149A

Fig. 62 — Removing Vibration Damper Assembly

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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/

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

CAMSHAFT SPROCKET

CRANKSHAFT

SPROCKET

Fig. 63 — Alignment of Timing Marks

58x150

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 movement 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 footpounds 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 direction 30 foot-pounds (with cylinder heads installed) 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.

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 prevent 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

PULLER BLOCKS (TOOL)

CHAIN CASE COVER

LIP OF SEAL

RETAINER

INSTALLING

PLATE

(TOOL)

ENGINE—59

S E A L "

ASSEMBLY

PULLER SCREW

(TOOL)

CHAIN CASE COVER

V '. " '.V-*.- / '• ' ^ . ?

^ ^ T >--• 58x152

Fig. 65 — Puller Blocks Expanded to Pulling Position

Tighten the nut as tight as possible by hand, forcing blocks into gap to a point of distorting the seal retainer lip (Fig. 65). This is important (puller is only positioned at this point). Place sleeve over the retainer and place removing and installing plate into sleeve. Place the flat washer and nut on puller screw. Hold the center screw and tighten lock nut to remove seal (Fig. 66).

b. Installation of Oil Seal

Insert puller screw through removing and installing plate so that the thin shoulder will be facing up.

Insert puller screw with plate through the seal opening (inside of chain case cover facing up). Place the seal in cover opening, with neoprene down. Place the seal installing plate into the new seal, with protective recess toward lip of seal retainer (Fig. 67).

Install the flat washer and nut on puller screw, hold screw and tighten the nut (Fig. 68).

The seal is properly installed when neoprene is tight against the face of cover. Try to insert a .0015

inch feeler gauge between neoprene and cover (Fig.

69). If the seal is installed properly, the feeler gauge cannot be inserted.

58x154

Fig. 67 — Positioning Installer Plate on New Seal

NOTE: It is normal to find particles of neoprene collected between the seal retainer and crankshaft oil slinger after the seal has been in operation.

c. Installing Chain Case Cover

Be sure the mating surfaces of chain case cover and cylinder block are clean and free from burrs. Using

PULLER SCREW (TOOL)

SEAL'

RETAINER

INSTALLING PLATE

(TOOL)

CHAIN CASE COVER

-: 58x155

Fig. 68 — Installing New Seal

FEELER GAUGE?

PULLER SCRFW (TOOL)

REMOVING AND

INSTALLING PLATE

(TOOL) •- \

SLEEVE (TOOL) ^ "••*' CHAIN CASE

COVER

SEAL

Fig. 66 — Removing Oil Seal

58x153

CHAIN CASE

Fig. 69 — Checking Seal for Proper Seating

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60—ENGINE

CHRYSLER SERVICE MANUAL

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.

Removal

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

BOIT

WASHER

CAMSHAFT SPROCKET CAMSHAFT

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. Remove 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 removed.

b. Installation

Slide new bushing over burnishing end of Tool C-

3053 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.

BUSHING

TOOL

'•**?* A * v

-DISTRIBUTOR DRIVE GEAR

(CAMSHAFT;

FUEL PUMP ECCENTRIC (CAMSHAFT)

LOCATING DOWEL

Fig. 71 — Camshaft and Sprocket Assembly

58x160

Fig. 73 — Installing Distributor Drive Shaft Bushing

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CHRYSLER SERVICE MANUAL

DISTRIBUTOR A N D OIL

PUMP DRIVE

GEAR

ENGINE—61

^ 5 8 x 1 6 1

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 position 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. The tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed.

NOTE: Whenever an engine has been rebuilt and a new camshaft and/or new tappets have been installed, one quart of factory recommended oil additive should be added to the engine oil to aid in breakin. The oil mixture should be left in the engine for a minimum of 500 miles. Drain the oil mixture at the next normal oil change.

CENTER LINE OF CRANKSHAFT

Fig. 76 — Distributor Drive Gear Installation

NOTE: Whenever the camshaft is replaced, all of the tappet faces must be inspected for crown with a straight edge. If any negative crown (dish) is observed, the tappet must be replaced.

d. Distributor (Basic) Timing

Before installing the distributor and oil pump drive shaft, time engine as follows: Rotate the crankshaft until No. 1 cylinder is at top dead center on firing stroke. When in this position, the straight line on the vibration damper should be under (DC) on the timing indicator. Coat shaft and drive gear with engine oil. Install the shaft so that after the gear spirals into place, it will index with oil pump shaft, so that the slot in top of drive gear will be parallel with center line of crankshaft as shown in Figure 76.

e. Installation of Distributor

Hold distributor over the mounting pad on cylinder block with the vacuum chamber pointing toward the center of engine. Turn the rotor until it points forward and to the approximate location of the No. 1 tower terminal in the distributor cap. Place distributor gasket in position. Lower distributor and en-

TOOL

ARM (TOOL)

DISTRIBUTOR DRIVE GEAR (CAMSHAFT) - C 58x162

Fig. 75 — Camshaft Holding Tool

CRANKSHAFT MAIN BEARING OIL HOLE

BEARING OIL HOLE]

58x164

Fig. 77 — Removing Camshaft Bearing

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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 C-

3132A) 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-3132-

A by sliding the new camshaft (bearing shell over the proper adapter. Position bearing in the tool. Install horse shoe lock and by reversing removal procedure, 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 installation 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.

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 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 piston 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 x

RING GROOVE

58x165

Fig. 78 — Measuring Piston Ring Clearance

MyMopar.com

CHRYSLER SERVICE MANUAL ENGINE—63 giving each cylinder wall 20 strokes in 20 seconds with the hone so that a cross hatch pattern will be obtained.

After honing, it is necessary that the block be cleaned again to remove all traces of abrasives, and to prevent excessive wear of engine parts. The hone may be safely used for removal of metal up to .005

inch and as high as .010 to .015 inch by an experienced operator.

CAUTION

Be sure all abrasives are removed from engine parts after honing. It is recommended that a solution of soap and water be used with a brush and then thoroughly dried. If this is impossible, use SAE 10 engine oil and CLEAN cloth. When the bore can be wiped with a clean white cloth and be withdrawn clean, the bore is clean.

c. Cylinder Walls

Cylinder walls which are badly scored, scuffed, scratched, or worn beyond specified limits should be rebored. Whatever type of boring equipment is used, boring operation should be closely coordinated with the fitting of pistons and rings in order that specified clearance may be maintained.

d. Fitting Pistons

The piston and cylinder wall must be clean and dry.

The specified clearance between the piston and the cylinder wall is .0005 to .0010 inch.

The piston diameter should be measured at the top of skirt 90° to the piston pin axis. The cylinder bores on used engines should be measured halfway down the cylinder bore and transverse to the engine crankshaft centerline.

NOTE: Pistons and cylinder bores should be measured at normal room temperature 70° F.

All service pistons include pins, and are available in standard and the following oversizes, .005, .020

and .040 inch.

NUT CTOOl)

ANVIL (TOOL)

PISTON

PILOT (TOOL)

MAIN

SCREW (TOOL)

GUIDE-SMALL

(TOOL)

58x195A

PISTON PIN

CONNECTING ROD

GUIDE-LARGE (TOOL)

Fig. 79 — Tool Arrangement of Removing Piston Pin

This measurement is the same for all rings. Measure the side clearance between piston ring and ring land. The clearance should be .0015 to .003 inch for the top compression ring, .001 to .0025 inch for the intermediate ring, and .001 to .003 for the oil control ring. Starting with the oil ring expander, place expander ring in the lower ring groove and install oil control ring. Install the compression rings in middle and top grooves. Use ring installer, Tool

C-3629 for the MC-1 and MC-2 engine and Tool C-

3628 for the MC-3 and MY-1 engine.

NOTE: Be sure the mark " T o p " on each compression ring is to the top of piston when the ring is installed.

REMOVAL OF PISTON PIN

Arrange Tool C-3624 parts for the removal of piston pin, as shown in Figure 79. Install pilot on the main screw. Install the screw through piston pin. Install anvil over the threaded end of the main screw with small end of anvil against the piston boss.

PRESS

MAIN SCREW

(TOOL) e. Fitting Rings

Measure the piston ring gap about two (2) inches from bottom of cylinder bore in which it is to be fitted. (An inverted piston can be used to push the rings down to insure positioning rings squarely in the cylinder wall before measuring.) Insert the feeler stock in gap (Fig. 78).

The ring gap should be between .013 to .025 inch.

PISTON

[58x166

Fig. 8 0 — Removing Piston Pin

MyMopar.com

64—ENGINE CHRYSLER SERVICE MANUAL

-«*>^—-—- ANVIL (TOOL)

- SPRING

PILOT (TOOL)

PISTON

PISTON PIN

MAIN SCREW

(TOOL)

GUIDE-SMALL

(TOOL)

NUT

(TOOL)

TORQUE WRENCH

SOCKET

ANVfL ( T O O t )

58x196 A GUIDE-LARGE (TOOL)

Fig. 81 — Tool Arrangement for Installing Piston Pin

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

MAIN SCREW

(TOOL)

5 8 x 1 6 8

Fig. 83 — Testing Fit on Piston Pin in 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 piston, 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.

* - PRESS

PISTON PIN «-

i 'L*- l V > A : N

SCREW

*• f TOOL)

PISTON

•• - ANVIL ITOOU

"58x16?

Fig. 82 — Installing Piston Pin

58x169

Fig. 84 — External Identification

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CHRYSLER SERVICE MANUAL ENGINE—65

83.

Place the assembly in a vise, as shown in Figure

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 footpounds 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. 8 5 ) .

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-

( 4

LETTERS

Fig. 85 — Internal Identification

55x162 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 undersize.

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 compressed material is evident, measure with the graduated 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 assemblies 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 operation. 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.

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

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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

UPPER

>THRUST BEARING

LOWER m m m.

Fig. 87 — Main Bearing Identification x!72

INSTALLING • [ 5 1 x 9 3 A

Fig. 88 — Removing and Installing Main

Bearing Upper Shell

MyMopar.com

CHRYSLER SERVICE MANUAL ENGINE—67 sis, the crankshaft must be supported in order to take up clearance between the upper bearing insert and the crankshaft journal. This can be done by snugging bearing caps of the adjacent bearings with

.005 to .015 inch cardboard between lower bearing shell and journal. Use extreme caution when this is done to avoid unnecessary strain on the crankshaft or bearings, or false reading may be obtained. Do not rotate crankshaft while plastigage is installed. Be sure to remove cardboard before reinstalling oil pan.

It is permissible to use one .001 inch undersize bearing shell with one standard bearing shell or one

.002 inch bearing shell. Always use the smaller diameter bearing half as the upper. Never use a new bearing with a used bearing and never use an upper bearing half more than .001 inch smaller than the lower bearing half.

PLUG

GASKET

BOLTS A N D WASHERS

OIL FILTER

|CHN»

SPRING

RELIEF VALVE

PLUNGER

INNER ROTOR

AND SHAFT

BODY

DRIVE SHAFT

A N D GEAR

SEAL RING

GASKET

" O " RING

58x173

Fig. 89 — Oil Pump and Filter Assembly b. Installation of the Upper Main Bearing

NOTE: When installing a new upper bearing shell, slightly chamfer the sharp edge from the plain side.

Start bearing in place, and insert Tool C-3059 into the oil hole of crankshaft (Fig. 88). Slowly rotate the crankshaft counter-clockwise sliding the bearing into position. After all bearings have been fitted, tighten all caps to 85 foot-pounds torque. The crankshaft end play should be .002 to .007 inch.

OIL PAN (ALL MODELS) a. Removal

Drain the oil and remove dipstick. Disconnect the steering linkage from steering arm to allow the steering linkage to be lowered. On single exhaust system, the exhaust crossover pipe must be removed.

Be sure the rest of exhaust system is sufficiently supported. It may be necessary to pull the brake line located across the crossmember slightly forward to allow enough clearance for pan removal. Remove oil pan attaching bolts and lower the oil pan on MC-1 only. Disconnect throttle linkage at transmission and at carburetor. Rotate the crankshaft until the centerline of the front counterweight is in the 10 o'clock position. Remove the front engine mounting nuts and raise the engine one inch. Remove the oil pan.

b. Installation

NOTE: Check the alignment of the oil strainer. The bottom of strainer must be on a horizontal plane machined surface of the cylinder block. The foot of strainer should touch bottom of the oil pan. Clean pan thoroughly and install new gasket, oil pan and attaching bolts. Tighten bolts to 15 foot-pounds torque. Lower the engine and install front engine mounting nuts and tighten to 85 foot-pounds torque.

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

FEELER

GAUGE

Fig. 90 — Checking Oil Pump Cover Flatness

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68—ENGINE

CHRYSLER SERVICE MANUAL

STRAIGHT EDGE

DIAMETER

51x66A

Fig. 91 —Measuring Outer Rotor Thickness pump cover should be smooth. Replace cover if it is scratched or grooved.

Lay a straight edge across the oil pump cover surface (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 measures 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 installed.

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

FEEIER GAUGE

Fig. 93 — Measuring Clearance over Rotors 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. 94 — Measuring Outer Rotor Clearance

.,- OUTER ROTOR

-INNER ROTOR

FEELER

GAUGE

5 1 x 6 7 A

Fig. 92 — Measuring Inner Rotor Thickness

58x1,77

Fig. 95 — Measuring Clearance Between Rotors

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CHRYSLER SERVICE MANUAL

ENGINE—69

OIL FILTER

ASSEMBLY

TOOL

58x239

Fig. 96 — Removing Oil Filter with Tool

RELIEF VALVE SPRING CHART

Color

Free Loaded

Length Length

Compression

Pounds

Gray(Lt.) 2.19 1.60 11.85 to 12.85

Red (Std.) 2.29 1.60 14.85 to 15.85

Brown (Hvy.).... 2.39 1.60 17.9 to 18.9

REMOVAL AND INSTALLATION OF OIL FILTER

The oil filter should be replaced every 5,000 miles to coincide with an engine oil change as follows:

Use care so as not to damage transmission oil cool-

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 y

turn more by hand. Start engine and check for leaks.

58x238

Fig. 98 — Trimming Rear Main Bearing

Lower Oil Seal

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 is seated in bearing bore. Hold tool in this position and cut off portion of seal that extends above the block on both sides.

NOTE: Be sure the bridge is removed from tool.

Install a new seal in the seal retainer so that the ends protrude (Fig. 97). Install bridge on tool and tap the seal down into position with Tool C-3625 until tool is seated. Trim off the portion of the seal that protrudes above the cap (Fig. 98). Install the two side seals in grooves in seal retainer. Install seal retainer and tighten screws to 30 foot-pounds torque.

BRIDGE

(PART OF TOOL)

OUTER CUP

INSTALL INDEX MARK

TOWARD ENGINE

SEAL

RETAINER

SIDE

GROOVES

58x237

Fig. 97 — Installing Rear Main Bearing

Lower Oil Seal

INSULATOR AND

BOLT ASSEMBLY

FRAME BRACKET - . ' •£

LOCKWASHER

L- PLATE

NUT

58x33

Fig. 99 — Right Front Engine Support

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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 the insulator stud does not interfere with the bottom of the slot in the frame bracket.

Install plates, washers and nuts. Neutralize the engine, and tighten nuts to 85 foot-pounds torque.

Connect throttle linkage to transmission and to carburetor. Refer to Transmission Section in this manual for adjustment.

Model

Section VIII

FUEL AND EXHAUST SYSTEM

DATA AND SPECIFICATIONS

MG-1

FUEL PUMP

Make Carter

Model M-2769S

Type Mechanical

Driven By Camshaft

Pump Pressure (pounds) 5 to 7

CARBURETOR

Type Dual Throat Downdraft

Model BBD-2795S-2872S

ADJUSTMENTS

Idle Mixture (both screws) One full turn open

Idle Speed. . 500 rpm

Fast Idle .017"

Fast Idle Cam On Index

Choke Unloader

34 inch

Accelerator Pump Travel 1 in. + or —l{i

Float Setting %

+ or —%

CHOKE

Control Cross over type

Setting On Index

Fast Idle Speed Setting 1375 to 1425 rpm

MG-2, MG-3 and MY-1 Model

FUEL PUMP

Make

Model

Type

Driven By

Pump Pressure (pounds)

Carter

M-2769S

Mechanical

Camshaft

5 to 7

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).

(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.

NOTE: To decrease sensitivity of either or both the potentiometers, turn potentiometer arms in the direction 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.

Section VII

ENGINE

DATA AND SPECIFICATIONS

ENGINE

Type

Number of Cylinders

Bore—MC-1, MC-2

MC-3, MY-1

Stroke

Piston Displacement—MC-1, MC-2

MC-3, MY-1

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

90° V

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"

.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 1.0925 to 1.0928"

CAMSHAFT

Drive Chain

Bearings Steel Backed Babbitt

Number 5

Thrust Taken by Cylinder Block

Diametral Clearance .001 to .003"

Maximum Allowable before Reconditioning .005"

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 2.001"

No. 2 1.984 to 1.985"

No. 3 1.969 to 1.970"

No. 4 1.953 to 1.954"

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"

PISTONS

Type Horizontal Slot w/Steel Struts

Material Aluminum Alloy Tin Coated

MyMopar.com

CHRYSLER SERVICE MANUAL

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 & MC-2

MC-3 & MY-1

No. 2—MC-1 &MC-2

MC-3 & MY-1

No. 3—MC-1 & MC-2

MC-3 & MY-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)

RING SIDE CLEARANCE

(Compression)

Upper

Intermediate

(Oil)

VALVES—Intake

Material

Head Diameter MC-1, MC-2

MC-3, MY-1

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.

ENGINE—43

.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

.0775 to .0780"

.1860 to .1865"

.013 to .025"

.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"

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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) 1.860" @ 95 —105 lbs.

Load when Compressed to (valve open) 1.470" @ 188—252 lbs.

Valve Springs I.D 1.010 to 1.030"

CYLINDER HEAD

Number Used 2

Combustion Chamber Wedge Type

Valve Seat Runout (maximum) .002'

•o

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"

E N G I N E 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

135

40 in.-lbs.

95 in.-lbs.

^8-24

^ - 2 4

%-14

J4-13

14 mr

%>—14

%-24

/i6-18

•HJ-16

^ - 1 6

%~1Q

%-W

J4-28

^ - 2 4

^ fi

-18

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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.

The engine has 10:1 compression ratio, is equipped with a dual carburetor on the Windsor Model

(MC-1), and a 4-barrel carburetor on all other models, and uses premium fuel. The engine has exceptional smoothness and performance throughout the entire speed range.

Some of the new features, as shown in Figures

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.

Check battery specific gravity, add water if necessary 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

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46—ENGINE CHRYSLER SERVICE MANUAL

Fig. 39 — Chrysler Engine Assembly

59x151

Fig. 40 — Engine End Sectional View

59x54

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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. Adjust 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.

Refer to specifications for compression pressures.

Test the coil, and condenser. Inspect the primary and secondary wires. Service the air cleaner — DO NOT

REMOVAL OF THE ENGINE ASSEMBLY (From Car)

Drain the cooling system and remove the battery.

Fig. 41 — Engine Side Sectional View

58x135

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48—ENGINE

CHRYSLER SERVICE MANUAL

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CHRYSLER SERVICE MANUAL ENGINE—49

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

NOTE: Place a roUaway jack under the transmission

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 R

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

56. Cylinder Head R

57. Crankcase Vent Tube

58. Rocker Cover Gasket R

59. Rocker Cover R

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

Place the engine in repair stand C-3167 and Adapter

RIGHT BANK

LUBRICATION

ROCKER

SHAFT

ROCKER ARM

NO. 4 CAMSHAFT

BEARING

RIGHT MAIN OIL GALLERY

LEFT ROCKER SHAFT

OIL FILTER

OIL PRESSURE

Oil PUMP RELIEF VALVE

Fig. 43 — Engine Oiling System

59x24

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50—ENGINE

WASHER

BOLT\

CAMSHAFT

CHRYSLER SERVICE MANUAL

RETAINER

SPACER

ROCKER

BRACKET

GEARAND SHAFT

SPROCKET

CHAIN

BOLT

OIL SEAL

(SERVICED IN PACKAGE)

BEARING

CRANKSHAFT

SPROCKET

OIL SLINGER

RETAINER -

SCREW

CAP

SCREW

_~-—~—SCREW

CAP {SERVICED IN ROD)

NUT

CAP

Fig. 44 — Engine Internal Parts

59x53

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CHRYSLER SERVICE MANUAL ENGINE—51

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.

Position the engine and install the nuts at front engine mounts. Position and install rear engine support bolts and remove the jack, hoist and engine lifting fixture.

Install the carburetor, fuel lines, wiring and linkage. Install the radiator, fan shroud and radiator hoses. Connect exhaust pipes, using new gaskets.

Check the entire system for leaks and correct as necessary.

INTAKE VALVES

EXHAUST

VALVES

&&^5>k:a

Fig. 45 — Cylinder Heads

58x136

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

a. Removal

NOTE: On air conditioned cars, number eight cylinder 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.

C-3626.

b. Installation

Clean the gasket surfaces of cylinder block and cylinder head. Check all surfaces with a straight edge if there is any reason to suspect leakage. Coat the

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52—ENGINE

EXHAUST MANIFOLD - RiGHT

, TOOL mam*

CHRYSLER SERVICE MANUAL

LOCATING ARROW ROCKER ARMS-RIGHT

V> X 1 M

Fig. 47 — Checking Cylinder Head Bolt Torque new gaskets with a suitable sealer, MoPar Part

Figure 47.

Install the rocker arm and shaft assembly starting each push rod into its respective rocker arm socket.

NOTE: Use extreme care in tightening bolts 30 footpounds torque, so the tappets have time to bleed down to their operating length. Bulged tappet bodies,

CYLINDER HEAD INTAKE PUSH RODS

ASSEMBLIES

58xl?9

• . ROCKER ARMS-RIGHT ; i

LOCATIMOARROW

Fig. 49 — Rocker Arms Installed bent push rods, and permanently noisy operation may result if the tappets are forced down too rapidly.

Adjust spark plugs to .035 inch gap and install the plugs, and tighten to 30 foot-pounds torque with

Tool C-3054. Install the tappet chamber cover and tighten end bolts to 8 foot-pounds torque (Fig. 49).

Adjust belt tensions as outlined in "Accessory Belt

Drives" in this supplement.

-BRACKETS-

OIL FEED

GROOVE

THIS SIDE

OIL FEED GROOVE

THIS SIDE

INSTALLING ROD

EXHAUST PUSH RODS "58x138

Fig. 48 — Push Rods Installed

S P A C E R S -

58x140

Fig. 50 — Rocker Arms & Shaft Assembly

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CHRYSLER SERVICE MANUAL ENGINE—53

ROCKER ARMS AND SHAFT ASSEMBLY

The rocker arms are of stamped steel and are arranged on one rocker arm shaft, per 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 disassembled for cleaning, inspection, or replacement, refer to Figure 49 and 50 for proper reassembly.

b. Installation

Figures 49 and 50.

Install the rocker arms, brackets, and shaft assembly.

NOTE: Use extreme care in tightening the bolts so

CYLINDER HEAD

ASSEMBLY

TOOL

REPAIR" STAND

(TOOL)

Fig. 51 — Compressing Valve Spring

58x141

" O O U

58x142

Tighten the bolts to 30 foot-pounds torque.

VALVES AND VALVE SPRINGS

Valves are arranged in-line in the cylinder heads and inclined 30° outward from vertical. Intake and exhaust 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.

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 and exhaust valve stem diameter should measure .371 to .372 inch. 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 follows : Install sleeve Tool C-3026 over the valve stem, as shown in Figure 52, and install valve.

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54—ENGINE

VALVE

CHRYSLER SERVICE MANUAL

TOOL

VALVE

58x143

Fig. 53 — Measuring Guide Wear

(Fig. 53).

Service valves with oversize stems are available in

.005, .015 and .030 inch oversizes. Reamers to accommodate the oversize valve stem are as follows: Reamer Tool C-3433 (.379 to .380 inch) Reamer Tool C-

3427 (.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

^MINIMUM MEASUREMENT

MAXIMUM MEASUREMENT 58x144A

Fig. 55 — Measuring Valve Stem Length

.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° degree 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 identical. When refacing the valve seats with Tool MTH-

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

VAtve

SPRiNG

STEM-

VALVE SPRING RETAINER

LOCK GROOVES

Fig. 54 — Intake and Exhaust Valve

54x33CC

Fig. 56 — Checking Valve Spring Squareness

MyMopar.com

CHRYSLER SERVICE MANUAL

ENGINE—55

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.

d. Testing Valve Springs

As an example, the compressed length of the spring to be tested is 1-15/32 inches. Turn the table of Tool

15/32 inch. Discard springs that do not meet these specifications.

Inspect each valve spring for squareness with a

RETAINER

EXHAUST

VALVE

SPRING

INTAKE VALVE

Fig. 57 — Valve Assembly

59x51

Fig. 58 — Installing Valves and Cup Seals 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

Compress the valve springs with Tool C-3422. Install locks and release tool.

HYDRAULIC TAPPETS a. Preliminary to Checking Hydraulic 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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b. Tappet Noises

Valve tappet noise ranges from a light noise to a heavy click. A light noise is usually caused by exces-

CYLINDER HEAD

ASSEMBLY

HYDRAULIC TAPPET

Fig. 59 — Removing Tappet

CHRYSLER SERVICE MANUAL

f 7*-PLUNGER RETAINING SPRING CLIP v—' y%+ -PLUNGER CAP

TAPPET PLUNGER

FLAT VALVE

VALVE SPRING-

VALVE RETAINER*

PLUNGER SPRING-

TAPPET BODY

52x389B

In either case, the tappet assembly should be removed for inspection and cleaning.

c. Removal of Tappets

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 twisting motion, as shown in Figure 59.

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: A diamond shaped marking stamped on the engine numbering pad indicates that all tappet bodies are .008 inch oversize, see Figure 84.

CAUTION

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-

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CHRYSLER SERVICE MANUAL ENGINE—57

51x971D

Fig. 61 — Testing Tappet pet at a time to avoid mixing of parts. Mixed parts are not compatable.

d. Disassembly (Fig. 60)

Separate the plunger, check valve retainer and check valve spring. Place all parts in their respective place in the tappet holder Tool C-3068.

e. Cleaning and Assembly

Clean all tappet parts in a solvent that will remove all varnish and carbon. Replace the tappets that are unfit for further service with new assemblies. Assemble the tappets, as shown in Figure 56.

f. Inspection

g. Testing

Fill a pan with clean kerosene. Remove cap from plunger and completely submerge the tappet in an upright position.

Allow tappet to fill with kerosene, remove tappet, and replace the cap. Hold the tappet in an upright position and insert the lower jaw of pliers, Tool C-

3160, in the groove of tappet body (Fig. 61).

h. Installation

Lubricate the tappets. Install tappets and push rods in their original positions. Install the rocker arm and shaft assembly. Start and operate the engine.

Warm up to normal operating temperature.

NOTE: To prevent damage to valve mechanism, the engine must not be run above fast idle until all of hydraulic tappets have filled with oil and have become quiet.

CHECKING VALVE TIMING

Turn crankshaft until the No. 1 exhaust valve is full open and the No. 1 piston is on TDC.

Turn the crankshaft clockwise (normal running direction) until intake valve has lifted .013 inch.

The timing on the timing indicator, located on the chain case cover, should read from 10° BTDC to

- C H A I N CASE COVER

- - TIMING INDICATOR

- -CYLINDER BLOCK

- TIMING MARK

VIBRATION DAMPER

58x149A

Fig. 62 — Removing Vibration Damper Assembly

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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/

inch pitch and is

% inch wide. Chain stretch is reduced because of fewer joints to wear.

a. Removal

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

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

CAMSHAFT SPROCKET

CRANKSHAFT

SPROCKET

Fig. 63 — Alignment of Timing Marks

58x150

TORQUE WRENCH

58x151

Fig. 64 — Measuring Chain Stretch camshaft sprocket bolt and tighten to 35 foot-pounds torque.

c. Checking Timing Chain for Stretch

15 foot-pounds torque (cylinder heads removed).

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 prevent 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

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CHRYSLER SERVICE MANUAL

PULLER BLOCKS (TOOL)

CHAIN CASE COVER

LIP OF SEAL

RETAINER

INSTALLING

PLATE

(TOOL)

ENGINE—59

S E A L "

ASSEMBLY

PULLER SCREW

(TOOL)

CHAIN CASE COVER

V '. " '.V-*.- / '• ' ^ . ?

^ ^ T >--• 58x152

Fig. 65 — Puller Blocks Expanded to Pulling Position

b. Installation of Oil Seal

Insert puller screw through removing and installing plate so that the thin shoulder will be facing up.

Install the flat washer and nut on puller screw, hold screw and tighten the nut (Fig. 68).

The seal is properly installed when neoprene is tight against the face of cover. Try to insert a .0015

inch feeler gauge between neoprene and cover (Fig.

69). If the seal is installed properly, the feeler gauge cannot be inserted.

58x154

Fig. 67 — Positioning Installer Plate on New Seal

NOTE: It is normal to find particles of neoprene collected between the seal retainer and crankshaft oil slinger after the seal has been in operation.

c. Installing Chain Case Cover

Be sure the mating surfaces of chain case cover and cylinder block are clean and free from burrs. Using

PULLER SCREW (TOOL)

SEAL'

RETAINER

INSTALLING PLATE

(TOOL)

CHAIN CASE COVER

-: 58x155

Fig. 68 — Installing New Seal

FEELER GAUGE?

PULLER SCRFW (TOOL)

REMOVING AND

INSTALLING PLATE

(TOOL) •- \

SLEEVE (TOOL) ^ "••*' CHAIN CASE

COVER

SEAL

Fig. 66 — Removing Oil Seal

58x153

CHAIN CASE

Fig. 69 — Checking Seal for Proper Seating

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60—ENGINE

CHRYSLER SERVICE MANUAL

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

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.

Removal

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

BOIT

WASHER

CAMSHAFT SPROCKET CAMSHAFT

58x159

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 removed.

b. Installation

Slide new bushing over burnishing end of Tool C-

3053 and insert the tool and bushing into bore, as shown in Figure 73.

BUSHING

TOOL

'•**?* A * v

-DISTRIBUTOR DRIVE GEAR

(CAMSHAFT;

FUEL PUMP ECCENTRIC (CAMSHAFT)

LOCATING DOWEL

Fig. 71 — Camshaft and Sprocket Assembly

58x160

Fig. 73 — Installing Distributor Drive Shaft Bushing

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CHRYSLER SERVICE MANUAL

DISTRIBUTOR A N D OIL

PUMP DRIVE

GEAR

ENGINE—61

^ 5 8 x 1 6 1

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

CENTER LINE OF CRANKSHAFT

Fig. 76 — Distributor Drive Gear Installation

NOTE: Whenever the camshaft is replaced, all of the tappet faces must be inspected for crown with a straight edge. If any negative crown (dish) is observed, the tappet must be replaced.

d. Distributor (Basic) Timing

e. Installation of Distributor

TOOL

ARM (TOOL)

DISTRIBUTOR DRIVE GEAR (CAMSHAFT) - C 58x162

Fig. 75 — Camshaft Holding Tool

CRANKSHAFT MAIN BEARING OIL HOLE

BEARING OIL HOLE]

58x164

Fig. 77 — Removing Camshaft Bearing

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 C-

3132A) 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-3132-

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).

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

a. Checking Cylinder Bores

b. Honing Cylinder Bores

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 x

RING GROOVE

58x165

Fig. 78 — Measuring Piston Ring Clearance

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CHRYSLER SERVICE MANUAL ENGINE—63 giving each cylinder wall 20 strokes in 20 seconds with the hone so that a cross hatch pattern will be obtained.

inch and as high as .010 to .015 inch by an experienced operator.

CAUTION

c. Cylinder Walls

d. Fitting Pistons

The piston and cylinder wall must be clean and dry.

The specified clearance between the piston and the cylinder wall is .0005 to .0010 inch.

NOTE: Pistons and cylinder bores should be measured at normal room temperature 70° F.

All service pistons include pins, and are available in standard and the following oversizes, .005, .020

and .040 inch.

NUT CTOOl)

ANVIL (TOOL)

PISTON

PILOT (TOOL)

MAIN

SCREW (TOOL)

GUIDE-SMALL

(TOOL)

58x195A

PISTON PIN

CONNECTING ROD

GUIDE-LARGE (TOOL)

Fig. 79 — Tool Arrangement of Removing Piston Pin

C-3629 for the MC-1 and MC-2 engine and Tool C-

3628 for the MC-3 and MY-1 engine.

NOTE: Be sure the mark " T o p " on each compression ring is to the top of piston when the ring is installed.

REMOVAL OF PISTON PIN

PRESS

MAIN SCREW

(TOOL) e. Fitting Rings

The ring gap should be between .013 to .025 inch.

PISTON

[58x166

Fig. 8 0 — Removing Piston Pin

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64—ENGINE CHRYSLER SERVICE MANUAL

-«*>^—-—- ANVIL (TOOL)

- SPRING

PILOT (TOOL)

PISTON

PISTON PIN

MAIN SCREW

(TOOL)

GUIDE-SMALL

(TOOL)

NUT

(TOOL)

TORQUE WRENCH

SOCKET

ANVfL ( T O O t )

58x196 A GUIDE-LARGE (TOOL)

Fig. 81 — Tool Arrangement for Installing Piston Pin

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

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

MAIN SCREW

(TOOL)

5 8 x 1 6 8

Fig. 83 — Testing Fit on Piston Pin in Connecting Rod through the piston pin hole. Position connecting rod over the pilot which extends through the piston hole.

Install the main screw and piston pin in the piston, as shown in Figure 81.

Install the nut on puller screw to hold assembly together. Place assembly on a press, as shown in

* - PRESS

PISTON PIN «-

i 'L*- l V > A : N

SCREW

*• f TOOL)

PISTON

•• - ANVIL ITOOU

"58x16?

Fig. 82 — Installing Piston Pin

58x169

Fig. 84 — External Identification

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CHRYSLER SERVICE MANUAL ENGINE—65

83.

Place the assembly in a vise, as shown in Figure

If connecting rod does not move under 15 footpounds torque, the piston pin and connecting rod interference is satisfactory, the tool may be removed.

CONNECTING RODS

IMPORTANT

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

( 4

LETTERS

Fig. 85 — Internal Identification

55x162 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 undersize.

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)

Reinstall the cap and tighten attaching nuts alternately to specified torque.

INSTALLING PISTON AND CONNECTING ROD

ASSEMBLY IN CYLINDER BLOCK

NOTE: Rotate the crankshaft so that connecting rod journal is on center of the cylinder bore.

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

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66—ENGINE CHRYSLER SERVICE MANUAL

CRANKSHAFT JOURNAL

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 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

UPPER

>THRUST BEARING

LOWER m m m.

Fig. 87 — Main Bearing Identification x!72

INSTALLING • [ 5 1 x 9 3 A

Fig. 88 — Removing and Installing Main

Bearing Upper Shell

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It is permissible to use one .001 inch undersize bearing shell with one standard bearing shell or one

PLUG

GASKET

BOLTS A N D WASHERS

OIL FILTER

|CHN»

SPRING

RELIEF VALVE

PLUNGER

INNER ROTOR

AND SHAFT

BODY

DRIVE SHAFT

A N D GEAR

SEAL RING

GASKET

" O " RING

58x173

Fig. 89 — Oil Pump and Filter Assembly b. Installation of the Upper Main Bearing

NOTE: When installing a new upper bearing shell, slightly chamfer the sharp edge from the plain side.

OIL PAN (ALL MODELS) a. Removal

b. Installation

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

FEELER

GAUGE

Fig. 90 — Checking Oil Pump Cover Flatness

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68—ENGINE

CHRYSLER SERVICE MANUAL

STRAIGHT EDGE

DIAMETER

51x66A

Fig. 91 —Measuring Outer Rotor Thickness pump cover should be smooth. Replace cover if it is scratched or grooved.

If the pump inner rotor length measures less than

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

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.

FEEIER GAUGE

Fig. 93 — Measuring Clearance over Rotors 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.

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. 94 — Measuring Outer Rotor Clearance

.,- OUTER ROTOR

-INNER ROTOR

FEELER

GAUGE

5 1 x 6 7 A

Fig. 92 — Measuring Inner Rotor Thickness

58x1,77

Fig. 95 — Measuring Clearance Between Rotors

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CHRYSLER SERVICE MANUAL

ENGINE—69

OIL FILTER

ASSEMBLY

TOOL

58x239

Fig. 96 — Removing Oil Filter with Tool

RELIEF VALVE SPRING CHART

Color

Free Loaded

Length Length

Compression

Pounds

Gray(Lt.) 2.19 1.60 11.85 to 12.85

Red (Std.) 2.29 1.60 14.85 to 15.85

Brown (Hvy.).... 2.39 1.60 17.9 to 18.9

REMOVAL AND INSTALLATION OF OIL FILTER

The oil filter should be replaced every 5,000 miles to coincide with an engine oil change as follows:

Use care so as not to damage transmission oil cool-

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 y

turn more by hand. Start engine and check for leaks.

58x238

Fig. 98 — Trimming Rear Main Bearing

Lower Oil Seal

REPLACEMENT OF THE REAR MAIN BEARING

OIL SEAL (Crankshaft Removed)

NOTE: Be sure the bridge is removed from tool.

BRIDGE

(PART OF TOOL)

OUTER CUP

INSTALL INDEX MARK

TOWARD ENGINE

SEAL

RETAINER

SIDE

GROOVES

58x237

Fig. 97 — Installing Rear Main Bearing

Lower Oil Seal

INSULATOR AND

BOLT ASSEMBLY

FRAME BRACKET - . ' •£

LOCKWASHER

L- PLATE

NUT

58x33

Fig. 99 — Right Front Engine Support

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70—FUEL AND EXHAUST SYSTEM CHRYSLER SERVICE MANUAL

FRONT ENGINE MOUNTS a. Removal

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 the insulator stud does not interfere with the bottom of the slot in the frame bracket.

Install plates, washers and nuts. Neutralize the engine, and tighten nuts to 85 foot-pounds torque.

Connect throttle linkage to transmission and to carburetor. Refer to Transmission Section in this manual for adjustment.

Model

Section VIII

FUEL AND EXHAUST SYSTEM

DATA AND SPECIFICATIONS

MG-1

FUEL PUMP

Make Carter

Model M-2769S

Type Mechanical

Driven By Camshaft

Pump Pressure (pounds) 5 to 7

CARBURETOR

Type Dual Throat Downdraft

Model BBD-2795S-2872S

ADJUSTMENTS

Idle Mixture (both screws) One full turn open

Idle Speed. . 500 rpm

Fast Idle .017"

Fast Idle Cam On Index

Choke Unloader

34 inch

Accelerator Pump Travel 1 in. + or —l{i

Float Setting %

+ or —%

CHOKE

Control Cross over type

Setting On Index

Fast Idle Speed Setting 1375 to 1425 rpm

MG-2, MG-3 and MY-1 Model

FUEL PUMP

Make

Model

Type

Driven By

Pump Pressure (pounds)

Carter

M-2769S

Mechanical

Camshaft

5 to 7

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70—FUEL AND EXHAUST SYSTEM CHRYSLER SERVICE MANUAL

FRONT ENGINE MOUNTS a. Removal

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 the insulator stud does not interfere with the bottom of the slot in the frame bracket.

Install plates, washers and nuts. Neutralize the engine, and tighten nuts to 85 foot-pounds torque.

Connect throttle linkage to transmission and to carburetor. Refer to Transmission Section in this manual for adjustment.

Model

Section VIII

FUEL AND EXHAUST SYSTEM

DATA AND SPECIFICATIONS

MG-1

FUEL PUMP

Make Carter

Model M-2769S

Type Mechanical

Driven By Camshaft

Pump Pressure (pounds) 5 to 7

CARBURETOR

Type Dual Throat Downdraft

Model BBD-2795S-2872S

ADJUSTMENTS

Idle Mixture (both screws) One full turn open

Idle Speed. . 500 rpm

Fast Idle .017"

Fast Idle Cam On Index

Choke Unloader

34 inch

Accelerator Pump Travel 1 in. + or —l{i

Float Setting %

+ or —%

CHOKE

Control Cross over type

Setting On Index

Fast Idle Speed Setting 1375 to 1425 rpm

MG-2, MG-3 and MY-1 Model

FUEL PUMP

Make

Model

Type

Driven By

Pump Pressure (pounds)

Carter

M-2769S

Mechanical

Camshaft

5 to 7

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CHRYSLER SERVICE MANUAL FUEL AND EXHAUST SYSTEM—71

DATA AND SPECIFICATIONS (Cont'd)

CARBURETOR

Make Carter

4 Barrel

Type Downdraft*

Model AFB-2797S

THROTTLE BORE

Primary 1% inch

Secondary l^f

inch

MAIN VENTURI

Primary 1%5 inch

Secondary \}/± inch

LOW SPEED JET PRIMARY ADJUSTMENTS

Idle Mixture (both screws) One full turn open

Idle Speed 500 rpm

Accelerator Pump Middle hole of arm

Pump Setting (top of plunger to air horn) .429 or % inch

Float Setting (casting to top of floats) %

m c n

Float Drop „ % inch

Choke Unloader

/i inch

Choke Setting On Index

Fast Idle .012 inch

CHOKE

Control Cross Over type

Setting On Index

Fast Idle Speed Setting 1375 to 1425 rpm

SPECIAL TOOLS - CARBURETOR

C-3411 Gauge

C-3400 Repair Stand

C-3582 Wrench

C-3584 Puller

T-109-22 Bending Tool

T-109-29 Gauge (.020 to .030 inch)

T-109-31 Float Gauge Q4 inch)

T-109-41 Bending Tool

T-109-43 Plug Removing Tool

T-109-58 Screw Driver Bit Q4 inch)

T-109-106 Float Gauge (% inch)

T-109-200 Gauge (.010 to .012 inch)

T-109-213 Bending Tool

T-109-280 Float Gauge

T-109-289U Set of 5 Elevating Legs

CARBURETOR

The carburetor is similar to that used in the 1958 cedures are basically the same as the 1958 Models

Models except for the new cross over type automatic except for the Data and Specifications, Carburetor choke and also on the 1959 Windsor Models the BBD Adjustments, and servicing of the new cross-over carburetor has a new large air horn. Servicing pro- type automatic choke.

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72—FUEL AND EXHAUST SYSTEM

l l j l INDEX MARK

CHRYSLER SERVICE MANUAL

UNLOADER GAUGE

(1/4 INCH)

LIGHT FINGER PRESSURE

AGAINST CHOICE VALVE

FAST IDLE

ADJUSTING

SCREW

BEND T A N G UNTIL

CORRECT CLEARANCE

HAS BEEN OBTAINED

THROTTLE VALVES

HELD CLOSED

58x253A

Fig. 100 — Checking Fast Idle Cam Indexing

THROTTLE VALVES IN

WIDE OPEN POSITION

CARBURETOR ADJUSTMENTS (BBD)

FAST IDLE ADJUSTMENT

The index mark on the fast idle cam should be in direct line with the fast idle screw shank. Now, invert the carburetor and open the throttle valves to wide open, position. Close the choke valve tightly and then close the throttle valves. Open the choke valve.

This will position the fast idle cam to fast idle. The index mark on the cam should split the center of the fast idle adjusting screw, as shown in Figure 100.

If an adjustment is necessary, bend the tang on the fast idle lever using Tool T-109-22 until mark on cam indexes fast idle screw.

With the choke valve held tightly closed, tighten the fast idle adjusting screw (on the high step of fast idle cam), until wire gauge T-109-29 (.020 inch) can be inserted between the throttle valve and the bore (side opposite port), as shown in Figure 101.

58x254A

Fig. 102 — Choke Unloader Adjustment

(wide open kick)

CHOKE UNLOADER ADJUSTMENT

(Wide Open Kick)

To make the choke unloader adjustment, lightly hold the choke valve closed, then open the throttle valves to wide open position. The choke valve should open sufficiently to allow unloader gauge T-109-31 (*4 inch) to be inserted between choke valve and wall of air horn, as shown in Figure 102. Adjust if necessary, by bending the arm on the fast idle lever using T-109-213, until correct clearance has been obtained (Fig 104).

ACCELERATOR PUMP TRAVEL ADJUSTMENT

To check the accelerator pump travel, backoff the idle speed (curb idle) adjusting screw until the throttle valves are fully seated in their bores. (Make sure the fast idle adjusting screw is off the fast idle cam.) With the throttle valves seated, the distance from the top of the plunger shaft down to the top

.020 INCH WIRE GAUGE

THROTTLE VALVE

FAST IDJ.E CAM

INDEX MARK

ti£$f FAST IDLE ADJUSTING SCREW

58x252

Fig. 101 - Setting Fast Idle

1 INCH

± 1/64

FROM TOP OF

PUMP SHAFT TO

BOTTOM OF

AIR HORN

THROTTLE VALVES SEATED

FAST IDLE

SCREW OFF

FAST IDLE

CAM

58x255 A '

Fig. 103 —Checking Accelerator Pump Travel

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CHRYSLER SERVICE MANUAL FUEL AND EXHAUST SYSTEM—73

.012 INCH WIRE G A U G E

FAST IDLE

ADJUSTING SCREW

TANG

SPECIAL TOOL

INDEX MARK O N CAM

58x256A

Fig. 104 — Bending Tang on Fast Idle Lever

HIGH STEP OF FAST IDLE CAM

CHOKE VALVE TIGHTLY CLOSED

Fig. 1 0 6 - Setting Fast Idle

58x289 of the air horn, should be 1 inch + or — 1/64 inch when measured with a steel scale, as shown in Figure 103. To adjust pump setting, bend accelerator pump connecting rod until correct pump travel has been obtained.

CARBURETOR ADJUSTMENTS (AFB)

FAST IDLE ADJUSTMENT

Invert the carburetor and open the throttle valves to wide open position. Close the choke valve tightly and then close the throttle valves. Release the choke valve. This will position the fast idle cam to fast idle. The index mark on the cam should split the center of the last idle adjusting screw, (Fig. 105).

If an adjustment is necessary, bend the fast idle connector rod at the angle, using Tool T-109-213, until the index mark on the cam indexes the fast idle adjusting screw.

With the choke valve held tightly closed and carburetor inverted, tighten the fast idle adjusting screw

(on the high step of the fast idle cam), until wire gauge, Tool T-109-200 (.012 inch) can be inserted between the primary throttle valve and the bore

(side opposite idle port), (Fig. 106). The index mark on the fast idle cam should be in direct line with the fast idle screw shank.

CHOKE UNLOADER ADJUSTMENT

With the throttle valves in the wide open position, it should be possible to insert Tool T-109-31 (% inch) gauge between the upper edge of the choke valve and the inner wall of the air horn (Fig. 107).

If an adjustment is necessary, bend the unloader lip on the throttle shaft lever, using Tool T-109-41, until correct opening has been obtained.

UNLOADER GAUGE

(1,4 INCH)

CHOKE VALVE OPEN

TO ADJUST, BEND

AT THIS ANGLE i SHANK OF FAST

-IDLE ADJUSTING

|~~ SCREW

THROTTLE VALVES CLOSED 58x290

Fig. 105 — Checking Fast Idle Cam Indexing

LIGHT FINGER

PRESSURE

AGAINST

CHOKE VALVE

BEND

UNLOADER LIP

THROTTLE VALVES WIDE OPEN

Fig. 107 —Checking Choke Unloader Adjustment

(wide open kick)

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74—FRAME CHRYSLER SERVICE MANUAL

SERVICING THE AUTOMATIC CHOKE

(CROSS-OVER TYPE)

To function properly, it is important that all parts be clean and move freely. Other than the occasional cleaning, the automatic choke control requires no servicing. It is very important that the choke control unit works freely at the thermostatic coil spring housing and at the choke shaft. Move the choke rod up and down to check for free movement of the coil housing on the pivot. If unit binds, a new unit should be installed. The Cross-Over Choke Control Unit is serviced only as a complete unit. (Fig. 108). Do not attempt to repair.

When installing the cross-over choke unit, make certain that the coil housing does not contact the sides of the wall in the intake manifold. Any contact at this point will affect choke operation.

CALIBRATION SETTING

(2 NOTCHES RICH)

DO NOT CHANGE

CHOKE ROD

DUST CAP

COVER

INDEX NOTCH

THERMOSTATIC COIL SPRING 58x288

Fig. 108 — Cross-Over Choke Control Unit

Do not lubricate any parts of the choke or control unit since this causes dirt accumulation which would result in binding of the choke mechanism.

Do not attempt to change the calibration setting

(2 notches rich). This is predetermined and should it be changed, improper choke action would result.

Section IX

FRAME

The shape and contour of the 1959 Chrysler frames remain the same as the 1958 with the exception of the following modification:

The front portion of the Chrysler frame (Figs. 109,

110) has been modified to accept a newly designed front bumper mounting.

The upper control arm pivot brackets are changed and relocated to provide a better means of adjusting front wheel alignment.

The 1959 Imperial frame includes the above change and in addition the following modifications:

GAUGE HOLE;IN EACH SIDE OF FRAME

Fig. 109 — Frame Dimensions (Windsor)

57x103B

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74—FRAME CHRYSLER SERVICE MANUAL

SERVICING THE AUTOMATIC CHOKE

(CROSS-OVER TYPE)

When installing the cross-over choke unit, make certain that the coil housing does not contact the sides of the wall in the intake manifold. Any contact at this point will affect choke operation.

CALIBRATION SETTING

(2 NOTCHES RICH)

DO NOT CHANGE

CHOKE ROD

DUST CAP

COVER

INDEX NOTCH

THERMOSTATIC COIL SPRING 58x288

Fig. 108 — Cross-Over Choke Control Unit

Do not lubricate any parts of the choke or control unit since this causes dirt accumulation which would result in binding of the choke mechanism.

Do not attempt to change the calibration setting

(2 notches rich). This is predetermined and should it be changed, improper choke action would result.

Section IX

FRAME

The shape and contour of the 1959 Chrysler frames remain the same as the 1958 with the exception of the following modification:

The front portion of the Chrysler frame (Figs. 109,

110) has been modified to accept a newly designed front bumper mounting.

The upper control arm pivot brackets are changed and relocated to provide a better means of adjusting front wheel alignment.

The 1959 Imperial frame includes the above change and in addition the following modifications:

GAUGE HOLE;IN EACH SIDE OF FRAME

Fig. 109 — Frame Dimensions (Windsor)

57x103B

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CHRYSLER SERVICE MANUAL FRAME—75

198

/64"

GAUGE HOLE IN EACH

SIDE OF FRAME^

TOP OF FRAME LINE'

57x138 A

Fig. 110 — Frame Dimensions Saratoga and New Yorker

The body mounts have been relocated and redesigned to include dual solid mounting points at the

Numbers 1, 2, 3 and 4 body mounts. This provides a more effective tie of the body to the frame. (Fig.

111).

The center bearing crossmember has also been redesigned to accommodate a smaller drive shaft tunnel in the floor pan.

The frame side rails have been depressed which permits the use of a new lower floor pan for increased leg room.

The "X" member frames are used only on Convertible Models.

/i6

GAUGE HOLE IN EACH

SIDE OF FRAMED

=FF

-f\r

TOP OF FRAME LINE'

Fig. I l l — Frame Dimensions — Imperial '

62^2

57x140B r

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76—STEERING CHRYSLER SERVICE MANUAL

Section X

STEERING

DATA AND SPECIFICATIONS

MODELS MC-1 MG-2 MC-3 MY-1

Steering Type

Manual Worm and Three

Tooth Roller None None None

Power Rack and Gear Sector, Recirculating Ball Nut

Ratio

Manual 20.4 . . . .

Power 16.1 16.1 16.1 16.1

Turning Radius (Curb to Curb) 42.3 45.4 45.4 49.5

Number Wheel Turns

Manual 5.6 . . . .

Power 3.5 3.5 3.5 3.5

Tread—Front 61.0 61.0 61.2 61.8

Rear 59.8 59.8 60.0 62.4

Wheel Base 122.0 126.0 126.0 129.0

Camber

Left + M degree + or —J^ degree

Right 0 degrees + or —34 degree

Preferred Left -f V% degree, right 0 degree

*Caster

Manual — ^ degree + or —% degree

Power + % degree -f or —% degree

Toe-in (outside thread inches) y

+ or —% in. (J^ in. preferred)

Toe-Out on Turns 21 degrees 45 minutes -f- or —1 degree

(inner wheel when outer wheel is 20 degrees)

Steering Axis Inclination at Camber (Degree) 5 to 7 degrees at 0 degrees camber

Steering Knuckle Type Ball and Socket

Front Wheel Bearing Type Tapered Roller Bearing-

Inner Bearing Size 1.25 1.25 1.25 1.375

Outer Bearing Size .75 .75 .75 .844

Spindle Thread Size %-16 (NF)

Steering Linkage Type Symmetric Idler Arm (Equal Length Tie Rods)

*Caster should be equalized as near as possible on Left and Right wheel.

POWER STEERING PUMP SPECIFICATIONS

MODELS Slipper Type

Fluid Capacity of Hydraulic System 64 Fluid ounces

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CHRYSLER SERVICE MANUAL STEERING—77

POWER STEERING PUMP SPECIFICATIONS (Confd)

Type of Fluid Automatic Transmission Fluid

Type "A"

Maximum Pump Pressure—MC-1, MC-2, MC-3 850 to 950 psi

MY-1 950 to 1050 psi

Maximum Fluid Flow at 3,000 rpm 2.25 gal.

NEW ADDED SPECIAL TOOLS

Tool Number Tool Name

C-3676 Worm Piston Ring—Remover and Installer

TIGHTENING REFERENCE

Foot-Pounds Torque

Steering Wheel Nut 40

Steering Arm Nut 120

Steering Gear Housing to Frame Bolt 50

Steering Valve End Plug 50

Steering Valve Body Attaching Bolts 15

Steering Column Support Nut 135

Steering Gear Shaft Cover Nut ,"...' 100

Steering Gear Shaft Adjusting Screw Lock Nut 50

Pressure Control Valve Body Screws 10

NUT — tOCKWASHER "'

GEAR ARM

59 x 2

SHIMS-—-~*_flto^ . ..^-PLATE

WASHER.

WORM

CAGE AND ROLLERS \ . i t v j

S C R E W A N D

CUP \ ..JUSfe»J»^ | \ LOCKWASHER j SPRING

SEAL j CUP

PLUG

CONE AND ROLLERS

SHAFT

WASHER

GASKET

NUT

TUBE

ADJUSTING SCREW"

LOCK RING-

COVER

SCREW AND LOCKWASHER —W

Fig. 112 —Manual Steering Gear Assembly

(Disassembled View)

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78—STEERING CHRYSLER SERVICE MANUAL

STEERING

MANUAL

The Manual Steering gear is somewhat different in appearance, as shown in Figure 112, however, the service procedures will remain the same as described in the 1958 Chrysler and Imperial Service Manual

D-16350.

CONSTANT CONTROL FULL TIME

POWER STEERING

The Constant Control Full Time Power Steering

(Fig. 113) is the same as used on the 1958 Models with the following exceptions: The wormshaft is knurled for more positive locking of the wormshaft bearing adjusting nut. The piston is fitted with a cast iron ring backed up by a rubber " 0 " ring. These rings separate and seal the power chambers of the housing. The valve lever is held firmly seated in, the center race and center race spacer by the lever spring load. A new steering column bearing and conical spacer are used to keep the bearing inner race tight on the steering tube.

The servicing procedure for the 1959 Constant

Control Power Steering is the same as that described in the 1958 Chrysler and Imperial Service Manual except for the following operations:

POWER PISTON

RIGHT TURN

POWER

CHAMBER

BACK PRESSURE

VALVE

OIL OUT OIL IN

| . VALVE 8O0Y

SPOOL VALVE

PIVOT LEVER

CENTER THRUST

BEARING RACE

STEERING

CCLUMN

CONNECTION

COLUMN JACKET

SUPPORT

UA\H HC : V

LE1-T 7 UR

CYUNOCRHPAD ^ FACTION

RIGHT TURN

WOW SHAFT REACTION R«NG

WORM SHAFT

BALANCING RING

Fig. 113 — Power Steering Gear (Sectional View)

59x140

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CHRYSLER SERVICE MANUAL

Installation of the Piston Ring:

Install the synthetic rubber " 0 " ring from the ring package in the piston ring groove. Install the cast iron piston ring in the ring groove. Locate the ring gap in line with the center of the recirculating ball guide hole plug nearest the piston flange. (The gap location will reduce pressure leakage to a minimum.)

Carefully hook the ends of the iron ring using Tool

C-3676.

OPERATION 17—ASSEMBLY OF POWER TRAIN

Refer to Figure 30 in the Steering Section of the

1958 Chrysler and Imperial Service Manual and proceed as follows:

Place the piston assembly on the bench in a vertical position (worm shaft up).

Slide the cylinder head assembly (with ferrule up) on the worm shaft, check the worm shaft seal ring making sure the gap is closed to avoid breaking the ring as the cylinder head moves against the piston flange.

Lubricate and install the following components in order:

(a) Install the lower thrust bearing race (thick).

(b) Install the lower thrust bearing.

(d) Install the lower reaction ring (flange up so ring protrudes through reaction spring).

(e) Install the center bearing race.

(f) Install the upper thrust bearing.

(g) Install the upper thrust bearing race (thin).

(h) Start the new worm shaft thrust bearing nut.

(Do not tighten.)

Turn the worm shaft counter-clockwise one-half turn. Caution, shaft must not be turned out more than one-half turn or the cylinder head seal will clear the oil ring on the worm shaft. Hold the worm shaft in this position while tightening the nut to

10 foot-pounds torque.

Rotate the worm center bearing race several times to position the parts.

When installing a new nut, or reinstalling the old nut, the following procedure is recommended:

(a) Tighten the nut to 50 foot-pounds to pre-seat and stretch the threads.

STEERING—79

(b) Loosen the nut and retighten to give a preload torque on center race of 8 to 16 inch ounces.

(c) Using a standard drift, having a flat point %" in diameter and with a sharp blow of a hammer, force the flanged section of the nut into the knurled section of the worm, as shown in Figure

114. The drift should be held on the center line of the worm and perpendicular to the worm, but at a slight angle to the flange of the nut. The operation of seating the flange of the nut into the knurled section of the worm should be performed at a minimum of four locations spaced at approximately 90°. It is the first crimp that establishes the preload. It is advisable to check the 8 to 16 inch ounces preload after the first crimping operation is performed. If the preload has changed and is either too tight or too loose, it may be corrected by striking the No. 1 crimp a glancing blow in the right direction to either tighten or loosen the nut. When the center race torque is correct after the No. 1 crimp, the other 3 crimps may be completed with very little effect on the preload. The adequacy of the crimping should be checked by torquing the nut in either direction to 20 foot-pounds. If the center race torque remains unchanged, the crimping operation is considered satisfactory.

Install the center bearing spacer with the dowel pin in the slot of the center bearing race and the valve lever hole in the center bearing spacer and race aligned.

Install the inner and outer reaction rings (flange down). Install the upper reaction spring with cylinder head ferrule through the small hole and outer reaction ring protruding through the large hole.

ADJUSTING NUT

CENTER THRUST BEARING RACE

CYLINDER HEAD

WORM SHAFT

BEARING RACE 59x141

Fig. 114 —Staking Worm Shaft Bearing Adjusting Nut

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80—TRANSMISSION

Install the new " 0 " ring in the ferrule groove.

Lubricate the small bore of the column jacket support (for cylinder head ferrule).

Install the jacket support assembly over the worm shaft carefully engaging the cylinder head ferrule and " 0 " ring, making sure the reaction rings enter the groove in the jacket support assembly.

Align the parts on power train so the valve lever

CHRYSLER SERVICE MANUAL hole in the center bearing spacer is 90° counterclockwise from the piston rack teeth and lock all parts to the worm shaft by entering a suitable drift through the jacket support and worm shaft groove.

Continue with Operation 18 — Reassembly of the

Steering Gear as described in the Steering Section of the 1958 Chrysler and Imperial Service Manual,

D-16350.

Section XI

TORQUEFLITE TRANSMISSION

The servicing of the 1959 TorqueFlite Transmission is the same as that of the 1958 Models as described in the 1958 Chrysler and Imperial Service Manual, with the following exceptions.

ion spring (N) from retainer (R). With a twisting motion, remove piston (Q) from retainer (R).

Inspection (Fig. 115)

The inspection procedure is the same as for the 1958 model transmissions.

FRONT CLUTCH (8-LEVER) DISASSEMBLY

(REFER TO FIG. 115)

Remove the input shaft fiber thrust washer (A). Remove snap ring (B). Remove input shaft (C) from retainer (R). Invert retainer (R), remove driving discs (D), plates (E), pressure plate (F) and hub

(G).

Install spring compressor, Tool C-3533 and compress spring retainer (I). Using pliers, Tool C-3301, remove spring retainer snap ring (H).

After removing compressor, Tool C-3533, remove spring retainer (I), spring (J), levers (L), lever retainer (K), cushion spring washer (M), and cush-

Assembly (Fig. 115)

Lubricate and install inner (rubber) seal ring (T) on hub of retainer (R). Make sure lip of seal is facing rear of retainer and seal is seated in groove.

Lubricate and install outer seal ring (S) on piston

(Q) with lip of seal towards rear of piston.

Place piston assembly in retainer (R) using a twisting motion to seat piston in bottom of retainer.

Install cushion spring (N) with dished side (concave) facing piston (Q). (Fig. 116).

Place washer (M) with chamfer towards front of

.020"-.040"

INSTALL WASHER

WITH CHAMFER

ON THIS SIDE

Fig. 115 — Front Clutch Assembly

1. Thrust Washer

2. Snap Ring—Large

3. Input Shaft

4. Driving Discs

5. Clutch Plates

6. Pressure Plate

7. Driving Disc Hub

8. Snap Ring-Small

9. Piston Return Spring Retainer

10. Piston Return Spring

11. Piston Lever Retainer

12. Piston Lever (8)

13. Cushion Spring Washer

14. Cushion Spring

15. Oil Seal Ring-Small

16. Oil Seal Ring-Large

17. Piston

18. Piston Retainer

19. Piston Seal Ring-Large

20. Piston Seal Ring—Small

Fig. 116 —Installing Cushion Spring

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80—TRANSMISSION

Install the new " 0 " ring in the ferrule groove.

Lubricate the small bore of the column jacket support (for cylinder head ferrule).

Install the jacket support assembly over the worm shaft carefully engaging the cylinder head ferrule and " 0 " ring, making sure the reaction rings enter the groove in the jacket support assembly.

Align the parts on power train so the valve lever

Continue with Operation 18 — Reassembly of the

Steering Gear as described in the Steering Section of the 1958 Chrysler and Imperial Service Manual,

D-16350.

Section XI

TORQUEFLITE TRANSMISSION

The servicing of the 1959 TorqueFlite Transmission is the same as that of the 1958 Models as described in the 1958 Chrysler and Imperial Service Manual, with the following exceptions.

ion spring (N) from retainer (R). With a twisting motion, remove piston (Q) from retainer (R).

Inspection (Fig. 115)

The inspection procedure is the same as for the 1958 model transmissions.

FRONT CLUTCH (8-LEVER) DISASSEMBLY

(REFER TO FIG. 115)

Remove the input shaft fiber thrust washer (A). Remove snap ring (B). Remove input shaft (C) from retainer (R). Invert retainer (R), remove driving discs (D), plates (E), pressure plate (F) and hub

(G).

Install spring compressor, Tool C-3533 and compress spring retainer (I). Using pliers, Tool C-3301, remove spring retainer snap ring (H).

After removing compressor, Tool C-3533, remove spring retainer (I), spring (J), levers (L), lever retainer (K), cushion spring washer (M), and cush-

Assembly (Fig. 115)

Lubricate and install inner (rubber) seal ring (T) on hub of retainer (R). Make sure lip of seal is facing rear of retainer and seal is seated in groove.

Lubricate and install outer seal ring (S) on piston

(Q) with lip of seal towards rear of piston.

Place piston assembly in retainer (R) using a twisting motion to seat piston in bottom of retainer.

Install cushion spring (N) with dished side (concave) facing piston (Q). (Fig. 116).

Place washer (M) with chamfer towards front of

.020"-.040"

INSTALL WASHER

WITH CHAMFER

ON THIS SIDE

Fig. 115 — Front Clutch Assembly

1. Thrust Washer

2. Snap Ring—Large

3. Input Shaft

4. Driving Discs

5. Clutch Plates

6. Pressure Plate

7. Driving Disc Hub

8. Snap Ring-Small

9. Piston Return Spring Retainer

10. Piston Return Spring

11. Piston Lever Retainer

12. Piston Lever (8)

13. Cushion Spring Washer

14. Cushion Spring

15. Oil Seal Ring-Small

16. Oil Seal Ring-Large

17. Piston

18. Piston Retainer

19. Piston Seal Ring-Large

20. Piston Seal Ring—Small

Fig. 116 —Installing Cushion Spring

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CHRYSLER SERVICE MANUAL TRANSMISSION—81 retainer (R).

Place lever retainer (K) over hub of piston and install levers (L), as shown in Figures 116 and 117.

Install return spring (J) over hub of retainer

(R) and position spring retainer (I) and snap ring

(H) on spring (J). Using compressor, Tool C-3533, compress return spring (J) sufficiently to seat snap ring (H) with pliers, Tool C-3301. Remove compressor tool.

Install pressure plate (F) (smooth side up) in retainer (R). Install discs (D) and plates (E) by first placing one of the discs (D) in retainer (R) followed by a steel plate (E). Repeat this procedure until all discs and plates have been installed.

CHECKING CLUTCH CLEARANCE

Clutch clearance can be measured as described in the

1958 Chrysler and Imperial Service Manual.

NOTE: If Part No. 1732114 or Part No. 1824319 are not available, clearance can be adjusted by using the front clutch cushion spring retaining plate (used in four lever clutch assembly) Part No. 1736393, and following the same procedure as previously outlined for obtaining clearance with the following important exception: Inasmuch as the front clutch cushion spring retaining plate (Part No. 1736393) is thinner and considerable less rigid, care must be exercised when checking clearance with the feeler gauge to prevent springing the plate and hereby obtaining a false reading on pack clearance.

Install hub (G). Install input shaft (C) by placing input shaft and retainer assemblies in an arbor press with the rear of retainer (R) resting on a suitable support. Make certain ball check (at rear of re-

LFVFR RFTA'-NFR

CUSHION

SPRING

CUTCH

RL1AINER

FRONT CtUTCH "FEED*

Fig. 118 — Reaction Shaft tainer) does not contact support during pressing operation.

Press input shaft (C) into retainer until snap ring (B) can be installed. Remove assembly from arbor press (or remove "C" clamps — if used) and place thrust washer (A) over input shaft (C) and against thrust surface on input shaft flange.

REACTION SHAFT (CAST IRON) (FIG. 118)

The reaction shaft, formerly made of aluminum, is now made of cast iron.

Transmissions equipped with the new reaction shaft have the letter "R" (or letters following alphabetically) on the rightside pan rail.

The cast iron reaction shaft can be used in early model transmissions provided the late production input shaft assembly is installed at the same time.

EXTENSION HOUSING (FIG. 119)

The extension housing has been redesigned to accommodate the bronze bushing, which has replaced the ball bearing, and also the smaller oil seal.

SERVICING THE OIL SEAL

The oil seal can be serviced with the transmission

THRUST WASHER

Fig. 117 — Clutch Retainer

58x753

Fig. 119 — Extension Housing

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82—TRANSMISSION

CHRYSLER SERVICE MANUAL installed in the vehicle.

Removal

Disconnect the front universal joint. Apply the hand brake (or use wrench, Tool C-3281) and remove the propeller shaft flange nut and flat washer. Release hand brake (or remove wrench) and install puller,

Tool C-452 (if necessary). Remove the propeller shaft flange and brake drum assembly. Remove the transmission brake support grease shield spring

(small one). Remove brake support grease shield from extension. If screwdriver or sharp instrument is used in performing this operation, care must be exercised not to damage the neoprene sealing surface at bottom of shield. Install puller, Tool C-3690, and remove the oil seal.

Installation

Using driver, Tool C-3691, install seal (metal portion of seal facing in) until driver bottoms on extension. Install brake support grease shield on extension. Indent on grease shield must match groove in extension for correct positioning. Also, shield must be located on extension far enough to permit installation of spring. Install brake support grease shield spring (opening in spring toward adjusting sleeve). Make sure spring is properly seated in groove. Install propeller shaft flange and drum assembly. Install propeller shaft flange, flat washer and nut. Apply hand brake (or use wrench, Tool

C-3281) and torque the propeller shaft flange nut to

175 foot-pounds torque. Connect front universal joint and torque tighten the nuts from 33 to 37 footpounds.

EXTENSION BUSHING

Removal

Drain approximately two quarts of fluid from transmission. Disconnect front universal joint. Apply hand brake (or use wrench, Tool C-3281) and remove propeller shaft flange nut and flat washer. Release hand brake (or remove wrench, C-3281). Using puller, Tool C-452, remove the brake drum and flange assembly.

Remove the brake support grease shield spring and remove grease shield from extension housing.

If screwdriver or sharp instrument is used in performing this operation, care must be exercised not to damage the neoprene sealing surface at bottom of shield. Install puller, Tool C-3690, and remove the oil seal.

Remove brake adjusting screw cover plate and loosen, cable clamp bolt on hand brake support. Disengage the ball end of the cable from operating lever and remove cable from brake support.

Disconnect speedometer cable and housing from extension and remove speedometer drive pinion and sleeve assembly. Proceed to remove extension housing assembly from transmission case as outlined in the Chrysler and Imperial service manual. If care is exercised, it is not necessary to remove hand brake support and shoe assemblies from extension to replace the bushing or seal.

With the large diameter end of the extension housing resting on a smooth, clean surface, proceed to drive the bushing from the housing using driver,

Tool C-3689.

Installation

Place a new bushing on installing Tool C-3692.

NOTE: When positioning bushings and tool on extension housing prior to the driving operation, make definitely sure that lubrication hole in bushing will index properly with lubrication hole in extension housing, when bushing has been driven into position.

Pulling the tool out of the bushing seats the bushing and removes any slight irregularities. The installed bushing should not be removed.

Using driver, Tool C-3691, install oil seal (metal portion of seal facing in) until driver bottoms on extension. Install brake support grease shield. Indent on shield must match groove in extension for correct positioning. Also, shield must be located on extension far enough to permit installation of spring. Install brake support grease shield spring

(opening on spring toward adjusting sleeve).

Install the extension housing assembly as described in the 1958 Chrysler and Imperial Service

Manual.

HAND BRAKE DRUM—FLANGE ASSEMBLY

The hand brake drum and flange assembly now contacts a shoulder (Fig. 119) on the output shaft instead of the race of a ball bearing. The flange assembly has been slightly modified.

This modification now provides for a straight (instead of a bevel as formerly used counterbore within the flange assembly.

OUTPUT SHAFT SUPPORT

To provide lubrication for the new tabbed thrust

MyMopar.com

CHRYSLER SERVICE MANUAL UNIVERSAL JOINTS AND PROPELLER SHAFT—83 washer (Fig. 119) which must be used in conjunction with the new design output shaft and extension housing, a redesigned output shaft support is also required.

The new output shaft support (Fig. 120) has redesigned webs which serve to act as locating guides for the tabs of the thrust washer.

NOTE: When installing the tabbed thrust washer, install with tabs facing output shaft support. The proper positioning of tabs, in relationship to webs, is obtained when minimum clearance exists between tabs of washer and output shaft support webs. This means that it may be necessary to rotate the washer to find the location which provides minimum tab-toweb clearance.

THRUST WASHER

MAINTENANCE, ADJUSTMENTS—TESTS

In investigating any transmission malfunction, first make certain that all external adjustments have been made correctly.

Check fluid level on any transmission complaint.

Erratic performance of the transmission, particularly its shifting performance, can often be traced to incorrect fluid level. Fluid level can be checked with fluid either hot or cold (oil pan is hot to touch), the engine running at normal idle speed, the transmission in neutral, and the hand brake applied. Make sure cap on dipstick is not loose. Cap acts as a stop and if loose, will give a false reading on dipstick.

All five push buttons should be operated slowly, returning to the neutral button each time. The fluid level should be as follows:

(a) Transmission hot; engine idling in neutral.

Fluid should be between the "F" and the "add 1 pint" marks. Fluid should be added or removed to bring the level between these two marks.

(b) Transmission cold (100°F or below) ; engine idling in neutral. Fluid should be between the "add

1 pint" and a point "i/

inch" below the "add 1 pint" mark. Fluid should be added or removed to bring the level between these two positions.

CAUTION: Do not add oil unless the level is below the specified range. Only automatic transmission fluid

Fig. 120 — Output Shaft Support

(type A) should be used. Overfilling leads to foaming, and loss of pressure, resulting in erratic shift performance. The addition of special compounds to transmission fluids for which improved performance, elimination of sludge, or reduction of fluid leakage may be claimed IS NOT RECOMMENDED.

CAUTION

To prevent dirt from entering the transmission, make sure the oil level indicator cap is seated properly on the filler tube.

THROTTLE LINKAGE ADJUSTMENTS

Throttle linkage adjustment remains essentially the same as for 1958 model vehicles, with the following exception:

Placing a pin through an appropriate slot and hole (in lever and bracket) will set the correct angle of the lever for easier adjusting of the entire throttle linkage.

BAND ADJUSTMENTS

The band adjustments are performed in the same manner as described in the 1958 Chrysler and Imperial Service Manual, except the kickdown band adjusting screw is backed off 2% turns, and the low and reverse band adjusting screw is backed off

2% turns.

UNIVERSAL JOINTS AND PROPELLER SHAFT

The universal joints and propeller shaft servicing procedure will remain the same as outlined in the

1958 Chrysler and Imperial Service Manual, D-

16350.

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84—WHEELS AND TIRES CHRYSLER SERVICE MANUAL

Section XII

UNIVERSAL JOINTS

AND PROPELLER SHAFTS

DATA AND SPECIFICATIONS

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

Propeller Shaft

Number used 1 1 *2

Diameter—All Cars

With TorqueFlite Transmission 2.75 in. 2.75 in. 2.75 in.

Diameter with Air Conditioning and TorqueFlite Transmission 2.75 in. 2.75 in. 2.75 in.

Length

Centerline to Centerline of "U

Joints with TorqueFlite Trans 58.96 58.96 63.64

Flange to Flange Length

With TorqueFlite Transmission 60.69 60.69 63.56

Lubrication **Prepack

Universal Joints

Type (Front) Ball and Trunion Cross Type

(Rear) Cross Type (3 Joints)

Bearing

Type Anti-Friction Roller

*Rear propeller shaft tube is rubber insulated.

**Every 20,000 miles.

Section XIII

WHEELS AND TIRES

DATA AND SPECIFICATIONS

MODELS MC-1 MC-2 MO-3 MY-1

WHEELS

Type Steel Disc

Rim Drop Center—Safety Wheel

Size 1 4 x 5 H 1 4 x 6 14 x 6J^ 14x7

Flange Type K K K K

No. of Nuts to Attach Wheel 5 5 5 5

Stud Hole Circle (Diameter) 4 ^ 4 ^ 4 ^ 53^

Stud Size V

x 20 Y

x 20 % x 18

TIRES

Type Super Soft Cushion Tubeless

Cord Material Rayon Rayon Rayon Rayon

Size . . . . 8.00x14 8.50x14 9.00x14 9.50x14

TIRE PRESSURE—Cold

Pounds—Front 24 22 22 22

Rear 22 22 22 20

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84—WHEELS AND TIRES CHRYSLER SERVICE MANUAL

Section XII

UNIVERSAL JOINTS

AND PROPELLER SHAFTS

DATA AND SPECIFICATIONS

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

Propeller Shaft

Number used 1 1 *2

Diameter—All Cars

With TorqueFlite Transmission 2.75 in. 2.75 in. 2.75 in.

Diameter with Air Conditioning and TorqueFlite Transmission 2.75 in. 2.75 in. 2.75 in.

Length

Centerline to Centerline of "U

Joints with TorqueFlite Trans 58.96 58.96 63.64

Flange to Flange Length

With TorqueFlite Transmission 60.69 60.69 63.56

Lubrication **Prepack

Universal Joints

Type (Front) Ball and Trunion Cross Type

(Rear) Cross Type (3 Joints)

Bearing

Type Anti-Friction Roller

*Rear propeller shaft tube is rubber insulated.

**Every 20,000 miles.

Section XIII

WHEELS AND TIRES

DATA AND SPECIFICATIONS

MODELS MC-1 MC-2 MO-3 MY-1

WHEELS

Type Steel Disc

Rim Drop Center—Safety Wheel

Size 1 4 x 5 H 1 4 x 6 14 x 6J^ 14x7

Flange Type K K K K

No. of Nuts to Attach Wheel 5 5 5 5

Stud Hole Circle (Diameter) 4 ^ 4 ^ 4 ^ 53^

Stud Size V

x 20 Y

x 20 % x 18

TIRES

Type Super Soft Cushion Tubeless

Cord Material Rayon Rayon Rayon Rayon

Size . . . . 8.00x14 8.50x14 9.00x14 9.50x14

TIRE PRESSURE—Cold

Pounds—Front 24 22 22 22

Rear 22 22 22 20

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CHRYSLER SERVICE MANUAL BODY AND SHEET METAL—85

WHEELS AND TIRES

OPTIONAL TIRE SIZES: use of the optional large size tires the following in-

To provide the utmost in riding comfort through the flation pressures are recommended:

MODELS MG-1 MC-2 MG-3 MY-1

TIRE SIZE. . .' 9.20 x 14 9.80 x 14 10.40 x 14 11.00 x 14

TIRE PRESSURE

Front

Rear

18 psi

16 psi

17 psi

14 psi

TOWN AND COUNTRY MODELS

MODELS Two Seat

MG-1

Three Seat

MG-1

Two Seat

MG-3

Three Seat

MG-3

WHEELS

Type Steel Disc

Rim Drop Center—Safety Wheel

Size 1 4 x 6 1 4 x 6 ^ 1 4 x 6 ^ 14x63^

Flange Type K K K K

No. of Nuts to Attach Wheels 5 5 5 5

Stud Hole Circle (Dia.) 4 ^ 4 ^ 4 ^ ^A

Stud Size 3^x20 }/

x 20 3^x20 Yv x 20

TIRES

Type Super Soft **Captive Super Soft **Captive

Cushion Air Cushion Air

Tubeless Tubeless

Cord Material Rayon Nylon Rayon Nylon

Size 8.50 x 14 8.50 x 14 9.00 x 14 9.00 x 14

TIRES PRESSURE—Cold

Pounds—Front 24 24 22 22

Rear *24 *24 *22 *24

*28 pounds when carrying heavy load on rear only, on Tubeless Rayon and Captive Air Nylon Tires.

**The captive-air safety tire is used on the three seat Town and Country Models only. They are special equipment on all other cars.

All tire pressures should be adjusted while cold (at els, and Town and Country models.

ambient temperature) before any amount of driving.

The wheels and tires servicing procedure is the same

NOTE: Large size tires are not available on True- as prescribed in the 1958 Chrysler and Imperial

Level Torsion Aire equipped cars, convertible mod- Service Manual, D-16350.

Section XIV

BODY AND SHEET METAL

While the sheet metal is somewhat changed due to Manual, D-16350 with the exception for adjusting styling changes, all servicing remains the same as rear deck lid locks, sealing roof mouldings in the outlined in the 1958 Chrysler and Imperial Service Chrysler Models for 1959 and the new Swivel Seats.

MyMopar.com

84—WHEELS AND TIRES CHRYSLER SERVICE MANUAL

Section XII

UNIVERSAL JOINTS

AND PROPELLER SHAFTS

DATA AND SPECIFICATIONS

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

Propeller Shaft

Number used 1 1 *2

Diameter—All Cars

With TorqueFlite Transmission 2.75 in. 2.75 in. 2.75 in.

Diameter with Air Conditioning and TorqueFlite Transmission 2.75 in. 2.75 in. 2.75 in.

Length

Centerline to Centerline of "U

Joints with TorqueFlite Trans 58.96 58.96 63.64

Flange to Flange Length

With TorqueFlite Transmission 60.69 60.69 63.56

Lubrication **Prepack

Universal Joints

Type (Front) Ball and Trunion Cross Type

(Rear) Cross Type (3 Joints)

Bearing

Type Anti-Friction Roller

*Rear propeller shaft tube is rubber insulated.

**Every 20,000 miles.

Section XIII

WHEELS AND TIRES

DATA AND SPECIFICATIONS

MODELS MC-1 MC-2 MO-3 MY-1

WHEELS

Type Steel Disc

Rim Drop Center—Safety Wheel

Size 1 4 x 5 H 1 4 x 6 14 x 6J^ 14x7

Flange Type K K K K

No. of Nuts to Attach Wheel 5 5 5 5

Stud Hole Circle (Diameter) 4 ^ 4 ^ 4 ^ 53^

Stud Size V

x 20 Y

x 20 % x 18

TIRES

Type Super Soft Cushion Tubeless

Cord Material Rayon Rayon Rayon Rayon

Size . . . . 8.00x14 8.50x14 9.00x14 9.50x14

TIRE PRESSURE—Cold

Pounds—Front 24 22 22 22

Rear 22 22 22 20

MyMopar.com

CHRYSLER SERVICE MANUAL BODY AND SHEET METAL—85

WHEELS AND TIRES

OPTIONAL TIRE SIZES: use of the optional large size tires the following in-

To provide the utmost in riding comfort through the flation pressures are recommended:

MODELS MG-1 MC-2 MG-3 MY-1

TIRE SIZE. . .' 9.20 x 14 9.80 x 14 10.40 x 14 11.00 x 14

TIRE PRESSURE

Front

Rear

18 psi

16 psi

17 psi

14 psi

TOWN AND COUNTRY MODELS

MODELS Two Seat

MG-1

Three Seat

MG-1

Two Seat

MG-3

Three Seat

MG-3

WHEELS

Type Steel Disc

Rim Drop Center—Safety Wheel

Size 1 4 x 6 1 4 x 6 ^ 1 4 x 6 ^ 14x63^

Flange Type K K K K

No. of Nuts to Attach Wheels 5 5 5 5

Stud Hole Circle (Dia.) 4 ^ 4 ^ 4 ^ ^A

Stud Size 3^x20 }/

x 20 3^x20 Yv x 20

TIRES

Type Super Soft **Captive Super Soft **Captive

Cushion Air Cushion Air

Tubeless Tubeless

Cord Material Rayon Nylon Rayon Nylon

Size 8.50 x 14 8.50 x 14 9.00 x 14 9.00 x 14

TIRES PRESSURE—Cold

Pounds—Front 24 24 22 22

Rear *24 *24 *22 *24

*28 pounds when carrying heavy load on rear only, on Tubeless Rayon and Captive Air Nylon Tires.

**The captive-air safety tire is used on the three seat Town and Country Models only. They are special equipment on all other cars.

All tire pressures should be adjusted while cold (at els, and Town and Country models.

ambient temperature) before any amount of driving.

The wheels and tires servicing procedure is the same

NOTE: Large size tires are not available on True- as prescribed in the 1958 Chrysler and Imperial

Level Torsion Aire equipped cars, convertible mod- Service Manual, D-16350.

Section XIV

BODY AND SHEET METAL

MyMopar.com

CHRYSLER SERVICE MANUAL BODY AND SHEET METAL—85

WHEELS AND TIRES

OPTIONAL TIRE SIZES: use of the optional large size tires the following in-

To provide the utmost in riding comfort through the flation pressures are recommended:

MODELS MG-1 MC-2 MG-3 MY-1

TIRE SIZE. . .' 9.20 x 14 9.80 x 14 10.40 x 14 11.00 x 14

TIRE PRESSURE

Front

Rear

18 psi

16 psi

17 psi

14 psi

TOWN AND COUNTRY MODELS

MODELS Two Seat

MG-1

Three Seat

MG-1

Two Seat

MG-3

Three Seat

MG-3

WHEELS

Type Steel Disc

Rim Drop Center—Safety Wheel

Size 1 4 x 6 1 4 x 6 ^ 1 4 x 6 ^ 14x63^

Flange Type K K K K

No. of Nuts to Attach Wheels 5 5 5 5

Stud Hole Circle (Dia.) 4 ^ 4 ^ 4 ^ ^A

Stud Size 3^x20 }/

x 20 3^x20 Yv x 20

TIRES

Type Super Soft **Captive Super Soft **Captive

Cushion Air Cushion Air

Tubeless Tubeless

Cord Material Rayon Nylon Rayon Nylon

Size 8.50 x 14 8.50 x 14 9.00 x 14 9.00 x 14

TIRES PRESSURE—Cold

Pounds—Front 24 24 22 22

Rear *24 *24 *22 *24

*28 pounds when carrying heavy load on rear only, on Tubeless Rayon and Captive Air Nylon Tires.

**The captive-air safety tire is used on the three seat Town and Country Models only. They are special equipment on all other cars.

All tire pressures should be adjusted while cold (at els, and Town and Country models.

ambient temperature) before any amount of driving.

The wheels and tires servicing procedure is the same

NOTE: Large size tires are not available on True- as prescribed in the 1958 Chrysler and Imperial

Level Torsion Aire equipped cars, convertible mod- Service Manual, D-16350.

Section XIV

BODY AND SHEET METAL

MyMopar.com

86—BODY AND SHEET METAL

CHRYSLER SERVICE MANUAL

Adjusting the Deck Lid Striker Plate (Fig. 121)

Loosen the striker plate mounting screws and move the striker plate either left or right until the locking bar is positioned under the latch rotor. Tighten the mounting screws securely.

Adjusting the Deck Lid Latch

With the striker plate correctly positioned, loosen the latch mounting screws and move the latch either upward or downward to obtain a firm locking of the deck lid. Tighten the mounting screws securely.

SEALING ROOF MOULDINGS

Should it ever be necessary to reseal the roof moulding retainers on the 1959 Chrysler Models, they can be sealed by snapping off the roof moulding and sealing around each retainer with a liquid sealer or mastic. Use white mastic for light colored roofs and black mastic for dark colored roofs.

Fig. 121 - Rear Deck Lid Latch and

Striker Plate

ROLLER

CHANNEL

LATCH

ASSEMBLY

PIVOT pJVOT

A s s y

- BEARING

NYLON ROLLERS SEAT BASE

59x86

Fig. 122 —Removing Swivel Seat Assembly

SWIVEL SEAT ASSEMBLY

The swivel seat is offered on some models as optional equipment. The swivel seat assembly operates on a swivel bolt assembly located at the center rear portion of the seat frame. A curved channel located on the front portion, of the seat rides on two nylon rollers to insure a smooth, easy turning of the seat.

OPERATION

The latch for releasing the seat or for holding it in the straight ahead position is located on the side of the seat assembly, next to the door. To release the latch, turn the handle up.

SEAT ASSEMBLY (FIG. 122) a. Removal

Remove the nut securing the swivel seat pivot assembly to the seat base. Release the seat latch assembly and swing seat outward. Raise the pivot out of the seat base and pull the seat straight back to remove the channel from the nylon rollers. Disconnect the anti-rattle spring from the seat frame. Remove the seat assembly.

b. Installation

Position the swivel channel on the nylon rollers and insert the pivot assembly in its mounting hole in the seat base. Install the pivot retaining nut and tighten securely. Connect the anti-rattle spring to the seat frame. Check the operation of the seat for smoothness.

SEAT BACK a. Removal

Remove the pivot seat assembly. Remove the retard-

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CHRYSLER SERVICE MANUAL

BACK

ASSY,

BODY AND SHEET METAL—87

HiNGE

ASSY.

SCREW

!SEAT BASE-

ANTI-RATTLE SPRING"^ 59x87

Fig. 123—Swivel Seat Installed

(SEAT BASE SCREWS

5 9 x 8 8

Fig. 124 — Swivel Seat Arm Rest Assembly er springs from the bottom of the seat assembly.

Remove the two hinge bolts, Figure 123, and lift the seat back assembly straight up to remove.

b. Installation

Insert the seat back support arms in the seat base assembly and insert the hinge bolts. Install the retarder springs. Install the seat back and cushion assembly.

NYLON ROLLERS (FIG. 122) a. Removal

Remove the seat assembly. Slide the rollers off their mountings and check for excessive wear or flat spots.

SEAT BACK RETARDER SPRING REPLACEMENT

Remove the pivot seat assembly and invert seat. Remove the screws, Figure 122, holding the retarder springs in place. The screws are located on the bottom of the seat frame and under the seat back hinges. Remove the retarder springs.

ARM REST HINGE ASSEMBLY (FIG. 124) a. Removal

Remove the alien head pivot screws. Lift the hinge assembly straight up to remove. Remove the nylon bearings from the hinge rod.

b. Installation

Lubricate the surfaces of the nylon roller mountings with Lubriplate. Insert the nylon rollers on their mountings. Install the seat assembly, and check operation of the seat.

PIVOT NYLON BEARING REPLACEMENT (FIG. 122)

When replacing the nylon bearing on the pivot assembly, it is necessary to remove the seat assembly.

b. Installation

Position the nylon bearings on the hinge rod. Place the hinge in position and install the alien screws.

Check the hinge operation.

ARM REST ASSEMBLY (FIG. 124) a. Removal

Swing the swivel seats to the outward position.

From the back portions of the seat frame assembly, remove the four phillips head screws attaching the arm rest to the seat frame assembly.

b. Installation

Position the arm rest assembly on the seat base assembly and install the four phillips head screws.

Turn the swivel seats to the straight ahead position.

ANTI-RATTLE SPRING REPLACEMENT (FIG. 123)

To replace the anti-rattle spring, it is necessary to remove the swivel seat assembly.

c. Worn nylon rollers

SERVICE DIAGNOSIS

SEAT DOES NOT SWIVEL a. Pivot assembly broken.

b. Obstruction in the roller channel.

SEAT SWIVELS HARD a. Broken pivot nylon bearing.

b. Worn nylon rollers.

c. Nylon rollers binding on mountings.

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88—LUBRICATION

CHRYSLER SERVICE MANUAL

Section XV

LUBRICATION

The lubrication procedure for the 1959 Chrysler and

Imperial Models is the same as the 1958 Models except that the engine crankcase capacities are five quarts for refill on all Models. Add an additional quart when the oil filter element is changed. The oil level indicator is located on the left side of the engine.

subjected to these conditions be reduced to 10,000 miles.

It is recommended that the TorqueFlite transmission and torque converter be drained and refilled with Type A MoPar Automatic Transmission Fluid at 10,000 miles if the vehicle usage includes the following types of driving:

MANIFOLD HEAT CONTROL VALVE

Every 1000 miles or 30 days whichever occurs first, apply Mopar Manifold Heat Control Valve Solvent

Part No. 1879318 to shaft and bushings and allow to stand several minutes, working shaft from closed to open position several times until shaft can be turned very easily with fingers.

Police car or Turnpike Patrol car

Frequent towing of trailers

Frequent heavy traffic operation in hot weather

Airport transportation

Continuous operation at higher than normal loading

TorqueFlite Transmission Continuous operation in mountainous areas.

Use Automatic Transmission Fluid, Type "A". To drain, remove the filler tube connector at the oil pan. Pull back on tube to drain. Retighten connector when drained. Remove access plate from bottom of housing and rotate torque converter until drain plug is accessible. Remove the plug and drain the fluid.

Install drain plug and tighten. Install access plate on housing and tighten screws. To refill, apply parking brake. Add 5 quarts of Automatic Transmission

Fluid, Type "A" through transmission oil pan filler tube. Start engine and add approximately 3 more quarts while engine is running. Allow engine to idle for 2 minutes. Operate the TorqueFlite Transmission drive selector push buttons through all speed ranges and push in the Neutral (N) push button.

Add sufficient fluid to bring fluid level to a level between the "add 1 pint" mark and a point "i/

inch" below the "add 1 pint" mark on transmission dipstick.

Certain types of service subject the fluids to more severe operating conditions. Therefore, it is recommended that the change interval for transmissions

CAUTION

To prevent dirt from entering transmission, make sure dipstick is properly seated in filler tube.

Special Low Temperature Recommendation

If difficult starting is encountered when average temperatures consistently range below 10 °F, replace one (1) quart of fluid with refined kerosene. This service should be performed only once during lowtemperature season. Thereafter, necessary replenrishment of TorqueFlite should be Automatic Transmission Fluid Type A.

NOTE: The factory does not recommend the addition of any fluid materials to the transmission other than Automatic Transmission Fluid Type "A".

Type "A" Transmission Oil is specifically designed for use in automatic transmissions and therefore, has sufficient cleaning, lubricating and cooling qualities to render the need for additional special additive compounds unnecessary.

Section XVI

RADIO AND HEATER

RADIO

Three new radios are used on the 1959 Chrysler and

Imperial Models, Model 928 (Fig. 125), 929 (Fig.

126) and 858 (Fig. 127). The servicing procedures are changed as follows:

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88—LUBRICATION

CHRYSLER SERVICE MANUAL

Section XV

LUBRICATION

The lubrication procedure for the 1959 Chrysler and

subjected to these conditions be reduced to 10,000 miles.

MANIFOLD HEAT CONTROL VALVE

Every 1000 miles or 30 days whichever occurs first, apply Mopar Manifold Heat Control Valve Solvent

Part No. 1879318 to shaft and bushings and allow to stand several minutes, working shaft from closed to open position several times until shaft can be turned very easily with fingers.

Police car or Turnpike Patrol car

Frequent towing of trailers

Frequent heavy traffic operation in hot weather

Airport transportation

Continuous operation at higher than normal loading

TorqueFlite Transmission Continuous operation in mountainous areas.

Install drain plug and tighten. Install access plate on housing and tighten screws. To refill, apply parking brake. Add 5 quarts of Automatic Transmission

Add sufficient fluid to bring fluid level to a level between the "add 1 pint" mark and a point "i/

inch" below the "add 1 pint" mark on transmission dipstick.

Certain types of service subject the fluids to more severe operating conditions. Therefore, it is recommended that the change interval for transmissions

CAUTION

To prevent dirt from entering transmission, make sure dipstick is properly seated in filler tube.

Special Low Temperature Recommendation

NOTE: The factory does not recommend the addition of any fluid materials to the transmission other than Automatic Transmission Fluid Type "A".

Section XVI

RADIO AND HEATER

RADIO

Three new radios are used on the 1959 Chrysler and

Imperial Models, Model 928 (Fig. 125), 929 (Fig.

126) and 858 (Fig. 127). The servicing procedures are changed as follows:

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CHRYSLER SERVICE MANUAL

ON-OFF VOLUME

CONTROL

CIVIL DEFENSE SYMBOLS

I240KC 640 KC

4=.

8* 8 II1114 IS

MANUAL TUNING

ON-OFF VOLUME

CONTROL

RADIO AND HEATER—89

CIVIL DEFENSE SYMBOLS

640KC ® I240KC

MANUAL TUNING

TONE

CONTROL

LOCAL SEARCH

TUNIN6

5 STATION

PUSH BUTTONS

DISTANCE SEARCH

TUNIN6

SPEAKER

CONTROL

TONE

CONTROL

5 STATION

PUSH BUTTONS

SPEAKER

CONTROL

Fig. 125-Operating Controls (Model 928)

REMOVAL—Models MC-1, 2 and 3

Remove the vent deflector at heater housing. Disconnect antenna, rear seat speaker plug, "A" lead to the radio terminal of fuse block, and dial lamp lead to the orange wire at harness. Remove the clutch nut, screw and washer from radio support bracket

Figs. 128, 129, 130). Remove the control knobs.

Remove the two nuts that attach radio to panel and remove the radio and mounting bracket from under neath the instrument panel. Remove the speaker from grille. Remove the grille if necessary.

CAUTION

Do not operate the radio with speaker detached, since damage to the transistor will result. If the rear seat speaker is disconnected from the radio, insert a juniper wire in rear seat speaker, socket or the receiver will not operate.

INSTALLATION

Install the speaker and grille if removed. Enter the radio from underneath instrument panel and install the spacers and the two control shaft mounting nuts.

Install bracket support screw, washer and clutch nut. Connect the antenna, rear seat speaker plug,

"A" lead to radio terminal of the fuse block and dial lamp lead wire to the harness connector. Install the radio control knobs. Install the vent deflector at heater housing.

CIVIL DEFENSE SYMBOLS

640 KC@1240 KC

ON-OFF, VOLUME CONTROL M A N U A L TUNING

TONE CONTROL 5 STATION PUSH BUTTONS / SPEAKER CONTROL

LOCAL SEARCH

TUNING

DISTANCE SEARCH

TUNING 57x433

Fig. 126 —Operating Controls (Model 929) fig. 127— Operating Controls (Model 858)

CAUTION

The antenna compensator must be properly adjusted for satisfactory operation of radio.

REMOVAL—Model MY-1

Disconnect the antenna, and the dial lamp lead from the orange lead of harness. Disconnect the two wire lead from speaker. Disconnect the "A" lead from radio terminal at fuse block. Remove the rear seat speaker wire plug. Remove mounting nut from the lower instrument panel to bracket on the radio. Remove the radio control knobs. Remove the radio from underneath instrument panel. Remove the speaker assembly.

INSTALLATION—Model MY-1

Install the speaker grille and speaker. Mount the radio to panel. Install control knobs. Attach the radio mounting bracket and nut to panel.

Connect the "A" lead to accessory terminal on the temperature gauge. Connect the rear seat speaker wire plug. Connect dial lamp lead to orange wire at the harness. Plug in the antenna lead.

INTERFERENCE

Install the suppression equipment for the elimination of interference and tire static.

CAUTION

The antenna compensator must be properly adjusted for satisfactory operation of radio.

ANTENNA COMPENSATOR ADJUSTMENT (FIG. 131)

The antenna compensator is provided for aligning the receiver to the particular antenna on the car.

This adjustment must always be made after the installation of receiver and antenna, or after any repairs to these units. The adjustment should also be

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90—RADIO AND HEATER

CHRYSLER SERVICE MANUAL

SPEAKER GRILL

TERMINALS AND

TERMINAL BOARD

SPEAKER LEAD

BLACK WIRE PLUGS

TO TERMINAL 8

IN FUSE BLOCK

ORANGE WIRE PLUGS

TO ORANGE WIRE

IN HARNESS

SCREW/WASHER

179075

"Ap WASHER 446161 (2 REQ'D)

<Sp NUT/WASHER 271169(2 REQ'D)

Fig. 128-Radio (Model 858)

CONTROL KNOB 1879780

(2 REQ'D)

NUT 1622400

( 2 REQ'D)

TONE AND SPEAKER CONTROL

1879781

(2 REQ'D)

SPACER 6015146 (2 REQ'D)

(ONLY ON MODELS WITH TRIM PLATE)

SPEAKER GRILL

TERMINALS ANO

TERMINAL BOARD

SPEAKER LEAD

CONTROL KNOB 1879780

( 2 REQ'D)

1622400

( 2 REQ'D)

TONE AND SPEAKER CONTROL

1879781

(2 REQ'D)

SPACER 6015146 (2 REQ'D)

(ONLY ON MODELS WITH TRIAA PLATE)

BLACK WIRE PLUGS

TO TERMINAL 8

ON FUSE BLOCK

ORANGE WIRE PLUGS

TO ORANGE WIRE

IN HARNESS

T RADIO SUPPORT 1841824

ggf <h* WASHER 446161 (2 REQ'D)

/ dp NUT/WASHER 271169(2 REQ'O)

SCREW/ WASHER

179075

Fig. 129 -Radio (Model 928)

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CHRYSLER SERVICE MANUAL

•SPEAKER GRILLE

RADIO AND HEATER—91

#8 & RECESS TAPPING OVAL HEAD

168496 SCREW

*NUT & LOCKWASHER

(4 REQ'D.)

TERMINALS & TERMINAL BOARD

ROUND HEAD & RECESS SCREW

(4 REQ'D.)

KNOB -2

A" LEAD-CONNECT TO

RADIO TERMINAL

OF FUSE BLOCK

KNOB -2

MOUNTING

NUT -2

INSTRUMENT PANEL

MOUNTING BRACKET

fa* MOUNTING SCREW

DIAL LIGHT LEAD-CONNECT TO

ORANGE LEAD OF WIRING HARNESS

* N O T SUPPLIED I N KIT PART OF VEHICLE

Fig. 1 3 0 - R a d i o (Model 929) checked whenever the radio reception is unsatisfac- FADER CONTROL PERFORMANCE t o r v

* This control is used only when car is equipped with

(a) Raise the antenna to maximum height.

a rear seat speaker. Full "counter-clockwise" posi-

(b) Turn radio to a station between 1400 and

1600 kc that can barely be heard with the volume turned on full.

(c) Adjust the antenna compensator (located on the rear of receiver chassis) by carefully rotating it back and forth until a position is found that gives peak response and maximum volume. Unless the receiver is properly aligned to the antenna, best performance cannot be obtained. This is particularly true in the case of the touch-tuner where the signal strength materially affects the overall efficiency of the radio receiver.

ANTENNA COMPENSATOR

ADJUST AT 1400 KC

-f-

ANTENNA

SOCKET

©o

FOOT SWITCH

SOCKET

REAR SPEAKER

SOCKET

Fig. 131 —Antenna Compensator Adjustment

(Model 928)

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®.

AU0I0

0.17 VOLTS AT AUDIO GRID

FOR I WATT OUTPUT

ADJUST R3I FOR

.110 AMP MEASURED

BETWEEN Y AND GHD

CD to

N O T E S -

ALL RESISTANCE IN OHMS, 1/2 WATT ±20% TOLERANCE UNLESS OTHERWISE

STATED K-1000, M-MEGOHM.

ALL CAPACITANCE IN MICROMICROFARADS, 100 VOLTS MIN. AND ± 2 0 % TOLERANCE

UNLESS OTHERWISE STATED.

TUNING RANGE FROM 530 KC TO 1605 KC

MEASUREMENTS:

A.VOLTAGE MEASURED AS FOLLOWS.

1.13.2 VOLTS INPUT, NEGATIVE TERMINAL GROUNDED.

2 VOLUME CONTROL MAXIMUM (FULL CLOCKWISE).

3.TONE CONTROL IN NORMAL POSITION (FULL CLOCKWISE).

4 RELAY IN " L " (LISTEN) POSITION AS SHOWN. I

5. NO R.F. SIGNAL INPUT. L_f—s

6.V0LTAGES MARKED WITH ASTERISK ( * ) MEASURED WITH VTVM, ALL "—

OTHER DC VOLTAGES MEASURED WITH A 20,000 OHMS/VOLT METER

B. VOLTAGE SHOWN IN PARENTHESIS ARE MEASURED AS IN "A" ABOVE

EXCEPT THAT RELAY IS IN THE

S"(SEARCH) POSITION.

C.VOLTAGES SHOULD BE WITHIN 1 2 0 % OF VALUES SHOWN.

DSENSITIVIES ARE MEASURED AS FOLLOWS:

LUSING A 40UUF SERIES AND 40UUF SHUNT DUMMY ANTENNA

FOR MEASURING ANTENNA SENSITIVITY. (FOR ALL OTHER

MEASUREMENTS FEED THE SIGNAL GENERATOR OUTPUT

THROUGH A O.I UF CAPACITOR).

2.WITH 400CPS,30% MODULATION OF R.F AND I F SIGNALS.

3 FOR I WATT OUTPUT AT SPEAKER TERMINALS. (CONNECT

OUTPUT METER TO FRONT SPEAKER LEADS).

&CUPON WIRE.

R95BC-S

Model 132-Wiring Diagram (Model 928)

(Schematic)

| MOTOR REVERSE SW|

A 6 ? 2> 6

/—'- 7S6

S8 SHOWN IN

CENTER POSITION

(BOTH FRONT &

REAR SPEAKERS

FULL ON)

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V ANT CAPACITY

40MMF SERIES

40MMF SHUNT

| 2 B L 6

RF AMPL

I-ALL RESISTANCE VALUES ARE IN OHMS

±20%,l/2WATTUNLESS OTHERWISE

INDICATED.

2-ALL CAPACITANCE VALUES OF 1.0 AND 3-"N.C."RELAY CONTACT NORMALLY

ABOVE ARE IN MMF AND VALUES BELOW CLOSED.

1.0 ARE IN MF ±20%,UNLESS OTHER- 4-"N0."RELAY CONTACT NORMALLY OPEN.

WISE INDICATED-

REAR

SEAT

SPEAKER

FOOT

SWITCH^ ANT ^ - , ,—,

SOCKETH P A D D E R V P t A N T SOCKET

OSC PADDER

RFPADD.ER \

13.2V

ARI3 I —

AUDIO

OUTPUT!

ARI3 I

AUDIO

OUTPUT

59 x 9 4

VOLUME CONTROL

Fig. 133-Wiring Diagram (Model 929)

(Schematic)

IF=262.5KC

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AUDIO

S

012 VOLTS AT GRID FOR

I WATT OUTPUT

1/2 I2FM6-I2FK6

V4.X4 5

~ 1-0.57V)

PINK DOT

397N0AAj

MOTES:

ALL RESISTANCE IN OHMS, I/2WATT AND ± 2 0 % TOLERANCE

UNLESS OTHERWISE STATED. K-1,000, M-MEG0HM.

ALL CAPACITANCE IN MICROMICROFARADS, IOOVOLTS MINIMUM

AND ±20% TOLERANCE UNLESS OTHERWISE STATED-

TUNING RANGE FROM 530 KC TO 1605 KC

I F FREQUENCY 262-5 KC.

VOLUME

CONTROL

RI4

2M ,

I M T A P < -

1/2 I2FAA6-I2FK6

CI4

0-OIUF ,

R24,68

90-300 [ —

ADJUST RI8 FOR

0.500 A M P S - T X 2 ? i

COLLECTOR CURRENT ~

VOLTAGE MEASUREMENTS••

1. VOLTAGES IN PARENTHESIS ARE MEASURED WITH VTVM-

2. ALL OTHER DC VOLTAGES MEASURED WITH A 20,000

OHMS/VOLT METER-

J _ CI2

Ta004UF

3-ALL AC VOLTAGES MEASURED WITH 1,000 OHMS/VOLT METER

4. ALL VOLTAGES MEASURED WITH RESPECT TO CHASSIS-

=- J5

13.2 V DC C Z 3

5- ALL VOLTAGES MEASURED WITH +13-2 VOLTS INPUT WITH I.25AMPS

NEGATIVE GROUND.

DUMMY ANTENNA-

TO INSTRUMENT

PANEL LIGHTS

TONE -

CONTROL

RI6

2 M

40UUF SERIES AND 40UUF SHUNT AT ANTENNA SOCKET,

O.I UF SERIES TO CONTROL GRID FOR GAIN MEASUREMENTS

®CUPRON WIRE.

A PRINTED ON PRINTED CIRCUIT BOARD- SQ X 11 1

Fig. 134-Wiring Diagram (Model 858)

(Schematic)

2N235A

TX2.X5

12.3V

FRONT

SPEAKER

REAR 3

SPEAKER

LS2

LSI

MODEL R94BC

MyMopar.com

CHRYSLER SERVICE MANUAL RADIO AND HEATER—95 tion allows operation of front speaker, Pull "clockwise" position allows operation of the rear seat speaker. Rotation between either extreme position will allow both speakers to operate with varying volume as desired, or with equal volume at mid-position.

PUSH BUTTON ADJUSTMENT—Radio Models 928,

929 and 858

Extend the antenna fully and turn radio on for fifteen minutes. Unlock the push buttons by pulling them out. Manually turn in desired station and relock the push button. Repeat the operation on other push buttons.

LOCAL AND DISTANT PUSH BUTTONS

Local push button will tune only the strong signal stations. Distant push button will tune all the stations within range of the radio.

NOTE: Do not set end push buttons.

In order to obtain the best performance from search tuning, the antenna should be fully extended.

FOOT SWITCH SEARCH TUNER

The foot switch search tuner, on Models 928 and 929, is located on the left forward end of the floor panel.

By depressing the foot switch, it will select a station on the radio.

The foot switch activates the touch-tuner mechanism in the same manner as the search-tuning buttons (LOC and DIST) except that the search sensitivity of the touch-tuner buttons was last depressed. Therefore, the foot switch will cause the search-tuner to operate at a sensitivity determined by which of the two search-tuning buttons last depressed.

See Figures 132, 133, 134 for Radio Wiring.

HOT WATER HEATER

An entirely new hot water heating system is used upper outlets. When the lever is to the left, air is on the 1959 Models. Heating, defrosting and ventinot being heated. Air temperature is increased by lating are controlled by five push-buttons and a temmoving the lever toward "WARM" position. Pushing perature control lever (Fig. 135).

"in" on the "Control Lever" will make the blower operate at low speed, and pulling "out" on the lever

Temperature Control Lever—Selects the temperature of the air discharged through the lower and will make the blower operate at full speed, provided the "off" button is not pushed in.

-COWL AIR INTAKE

OUTSIDE-AIR

DOOR

DEFROSTER OUTLETS

ON INSTRUMENT PAN

UPPER SURFACE

WATER TEMPERATURE

CONTROL VALVE

DEFROSTER DOOR

PUSH-BUTTON

CONSOLE ON

INSTRUMENT PANEL

TYPICAL

VACUUM SERVO

SHUT-OFF DOOR

HEAT OUTLETS UNDERNEATH

INSTRUMENT PANEL

Fig. 135—Push-Button Operated Heater

(Schematic)

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96—RADIO AND HEATER CHRYSLER SERVICE MANUAL

OFF Button—When the "OFF" button is pushed in, the system will not operate. The "OFF" button cuts off the current from the control lever switch and blower, motor. The ventilation doors are closed, preventing outside air from entering car.

VENT Button—Opens the ventilation door to allow outside air to enter the car directly. It does not operate the blower.

DEF Button—Causes a major portion of the air to be forced onto the windshield through air outlets on top of instrument panel for defrosting or defogging.

HEAT Button—Causes major portion of air to be directed toward the car floor.

Heating the Car

Until the engine warms up, make sure the "OFF" button is pushed in and the temperature control lever is in the "WARM" position. Then, push in the

"HEAT" button and leave the temperature control lever in the "WARM" position for fast initial car warm-up. After warm-up, use the control lever knob to adjust the speed as desired, and adjust the position of the temperature control lever to maintain comfortable condition.

NOTE: When the "HEAT" button is pushed in, sufficient warm air will be forced onto windshield through the upper air outlets for adequate defogging during average driving conditions.

Defrosting or defogging the Windshield

Push in the " D E F " button for maximum defrosting, move the temperature control lever to the

"WARM" position.

Summer Ventilation

Push in the "VENT" button to open the ventilation door. Move the temperature control lever to the extreme left. The ventilation door may be left open during rain.

Rear Window Defroster (when so equipped)

A toggle switch (at left and under the instrument panel) operates a blower which circulates air over the rear window to prevent fogging.

HEATER BLOWER—REMOVAL AND INSTALLATION

Removal

Disconnect the battery ground cable. Disconnect the heater ground wire at windshield wiper motor mounting bracket and disconnect the heater wires from harness connectors.

Disconnect the vacuum hoses at each vacuum unit and remove hoses from their attaching clips. Remove heater valve capillary coil from the opening in heater housing (driver's compartment, passenger side). Remove the clip from housing.

Remove the three screws attaching the heater chamber to dash panel, (one is located to the left of vent door and to the right of brake pedal bracket; one below the heater at passenger side and one screw is located at the windshield wiper motor right link pivot).

NOTE: To facilitate removal, disconnect the windshield wiper right link at pivot to expose the housing screw.

Remove the housing and blower by pulling down and out of driver's compartment. Remove the blower, mounting plate and motor.

Installation

NOTE: If the blower motor was removed from the mounting plate; be sure the mounting grommets are installed at the attaching bolts.

Install the blower motor and mounting plate to the heater housing. Be sure the blower wheel is free and does not rub. Position the housing on dash panel and install the three attaching screws.

CAUTION

There is a spacer at each attaching screw, be sure these spacers are installed between the heater housing and the dash panel when installing housing; otherwise, the housing could be damaged when tightening the screws.

Reposition the heater water valve capillary coil in the heater housing and install attaching clips. Connect the vacuum hoses at vacuum unit and install the attaching clips. Connect the heater wire at harness connectors and install the ground wire at windshield wiper motor bracket.

Attach the windshield wiper motor pivot link (if disconnected). Connect the battery ground cable.

HEATER VACUUM UNITS REPLACEMENT

To replace a vacuum unit, disconnect the vacuum hoses. Remove the two nuts and lockwashers attach-

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CHRYSLER SERVICE MANUAL HEATER—AIR CONDITIONING—97 ing the vacuum unit to housing, and the one clip attaching the vacuum unit rod to the actuated unit.

VENT DEFLECTOR—REPLACEMENT

The vent deflector is held to the heater housing by three screws. This deflector should be removed whenever the radio is to be removed.

HEATER CORE—REMOVAL AND INSTALLATION

Removal

Disconnect the battery ground strap. Drain the cooling system as necessary. Disconnect the heater hoses at heater. Remove the screws attaching the heater core housing to the dash panel and remove the housing and core as an assembly.

Remove the gasket to expose rivets (if used). Remove the heater core from outer housing.

NOTE: The core is held in position in the outer housing with plastic rivets. Care should be used when pressing out these rivets to avoid damaging the housing or the rivets.

Installation

Place the heater core in the heater outer housing and install plastic rivets. Install the gasket. Position the heater housing and core assembly on the dash panel.

Install all screws before tightening to insure proper alignment.

Connect the heater hoses at heater. Refill the cooling system as necessary.

INSTANT HEAT CONDITIONAIRE

MODEL 805 HEATER

While the Instant Heat Conditionaire Model 805

Heater is different in construction and appearance, the operation of the heater controls is the same as that of the hot water heater. The servicing of the

1959 Instant Heat Conditionaire Model 805 is the same as that described in the 1958 Chrysler and Imperial Service Manual except for the following operation.

THERMOSTAT

If the thermostat fails to control the duct outlet temperature, it is usually an indication that the cam is loose on the helix shaft, or the end of the helix has dropped out of the slot in the control shaft. To correct this condition, adjust the thermostat as follows:

Remove the thermostat cover at blower housing.

Disconnect the control cable and the two lead wires.

Remove the two sheet metal screws and remove the thermostat. Inspect the helix to make sure it is crimped tightly in the end of the control shaft. Fit the helix in the slot and crimp the shaft with pliers if necessary. With the helix at room temperature, loosen the Allen set screw in the plastic cam on the base end of the control shaft, making sure the shaft is completely free to revolve and take its normal position at room temperature (about 75° to 85°F.)

With the plastic cam free on the shaft and the micro-switch down, move the control cable linkage as far as it will go to the left and hold in this position. While holding the linkage, turn the plastic cam in a counter-clockwise direction until the microswitch just clicks, then tighten the set screw in the cam.

Section XVII

HEATER - AIR CONDITIONING

The Heater-Air Conditioning Unit (Fig. 136) on the 1959 Chrysler and Imperial Models is a dual purpose unit combining the functions of both heating and cooling the air for winter and summer air conditioning.

The new unit is controlled by vacuum actuators which are controlled by push buttons (Fig. 137). The heating and cooling cycle is similar to the 1958 Models. A water valve and capillary tube (Fig. 138) is used to control water temperature regulated by a sliding temperature control lever designed integral with the push button assembly to increase or decrease temperature.

During the operation of the new unit on the cooling cycle, 75 per cent of the air drawn in through the fresh air door, (Fig. 139), is passed around the heater core. The remaining 25 percent passes through the heater core, and is used for temperature control of the unit.

OPERATING CONTROLS

The blower switch (Figs. 140 and 141) is an integral

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CHRYSLER SERVICE MANUAL HEATER—AIR CONDITIONING—97 ing the vacuum unit to housing, and the one clip attaching the vacuum unit rod to the actuated unit.

VENT DEFLECTOR—REPLACEMENT

The vent deflector is held to the heater housing by three screws. This deflector should be removed whenever the radio is to be removed.

HEATER CORE—REMOVAL AND INSTALLATION

Removal

Remove the gasket to expose rivets (if used). Remove the heater core from outer housing.

NOTE: The core is held in position in the outer housing with plastic rivets. Care should be used when pressing out these rivets to avoid damaging the housing or the rivets.

Installation

Place the heater core in the heater outer housing and install plastic rivets. Install the gasket. Position the heater housing and core assembly on the dash panel.

Install all screws before tightening to insure proper alignment.

Connect the heater hoses at heater. Refill the cooling system as necessary.

INSTANT HEAT CONDITIONAIRE

MODEL 805 HEATER

While the Instant Heat Conditionaire Model 805

Heater is different in construction and appearance, the operation of the heater controls is the same as that of the hot water heater. The servicing of the

1959 Instant Heat Conditionaire Model 805 is the same as that described in the 1958 Chrysler and Imperial Service Manual except for the following operation.

THERMOSTAT

Remove the thermostat cover at blower housing.

Disconnect the control cable and the two lead wires.

Section XVII

HEATER - AIR CONDITIONING

OPERATING CONTROLS

The blower switch (Figs. 140 and 141) is an integral

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98—HEATER—AIR CONDITIONING

CHRYSLER SERVICE MANUAL

COMPRESSOR ASSEMBLY

VACUUM ACTUATOR

BY-PASS DOOR LINKAGE

•MM.

EVAPORATOR HOUSING -"*

COWL VENT INTAKE

HOUSING ATTACHING

SCREWS i V A C U U M

i HOSE

WINDSHIELD

WIPER

HOSE

COMPRESSOR MUFFLER

P • — I

COMPRESSOR BRACKET ATTACHING BOLTS

BRAKE MASTER CYLINDER ASSY.'J.

59x183

Fig. 1 3 6 - Air Conditioning Unit Installed part of the temperature control lever. The temperature control lever is pushed in for low speed and pulled out for high speed.

The blower will be off only when the "OFF" button is depressed.

Either half of the lower distribution doors, (Fig.

142) can be operated manually to override the automatic setting of the actuator.

The main damper door is operated by a vacuum actuator. Air is directed to the upper or lower air outlets depending on whether the cooling or heating push button is depressed. In addition, the percentage of air up or down may be selected as desired by rotating the manual main damper door control knob,

(Fig. 139).

On cars equipped with thumb screw main door control, the percentage of air flowing to the lower or upper outlets can be selected by changing the thumb screw location on the main-door adjusting lever (Fig. 142).

NOTE: Locating the thumb screw in number one hole will allow 10 per cent of the air to be deflected to the lower distribution door deflectors. Rotating the adjusting lever counter-clockwise will increase the percentage of air flowing through the distribution door deflectors.

"OFF" Button Depressed

"The fresh-air door will be closed.

The compressor clutch is disengaged.

The blower motor and Heater-Air Conditioner are made inoperative.

NOTE: To close the fresh-air door, the "OFF" button is depressed and it is recommended that the engine be allowed to operate for approximately ten seconds before shutting off the ignition switch to permit the actuators to complete the cycle.

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CHRYSLER SERVICE MANUAL

HEATER—AIR CONDITIONING—99

Fig. 137 — Air Conditioning Push Button Controls

Fig. 138 — Water Valve and Capillary Tube

"MAX" Button Depressed

The compressor clutch will be energized.

The blower is operating.

The fresh-air damper door is closed.

The recirculating door opens.

The main door is positioned to the preset manual control cable stop.*

The distribution door is positioned to direct the air upward in the passenger compartment.

"FRESH" Button Depressed

The temperature control lever can be adjusted to the desired temperature.

The compressor clutch will be energized.

The blower is operating.

The fresh-air damper door is open.

The recirculating door is closed.

The main door is positioned to the preset manual control cable stop.*

The distribution door is positioned to direct the air upward in the passenger compartment.

"HEAT" Button Depressed

The temperature control lever can be adjusted to the desired temperature.

The fresh air door opens and the by-pass door closes allowing outside fresh air to pass through the evaporator coils and heater core.

The main door is positioned according to the preset manual control cable stop.*

The blower is operating.

The lower distribution doors are positioned so as to direct all of the air downward.

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100—HEATER—AIR CONDITIONING

COWL AIR INTAKE

FRESH-AiR

DOOR

RECiRCULATiNG

DOOR ~~-

ADJUSTABLE AIR OUTLETS ON

INSTRUMENT PANEL UPPER SURFACE

RAISED -COLLAPSED

POSITION POSITION

CHRYSLER SERVICE MANUAL

WATER TEMPERATURE

CONTROL VALVE

HEATER BY™PASS DOOR

J BLOWER

AIR DISTRIBUTION

CONTROL KNOB

VACUUIVI

ACTUATOR

PUSH-BUTTON

CONTROL

(TYPICAL)

59x156

Fig. 139 — Heater Air Conditioning Air Circulation

"DEF" Button Depressed

The fresh-air door opens.

The by-pass door is closed.

The air passes through the heater core.

The main door will direct air to the upper defroster outlets according to the preset manual control cable stop.*

On cars not equipped with manual main door control, 90 per cent of the air is directed through the upper control outlets and 10 per cent through the lower outlets. The opposite condition exists during the heating cycle.

On cars with the thumb screw main door control

(Fig. 142) selects a percentage of air between the upper defroster outlets and the lower distribution door, by locating the thumb screw in one of the four holes of the defroster door adjusting lever.

DEHUMIDIFYING THE PASSENGER COMPARTMENT

"FRESH" Button depressed:

The temperature control lever is set to the temperature desired.

NOTE: The heater by-pass door is designed to allow approximately 25 per cent of the incoming air to pass through the heater core in the "Maximum Cooling" and "Fresh Cooling" position of the push buttons.

Outside air dehumidifies as it passes over the evaporator coil. Cool air from the evaporator coils passes through the heater core, which raises the temperature to the desired comfort condition by decreasing the dampness of the air inside the vehicle.

REMOVAL, INSTALLATION AND SERVICING

The procedures for servicing of the unit including discharging, charging, removal and installation of the engine side housing, evaporator coils, expansion valve, refrigerant strainer drier, condenser and other components remain the same as outlined in the

1958 Chrysler and Imperial Service Manual. How-

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CHRYSLER SERVICE MANUAL

HEATER—AIR CONDITIONING—101

BEZEL ATTACHING NUTS,

VACUUM SWITCH ATTACHING SCREWS

FEED TERMINALS

CLIP ATTACHING

SCREW

CABLE CLIP

TEMPERATURE

CONTROL CABLE

4 COILS SHOWING

CONTROL CABLE WIRE

BLOWER SWITCH ASSEMBLY PUSH BUTTON EXTENSIONS

RECIRCULATING DOOR MAIN DOOR

CLOSED - WHITE STRIPE DOWN - WHITE STRIPE

MAIN DOOR U P - R E D STRIPE

COMPRESSOR CLUTCH 18 BLUE

RECIRCULATING DOOR

O P E N - R E D STRIPE

BLOWER (LOW SPEED) 16 BROWN

CONTROL ARM SWITCH

(HIGH SPEED) 16 TAN

FEED

BY-PASS AND DISTRIBUTING

CLOSED - RED

PUSH BUTTON CONTROL ASSEMBLY

TEMPERATURE

CONTROL CABLE CLIP

BY-PASS AND

DISTRIBUTING DOOR

O P E N - W H I T E STRIPE

VACUUM SOURCE BLACK

PUSH BUTTON EXTENSION

CONTROL LEVER

BLOWER SWITCH AND WIRE ASSEMBLY

BRACKET ATTACHING SCREW

59x169

Fig. 140— Blower Switch and Push Button Assembly

(Windsor) (Schematic) ever, caution must be emphasized when making a compressor capacity test not to exceed a total of five minutes of continuous compressor operation tests to avoid damage to the compressor from overheating.

WARNING

When replacing compressor assembly, the crankshaft should be rotated at least two complete revolutions, to clear oil accumulation from compressor head before the clutch is energized to avoid damaging the compressor reed valves.

Whenever it is necessary to add refrigerant 12 to the system, the refrigerant should be added while operating at a head pressure of 225 to 250 psi until the sight glass in the dry-eye unit is completely clear of bubbles, then add an additional 1/2 pound

(EXACTLY) of refrigerant 12 to complete the charging operation.

WARNING

Compressor head pressures should not exceed 225 to 250 psi when charging the unit.

NOTE: Individual refrigerant 12 containers have been developed and are available for servicing the air-conditioning unit and can be interconnected or used individually, as shown in Figure 143.

In the new Air Conditioning Unit it will not be necessary to remove the engine side housing except to seal or replace the evaporator coil assembly. The heater core can be removed from the engine side housing by removing the heater core housing attaching bolts and remove the assembly, as shown in

Figure 144.

NOTE: The core is assembled and held in the housing by two plastic rivets which must be removed before the core can be removed from housing.

Refer to the Heater Section for removal and installation of the heater assembly.

NOTE: When replacing the evaporator coil, extreme care must be taken to see that the fresh air door

(Fig. 145) is completely closed before any attempt is made to remove or install the unit. Damage to the door seal and the distortion of vent and recirculating doors may result if this precaution is not taken.

Servicing of the centrifugal fan assembly can be accomplished by the removal of the distribution duct assembly as shown in Figure 146.

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102—HEATER—AIR CONDITIONING CHRYSLER SERVICE MANUAL

BY-PASS A N D DISTRIBUTING DOOR

C L O S E D - R E D STRIPE

O P E N - W H I T E STRIPE

RECIRCULATING DOOR

C L O S E D - W H I T E STRIPE

OPEN - RED STRIPE

V A C U U M SWITCH ASSEMBLY

LIGHT CONDUCTOR ASSEMBLY

PANEL ATTACHING SCREW

M A I N DOOR

D O W N - W H I T E STRIPE

U P - R E D STRIPE

PUSH BUTTON

EXTENSIONS

PUSH BUTTONS

SWITCH

ATTACHING

SCREWS

V A C U U M

SOURCE

BLACK

COMPR

CLUTCH

18 BLUE

TEMPERATURE CONTROL LEVER

BLOWER SWITCH A N D WIRE ASSEMBLY

CLAMP ATTACHING SCREW

TEMPERATURE CONTROL CABLE

CONTROL TO DASH PANEL ATTACHING SCREWS

ONTROL ARM SWITCH BLOWER (HIGH SPEED) 16 T A N

LOW BLOWER (LOW SPEED) 16 BROWN

CONTROL ASSEMBLY

Fig. 141 —Vacuum Actuator and Push Button Assembly (Imperial) (Schematic)

REMOVAL AND INSTALLATION OF

PUSH BUTTON CONTROL ASSEMBLY

Remove the vacuum line plug, clutch and blower motor leads from the control assembly. Disconnect the water valve control cable. Remove the push button assembly attaching screws from the push button bracket and remove the assembly.

NOTE: Whenever the push-button control unit is replaced, care must be taken to align the assembly properly within the instrument panel opening so

ADJUSTING VACUUM ACTUATED DOORS

Recirculating Door (Fig. 147)

5 9 x 1 7 0 that buttons will operate without binding. The vacuum hoses must be aligned and protected, so they will not be pinched or damaged by clips or other movable attachments.

^ O U T L E T HOSE-UPPER

DOOR CONTROL LEVER

VACUUM

: ACTUATOR

PISTON RODS

DISTRIBUTOR DOOR DEFLECTORS

Fig. 142 — Locating Main Door Adjusting Screw

(Imperial) Fig. 143 —Servicing the Air Conditioning System

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CHRYSLER SERVICE MANUAL HEATER—AIR CONDITIONING—103

BiOWiR MOTOR MOUNTING BRACKET

DISTRIBUTION DUCT

BLOWER MOTOR WHEEL

AIR DEFLECTING

VACUUM ACTUATOR

BLOWER

MOTOR

BLOWER MOTOR

MOUNTING PLATE 59x47

Fig. 144 — Removing or Installing Heater Core

Housing Assembly

NOTE: These recirculating and fresh air doors are interconnected for unified operation and should be adjusted accordingly.

(a) Cycle the opening and closing of doors several times to make sure that the door hinges are not sticking and that the doors are operating freely without binding.

(b) Remove the operating rod to recirculating door bracket clip.

(c) Remove the rod from the bracket. Check the actuator rod for full travel against the full travel of the recirculating door bracket.

(d) Close the recirculating door by hand and make sure the (overcenter) toggle force of the links exert enough pressure on the door to completely close and seal the door. If the door is not sealing, loosen the "L" bracket adjusting screws. Adjust and tight-

Fig. 146 — Removing or Installing Blower Motor Assembly en the screws. Recheck the rod to linkage travel and install the rod and clip. Recheck the door seal.

Fresh Air Door

(e) Cycle the opening and closing of the doors several times to make sure the hinges are not sticking and that doors are operating freely without binding.

(f) Check the recirculating door for proper sealing and adjust if necessary as outlined in a, b and c.

TURNBUCKLE UNK-UPPER

FRESH AIR DOOR

DOOR

HINGE PIN

DOOR HINGE

[RETURN SPRING

;RECIRCUIATING DOORI

TURNBUCKLE LINK-LOWER'.

•TURNBUOaE LOCK NUT ' ' ' *V'': ' ' "

: RECIRCULATING

DOOR LINKAGE

BY-PASS DOOR

ACTUATOR LINKAGE

Fig. 145 — Removing or Installing Evaporator Assembly

VACUUM ACTUATOR

ASSEMBLY

Fig. 147 — Adjusting Fresh Air and Recirculating Door

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104—HEATER—AIR CONDITIONING

BY-PASS DOOR

OVER CENTER

LEVER

59*162;

Fig. 148 — Adjusting By-Pass Door

(g) With the engine operating and with a beam of light projecting through the cowl opening, look up through the recirculating door opening carefully to see if light is showing through the seal around the door.

NOTE: The rear edge of fresh air door will not seal

completely without vacuum source.

CHRYSLER SERVICE MANUAL

(h) If adjustment is to be made, remove the cowl vent intake screen and adjust the fresh air door link turnbuckle through the intake screen opening, so that the door will completely close with engine operating.

Adjusting Heater By-Pass Door

Refer to Figure 148 and proceed as follows:

Remove the vacuum actuator piston rod clip and rod from by-pass actuator lever assembly. Operate the engine. Remove vacuum lines from the actuator.

Check the vacuum source and for proper actuator operation. Check the by-pass door for full travel by moving the levers to open and closed position without vacuum.

Install the actuator rod and clip assembly to the by-pass door. Adjust the door and tighten screw in closed position, as shown in Figure 148.

Adjusting Main Door on Cars Equipped with

Manual Control

Refer to Figure 142 and proceed as follows:

BLACK-WHITE STRIPE

BLACK - RED STRIPE BLACK-WHITE STRIPE

BLACK

59x175

BLACK-WHITE STRIPE

BLACK-RED STRIPE

Fig. 149 — Vacuum Hose Alignment (Passenger Compartment)

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CHRYSLER SERVICE MANUAL

BLACK-RED STRIPE

HEATER—AIR CONDITIONING—105

BIACK-TO BE CONNECTED

TO ENGINE VACUUM SOURCE

59x176

Fig. 150 — Vacuum Hose Alignment (Engine Compartment)

Remove the control cable, actuator rod clip (and thumb screw if so equipped) from the main door control lever assembly.

Remove the vacuum actuator and distributor door rods from the lever control assembly. Check for proper operation of the main door by cycling lever to full open and closed positions.

Rotate the control knob to the closed position. Adjust control cable to full travel of defroster door in the closed position. Reinstall the actuator rods.

Tighten lever screw, and check for proper operation.

Adjusting Distribution Door

Fig. 151 — Roof Air Conditioning Unit Installed.

Fig. 1 5 2 - A i r Conditioning Unit Air Flow (Roof Unit)

NOTE: The distribution door will automatically adjust itself by the travel of vacuum actuators to distribute the air flow to passenger compartment as desired.

Deflector Removal

Remove the vacuum actuator rod clip and rod from control lever. Remove the deflector shaft lock screw.

Remove shaft from lower distribution duct housing.

Remove the deflectors.

Deflector Installation

Install the deflectors, shaft, lock and screw. Install

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106—HEATER—AIR CONDITIONING

LIQUID LINE CUP OUTLET GRILLE

\ HINGE BRACKET ATTACHING BOLTS

\ LIQUID

CHRYSLER SERVICE MANUAL

BLOWER M O T O R S — -

U Q U I D H

QSE

^ E V A P O R A T O R COIL .'.-•'

EXPANSION VALVE

--"/,- •££ .;K ^ 59x48;

Fig. 153 — Removing or Installing Pillar Cover actuator rod and clip. Check the assembly for individual deflector operation. Adjust the deflector control lever for full travel of vacuum actuators.

DISTRIBUTION DUCT

Removal

Remove the deflector outlet tubes. Remove manual control cable to duct attaching clip. Remove the cable wire from main door control bracket. Disconnect the vacuum hoses from actuators.

Disconnect the blower motor ground and feed wires. Remove the duct to dash attaching bolts and remove the duct.

EVAPORATOR UNIT

''"'\ OUTLET GRILLE

H ! N G £

BRACKET

\ HINGE BRACKET PIN

BLOWER MOTOR WIRES

EVAPORATOR DRAIN

HOSE

Fig. 154 — Removing or Installing Air Conditioning

(Roof Unit)

Fig. 155 — Rear Deck Compartment Unit Installed

Installation

Install the distribution duct assembly. Make sure the assembly is located properly up against the dash panel and that the tubes, cables, and electrical wires will not be pinched between the duct and dash panel, before completely tightening the assembly. Install the attaching bolts, ground wires and clips (Figs.

149 and 150).

TOWN AND COUNTRY ROOF MOUNTED

AIR CONDITIONING UNIT (FIG. 151)

A new roof mounted evaporator has been developed and is available for Town and Country Models. This unit employs centrifugal cage type blowers to draw air through the evaporator (Fig. 152) for distribution through adjustable discharge grilles. A switch located on the instrument panel controls the two speed blower motor.

Removal (Refer to Fig. 153)

Discharge the refrigerant in the system (preferable in open area). Remove the pillar cover garnish mouldings. Remove liquid lines and clips. Remove the drain hoses. Disconnect the blower motor wires.

Remove the hinge pins and remove assembly.

Installation (Fig. 154)

Mount the roof unit to one side of the hinge bracket, and install hinge pin. Raise the assembly up to the contour of roof panel and install the other hinge pin.

Install the refrigerant lines, drain hoses, and connect the blower motor wires. Recharge the unit.

Check the entire system for leaks.

REAR COMPARTMENT AIR CONDITIONING

UNIT (FIG. 155)

A combination rear air conditioning unit is avail-

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CHRYSLER SERVICE MANUAL

HEATER—AIR CONDITIONINGS 107

COMPRESSOR CLUTCH

18 LIGHT BLUE

BLOWER MOTOR

16 DARK GREEN

18 LIGHT BLUE

HEATER AND AIR

CONDITIONING FEED

18 AMP FUSE

(SLOW BLOW)

DASH

59x166

D A

SH GROMMET

Fig. 156— Heater Air-Conditioning Wiring Diagram (Dash Unit)

FUSE BLOCK 20 AMP FUSE

ACC.

BATTERY

4-NilHi

+ AMM.

IGNITION SWITCH

-14 BLACK

RIGHT BLOWER MOTOR

14 BROWN •

14 DARK GREEN-

GROUND AT LEFT ROOF RAIL

•+-•—14 BLACK-

14 DARK GREEN

14 BROWN

REAR BLOWER

MOTOR SWITCH

u D A R K G R E E N

_ ^ .

14 BROWN-

59x186

LEFT BLOWER MOTOR

LOW

FUSE BLOCK

18 AMP FUSE

(SLOW BLOW)

14 BLACK

•14 BROWN-

-14 DARK GREEN-

Fig. 157 — Heater Air-Conditioning Wiring Diagram

(Roof Unit)

HIGH

REAR BLOWER

MOTOR SWITCH

CONNECTOR

REAR BLOWER o

M O T O R able for all models except the Town and Country.

This unit operates in conjunction with the front unit. In addition, the rear unit air conditioning is available with a heater only at the front.

The rear air conditioning unit operates exclusively on the recirculation principle. The rear unit utilizes the same compressor and condenser as is used by the front unit.

Refer to figures 156, 157, and 158 for wiring diagrams applicable to the dash, roof, and rear deck mounted unit installation.

59x188

REAR BLOWER MOTOR

Fig. 158 — Heater Air Conditioning Wiring Diagram o

(Rear Deck Unit)

The rear unit is mounted in the luggage compartment on the stepped up area above the rear axle, with the liquid lines located along the left side of car.

Figure 159 shows the newly developed tools required to service the 1959 Air Conditioning Unit.

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108—HEATER—AIR CONDITIONING

CHRYSLER SERVICE MANUAL

C o

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Hello! I'm familiar with this 1959 Chrysler and Imperial Service Manual Supplement. I can answer your questions about the new front suspension adjustments, the True-Level Torsion Aire system, and the Total Contact brake system.

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Key features

Front suspension caster and camber adjustment simplification
True-Level Torsion Aire suspension system (optional)
Total Contact (Floating Shoe) service brakes

Frequently asked questions

Refer to the corresponding models covered in the 1958 Chrysler and Imperial Service Manual D-16350.

Understand the corresponding or superseding car models in the supplement. For example, the 1959 Windsor model LC-1 supersedes the 1958 Windsor Model.

CONTENTS

SERVICING THE 1959 CHRYSLER AND IMPERIAL

CHRYSLER DIVISION

2—GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS—3

GENERAL DATA AND SPECIFICATIONS

4—SUSPENSION CHRYSLER SERVICE MANUAL

DATA AND SPECIFICATIONS

FRONT HEIGHT SPECIFICATIONS

.iy

"+or

CASTER AND CAMBER WITH MANUAL STEERING

~H° ± H°

y% ± w

WITH POWER STEERING

± W

REAR SUSPENSION

REAR SUSPENSION (Cont'd)

TRUE-LEVEL TORSION AIRE

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (Cont'd)

TOOL LIST

SUSPENSION (FRONT SUSPENSION)

SUSPENSION—7

REAR SUSPENSION

TRUE-LEVEL TORSION AIRE

SUSPENSION—9

10—SUSPENSION

SERVICE PROCEDURES

12—SUSPENSION

14—SUSPENSION

SUSPENSION—15

TRUE-LEVEL TORSION AIR

SERVICE DIAGNOSIS

REAR AXLE

REAR AXLE

BRAKES

DATA AND SPECIFICATIONS

HAND BRAKE

18—BRAKES

ARBOR f-<

(TOOL) ^

GAUGE

BLOCK

(TOOL)

57x17

22—BRAKES

SERVICE DIAGNOSIS

Section IV

ACCESSORY BELT DRIVES

SERVICE DIAGNOSIS

Section IV

ACCESSORY BELT DRIVES

BELT TENSION SPECIFICATIONS

TORQUE METHOD

BELT DEFLECTION METHOD

Vs

Vs

SERVICE DIAGNOSIS

26—COOLING SYSTEM

COOLING SYSTEM

DATA AND SPECIFICATIONS

BATTERY

STARTER

COOLING SYSTEM

DATA AND SPECIFICATIONS

BATTERY

STARTER

28—ELECTRICAL SYSTEM

STARTER (Cont'd)

LIGHT BULBS

CIRCUIT PROTECTORS

GENERATORS

REGULATOR

DISTRIBUTOR

SPARK PLUGS AND COIL

32—ELECTRICAL SYSTEM CHRYSLER SERVICE MANUAL

SPARK PLUGS AND COIL (Cont'd)

HORNS

ELECTRIC WINDSHIELD WIPER