Jeep CJ '49'86 (Haynes Repair Manual)

JeepCJ Automotive Repair Manual by Larry Warren

and John H Haynes

Member of the Guild of Motoring Writers

Models covered CJ-2A, CJ-3A, CJ-38, CJ-S, CJ-SA, CJ-6, CJ-7 Scrambler, Renegade , Laredo and Golden Eagle Automatic and manual transmissions

ISBN 1 56392 221 5

©

Haynes North America, Inc. 1996 Willi I*T'I'IIIOI'IIrom J H

~ ...

10 Co lid

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic: or mechanical, h:Iuding photocopying, IlKXlI'ding or by any information storage or retrieval system, -Mthout pemVssion in .....ntJng from the copyright holder.

Printed in the USA

i9Z2 - 50020) (412)

Haynes Publishing Group

Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc. BS1 Lawrence Drive Newbury Park California 91320 USA

97-70336

Acknowledgments Special thanks are due 10 American Motors Corporation for their supply of technical information BOO certain illustrations.

About this manual Its purpose The purpose of this manual is to help you get the besl value from your vehicle. It can do so in several ways. It can help you decide what work must be dona, even If you choose to have it done by a dealer ser-

vice department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it oHers diagnostic and repair procedures to follow when trouble occurs. It Is hoped that you will use the manuel to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than ,manging an appointment to get the vehicle into a shop and making the trips to lallve it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of sstisfaction and accomplishment that you feel after having done the job yourself.

Using the manual ' The msnual is divided into Chspters. Esch Chspter is divided into numbered Sections, which are headed in bold type between horizontsllines. Each Section consists of consecutively numbered paragraphs.

The two types of illustrations used (figures and photographsl. sre referenCed by a number preceding their caption. Figure reference numbers denote Chapter and numerical sequence within the Chspter; U.e. Fig. 3.4 means Chapter 3, figure number 4). Figure csptions are followed by a Section number which ties the figure to a specific portion of the text. All photogrephs apply to the Chapter in which they appear and the reference number pinpOints the pertinent Section and paragraph; i.l.l., 3.2 means Section 3, paragraph 2 . Procedures, once described in the text, are not normally repeated . When it is necessary to refer to another Chapter, the reference will be given ss Chapter and Section number i.e. Chapter 1/16). Cross references given without use of the word ' Chapter' apply to Sections and/or paragraphs in the same Chapter. For example, ' see Section B' means in the same Chapter. Reference to the left or right side of the vehicle is based on the assumption that one is sitting in the driver's seat. facing forward . Evan though extreme care has been taken during the preparation of this manual, neither the publisher nor the author can accept respon · sibility for any errors in, or omissions from. the information given.

Introduction to the Jeep CJ The Jeep CJ is available in an open utility body style with a folding windshield. Later models feature removable, folding tops or hsrdtops in both conventional and pick-up styles. Power from the engine is passed through the trsnsmission to a trsnsfar casa and then to tha front snd resr allies by driveshatts. Both msnual and sutomatic trsnsmissions ara available on these vehicles.

Esrly models used a csm snd lever type staering gear while later models featured a recirculating ball type steering gear with power assist as an option. Suspension is by semi-elliptic springs with tubular shock absorbers. Both four-wheel drum and front disC/rear drum brakes are used on these vehicles. with power assist as an option.

Contents

Page

Acknowledgements

0-2

About this manuel

0-2

Introduction to the Jeep CJ

0-2

General dimensions

0-6

Vehicle identification numbers

0-7

Buying perts

0-8

Maintenance techniques, tools end working facilities

0-9

Booster battery (jump) starting

0-15

Jacking end towing

0-15

Automotive chemicals and lubricants

0-16

Safety firstl

0-17

Troubleshooting

0-18

Chapter 1 Tune-up and routine maintenance

1-1

1

Chapter 2 Pert A General engine overhaul procedures

2A-l

2A

Chapter 2 Part B 151 cu in four-cylinder engine

26-'

28

Chapter 2 Part C 150 cu in four-cylinder and aJi in-line six-cylinder engines

2C-1

2C

Chepter 2 Part 0 VB engine

20-1

20

va engine

2E-l

2E

2F-O

2F

Chapter 2 Part E

Chapter 2 Part F L-and F-head four-eck lOf the ComICt plug heat range, OVet· adv~ Ignition tinliog, te.l fuel mIlrtl.nI, InI!IufIicient BI1gIIlB cooling and lack of lubrication .

HIGH SPEED GLAZING S)rmptoms: Insulalor /las yellow. Ish, gWed appear1II'ICB. 1ncIicat_ thaI combustion cI"Iarnt:.- temper· ,tInS haYI risen -..:IdenIy dln1g h8rd aoceI«etion. Normal depos/tI!I melt 10 farm , conductMl coating. Causes miI!I1irlng al high speeds. R&eommflfld,tfon: Inslall new plUQI!I. ConsIder using , colder plug if drMng I"Iabits warrant.

DETONATION Symptoms: Insulalors may be cracked or chipped. Improper gap !letting techniques can also result In a fractI.nd insuIalOf bp. Con lead 10 piston damage R_~tIon: Make __ the

fuel ri-l!nock values meet engIOB requlflm8ntl. Use care wtlII"I set· ling lhe gaps on new plugs. Avoid lugging lhe engine.

mechanical condition with neces· sary ~ and install new plugs.

MECHANICAl DAMAGE GAP BRIDGING Symptom.., CombustlO(1 deposits lodge between the electrode,. Heavy deposi" accumulate and bridge the electrode gap. The plug ceaI!IeS to fire, resultlflQ In , deed

"If'--

Reeomm,nd.tlon:

Locale the faulty plug end remove too deposits from b e ' - the electrodes.

SympIoms: May be c.JIed by a foreign objecl In the combusllon charnbef Of the piston sttiklng an l!"lCOfl'eCt reach (100 long) plug. Causes a dead cylinder and could result In plslon~. Rec:otnmMcNltlon: Aepair the mechanIceI damage. Remove the foreign obte 36.46 Withdr8wing the pressure regulator valve Iisembly

36.6 If the gears show signs of weilr or dlmege they should be replaced with new ones

6 Place the oil pump housing Ilange in position and josteD the mounting boh(.1. No ;aaket is needed between the pump flange and the block. 7 Install the oil pump screen bracket over the main be8ring cap bolt

and Inllal1 Ihe nut. a

rtghten the pump mounting boltla, and screen support nut to Ihe

specified torque. 9

36

Inllall the oil pan.

011 pump -

dl .....mbly. Inlpectlon and reassembl y

In moSI cases it will be more praclical and economical 10 replace a laully oil pump wilh a new or ",buill unh. II h Is decided 10 overhaul Ihe oil pump. check on availability 01 inlernal parts before beginning. 2 Remove the pump COV1!f relaining screws and the pump cover. In · du mark the geer teeth to permit reassembly in the same position. 3 Remove the idler gear, drive gear end sheft Irom the body (photol. 4 Remove the pressure regulator valve retaining pin (photol, the regulator valve and Ihe related parts (phoIO), 5 The screen assembly is factory-fiuad 10 Ihe pump body and can· not be separated. 6 Wash all the parts in solvent and dry them thoroughly. Inspect the body for cracQ, wear and damage. InspeCI Ihe gears (photo). 7 Cheek the drive gear for Ioosenell In the pump body and the inside of the pump cover for wear that would permit oil leakage past the ands of the gears Iphoto). If either the gears or body are WQm or damaged, the enti", oil pump assembly must be replaced . 8 In'Peet the pickup screen and pipe nsembly for damage to the scr"", pipe and relief grommet. 9 Inslall the p",ssure regulator valve and related parts. 10 Inslali the drive gear and shah in the pump body, followed by the Idler gaar with the smooth side toward the pump cover opening. lubricate the parts with engine oM. 11 Install Ihe cover and tighten the screws to Ihe 5pecified torque. 12 Turn Ihe driveshaft to ensure thet the pump operata5 fraely.

37

Flywha~

36.4A Removing the pressure regulator valve retaining pin with needle -nose phers

36.7

Inspect the pump cover for wear

and fear main 011 se.1 -

removal and installation

To gain access to the flywheel, either the engine or the transmisSion must be removed from the vehicle. If other engine work is needed, remove Ihe engine as descflbed in Section 22. If no other work necessiteting the removal of the engine needs 10 be done, It would be easier 10 remove the trensm sission as described in Chapter 7. 2 If equipped with e manual transmi ssion, remove the clutch from Ihe flywheel as described in Chapter 8 . 3 The flywheel can be unbolted from the rear flange of Ihe crankshafl. To prevent the flywheel from IOrning, e long screwdriver or similar tool can be run through the flywheel and positioned against the engine block (pho to ). 4 Once the bolts are removed, the flywheel can be lilled off. 5 Remove the flywhee l spacer if so equipped. 6 If the rear main bearing seal mull be replaced, pry it out of tts bore. 7 hamine the flywheel ring gear for any broken or chipped teeth . If Ihls condition exists, the flywheel muSI be replaced with a new one. a On manual transmission ffywhBfJ/s, inspact the clutch friction face for 1C0ring. Light scoring may be corrected using emery cloth, but where Ihere is deep scoring the lIywheel must be repleced with e new one or clutch damage will soon OCCur. 9 On automatic transmission fI'Iwhaafs , examine the converter securing bolt holes for distortion. This condition, too, necessitates the replacement of the flywheel . 10 Before installing the flywheel. clean the mating surfaces of the flywheel and the crankshaft. 11 "the oil seal was removed . apply a light coat of engine oil to Ihe inside lip of the new sea' and instaM i t in ita bore. 12 To install the flywheel , use a new spacer lif equipped I and posi lion it in place against the crenkshaft and insert the mounling bolts, securing them only finger light, It is a good idee to use a Ihread locking agent such as LDctite, or equivalent, on the bolt threads. 13 Again, while preventing the flywheel from lurning. tighten the bolts

Chapter 2 Part B 151 cu in four-cylinder engine

37.3 A long screwdriver can be used to prevent tha flywheel from turning during bolt removal

38.21 Lubrlcata the camshaft lobes and journals prior to Installation of the shaft In the block Ithe dial indicator is usad here to verify that the piston is at TQP Oaad Centar)

38.13 Support the camshaft Insida the block (arrQw) during removal (withdraw the camshaft straight out, teking cere not to gouge the bearing surfaces with the cam lobesl

Camshaft and bearlngl -

38.17 M. .suring the cam bearing jourllli diameter with a micromater

2B 38.22 Tha camshaft and crankshaft gears muSl be positioned with the timing marks (arrQwsl aligned

a little at a time until they ara all at the specified torque. 14 Complete the remainder of the instellation procedure by revers· ing the famoval Slaps. 38

2B-11

removal and Installation

•

Remove the engine as described in Section 22 and mount it on a suitable stend. 2 Remove the rocker arm cover. 3 Loosen the rocker arm nuts/bolts and pivot the rocker arms clear of Ihe pushrods. 4 Remove tha pUlhrods. 5 Remove the pushrod cover 6 Remove the valve lifters as descflbed in Section 26. 7 Remove the distributor. 6 Remove the fuel pump. 9 Remove the oil pump drlveshaft and gear assembly. 10 Remove the front pulley hub as described in Section 31. 11 Remove the timing gear cover as described in Section 32. 12 Remove the two camshaft thrust plate screws by working through the holes in the camshaft gear. 13 While supporting the camshaft with your fingera Inserted through theluel pump hole to PllM!f1t damaging the camshaft bearings. carefully and slowly pull the camshaft straight out Irom the block (photol. 14 If the gear must be removed Irom tha tams haft. it must be pressed off. II you do not heve access to a preas. taka it to your daalar Of an automotlva machine shop. The thrust plata muat be positioned so that the Woodruff key in the shaft does not damage It when the shalt is pressed out. IS E~amine the beaflng surfaces and the surfaces of the cam lobel. The oil pan may have to be removed to thoroughly inspect the bear· ings. Surface scratches. if they are very shallow. can be re' mQved by rubbing with a fine emery ClOth or oilaton e. Any deep scar· Ing will necessitate a new camshaft.

40.5 Installing the main bearings in the block

16 Mount the camshaft on V-blocks and usa a dial gauge tQ measure lobe lift. Reject a camshaft Which does not meet the specified limits. 17 USing a micrometer, measure the journal diameters (photQ). Again, reject a camshaft which does not meet the specified limits. 18 If the camshaft bearings are worn, they must be replaced using the following procedure: 8) Remove the Qil pan 11 it is stili in place. b) Remove the flywheel. CI Driving irQm the inside ou t. remove tha expansion plug from the rear cam bearing. d) Using a camshaft bearing remover set, available from a dealar or auto parts stQre, drive out the frOflt bearing toward the rear. al Drive Qut the fear bearing toward the front. fl USing an axtension on the bearing remover. drive out the centef bearing toward the raar. g) Install the new bearings by reversing the removal procedure. Be lura all of the oil holes are aligned. Note: The (ront bMtring must be driwn in until it is .pproximattlly 118-inch from the front of the cylinder block In ordar to unCOVflr the oil hole to tha timing gear oil nozzltl. hI Aher installing the new bearings. Instell a new camshaft fear ellpenaion plug flush with the rear surlace of the block. il Reinstall the flywheel and Qil pan.

19 If the camshaft gear has been removed from the camshaft. it must be prassed on prior to installation of the camshaft. a) SUPPOft the camshaft in an arbor pre .. by using press plate adaptors behind tha front journal. b) Place the gear spacer ring and the thtVst plate over the end of the shaft. c) Install tha Woodruff key in the shaft keyway. dl Install the camshaft gear and prell It onto the shaft until it bottoms against tha geaf spacer ring. el USe a feeler gauge to check the end clearance of the thrust plate. It should be 0.0015 to 0.0050·lnch. II the Clearance Is

2B-12

Chapter 2 Part B 151 cu in four-cylinder engine

40.10 Place the Plastigage strip (arrow) on the journal, parallel to the journal Ixis

40.14 The oil clea'llnce is obtained by comparing the crushed Plastigage to the scale printed on the container

• less than a.OOl5-inch, the spacer ring should be replaced . If the clearance is more than O.OO50-inch, the thrust plate should be replaced. 20 Prior to Installing the cemshaft, verify that the numbs. one pislon is 8t TOC. Coat 8ach of the lobes and journals liberally with a molybased grease or engine assembly lube. 21 Slide the camshaft into the engine block, again taking extra care nOI to damage the bearings (photo). 22 Position the camshaft and crankshaft gears so that the valve tim ing marks line up (photo). With the shafts in this position, the engine is in the number four (4t cylinder firing position. 23 tnstallthe camshaft thrust plate mounting screws and tighten them to the specified torque.

39 Crankaheft - ramoval 1 Remove the engine from the vahicle liS dascribed in Saction 22. 2 Remove the crankshaft pulley and hub assembly as described in Section 31. 3 Remove the oil plln. 4 Remove the oil pump assembly. 5 Remove the timing gear cove r. 6 Remove the pistons and connecting rods from tha crankshaft as described in Chapter 2A. 7 Remove the flywheal as described in Section 37. 8 Refar to Chap tar 2A for tha remainder of the crankshaft removal procadure.

40

Cranka heft - Install ation and main baaring 011 claa ranca chac k

Nota: H a naw or fflground crankshafr Is being ins raIled, or if rhe original crtJnkshaft hB$ been fflground, maka sure rha correct bearings are used. 1 Crllnkshilit instalilltion is ganerally one of the lirst steps In engine reassembly; it is assumed at this point that the engine block and crankshaft hllV8 been cleaned, inspected and repaired or reconditioned . 2 Position the engine with the bottom fac ing up. 3 Remove the main bearing cap bolts and lift out the ClipS. LilY them out in the proper order to help ensura correct InSl8l1l1lion. 4 I! they are still in placo, ramove the old bearing insert s from the block lind the mllin bearing caps. Wipe the main bearing surfacas of tha block lind CliPS with II clean, lint-free cloth (they must be kept spotlessly clean). 5 Clean the back side o f the new main bearing inserts and lay one

bearing hal! in each main bearing saddle (in the block) (photo) _ Place the o ther bearing half from each bearing set in the corresponding main bearing cap. Make sure the tab on the bearing insert fits into the recass in the block or cap. Also, the oil holes in the block and cap must line up with the oil holes in the bearing insert. Do not hammer the bearing into pface and do not nick or gouge the bearing faces_ No lubrication should be used at this rime. 6 The thrust bearings must be installed in the number five (rea.) cap and saddle. 7 Clean the face ~ of the bearings in the block and the crankshaft main bearing journals with a clean, lint-free cloth _ Check or clean the oit holes in the crankshaft, as any dirt here can only go one way straight through the new bearings. 8 Once you are certain that the crankshaft is clean, carefully lay it in position (lin assistant would be very helpful here) in the main bearings with the counterweights lying sideways. 9 Before the crankshaft can be permanently installed. the main bearing oil clearllnce must be chllcked. 10 Trim seven pieces of the appropriate type of Plastigage slightly shorter than the width of the main bearings lind place one piece on each crankshaft main bell ring journal, pllrallel with the journal IIxis !photol. Do not lay them across any oil holes. 11 Clean the faces of the bllarings in the CliPS lind install the caps in their respective positions (do not mix them up) with the arrows pointing toward the front of the engine. 00 not disturb the Plastigage. 12 Stllrting with the center mllin and working out toward the ends, tighten the main bellring CliP bolts, in three steps, to the spacified torque. Do not rotata the crankshaft at any time during this operation. 13 Ramove the bolts and carfefully lift off the main bearing caps.. Keep them in order. Do not disturb the Plastigage or rotate the crankshaft. I! IIny of the main bearing caps are difficult to remove. tap gantly from side-to-side with a soft-Illced hllmmer to loosen them. 14 Compare the width of the c rushed Plastigllge on each journal to the scale printed on the Plastigllge container to obtllin the main bearing oil clearance (photo). Check the Specifications to make sure it Is correct. 15 If the clearance is not correct, double-check to make sure that you have the right size bearing inserts. Also. reCheck the crllnkshllft main bearing journal diameters and makll sure that no dirt or oil WIIS between the bearing inserts and the main bearing caps or the block when the clearance was measured. 16 Using II piece of hardwood or your fingernail, carefully scrape 1111 traces 01 the Plastigage mllterial off the mllin bearing journilis lind lor the bearing Illces. Do not nick or scrlltch the bearing faces, 17 Carefully lift the crankshaft out of the engine. Clelln the bell ring faces in the block. then apply a thin laver of clean, high-Quality moly-

Ch apter 2 Part B 151 cu in four-cylinder engine based gruse or engine assembly lube to each 01 the bearing laces. Be sure to coat the thrust Dearing laces as well. Make sure the cranklhalt journals are clean, then carefully lay it back in place in the block. Clean the Iscas 01 the Dearings in the caps, then spply a thin leyer 01 clean, high·quality moly·based greese or engine assembly lube to each of the bearing laces and install the caps In their respective posi· tions with the arrows pointing toward the front 01 the engine. Install the bolts Ind tighten the bolts in caps one through four to the specified torque. "erting with the center mlin and working out toward the ends. Work up to the linal torque in three steps. Tighten the bolts in the number five (reer) cap to 10 It-Ib, then use a lead or brass hammer to tap the crenkshaft to the rear, then the IrOn1, to center the thrust bearIng. Tighten the rur cap bolts to the specified torque. 18 Rotate the crankshaft a number of times by hand and check for any obvioul binding. 19 Nelft, check the crankshaft end play. Thil can be done with a feeler gaUge or a dial Indicator set (see Section 12 In Chapter 2A). 20 wbricate the seal lip with moly-based grelse or engine assembly IUDe, then center the seal over the reer end of the crank.shsft with the sesl lip feclng the from of the engine. Using s soit-fsced hammer, cSf8fully drive the 5esllnto the groove in the meln beering cap and block until it i••eated. Mske sure it is driven in aquarely. 21 InSlall the Woodruff key in the front of the crenkshaft, then slip the liming gelr into place. 22 Refer to the Ippropriata Sections Ind inlllil the pistonfconnectII\g rod Issemblies, the camshaft, the oil pump, the oil pan, the flywheel, the timing gear cover and the pulley hub.

41

Engine -

InstaHatian

Lower the engine carefully into the engina co~partment and mate

26 -13

it to the transmission. On rMnUM tr8flsmisslon$, make sure the tranarrns· sion input shah is COmtC1/y installed in the pilot bushing and clutch disc. 2 Connect the hoses to the power IIeering pump. 3 Connect the heater hoses to the heater core. 4 Connect the coolsnt temperature sending unit, oil pressure send Ing unit, choke, solenoid and milo:ture conlrol solanoid wires. 5 Connect the carburetor end evaporative system vacuum hOles. 6 Connect the csrburelor bowl vent hose. 7 Connect Ihe ailemllor wiring harness. 8 Attach the Ihrottle cable to Ihe carburetor and secure it with the bracket. 9 Place the fan shroud In position over Ihe fan and install the radiator and ho.as. Attach the shroud 10 Ihe ,.Idiator and fill the radiator with the .pecified coolant. '0 Reise the vehicle and .• uppon it securely. 11 On automlltic transmissions. align the convener-Io-driveplate marX. made during l"Ii'TIO'II'al, then Install the attaching bolt. end lighten them to the specified forque. Apply thread-locking compound to the bolt threads before inslllllng them. '2 Install the transmission-to-torque converter housing attaching bolt. and tighten them to t he specified torque. '3 On mlInuaJ transmissions, in.leilihe flywheel inspection plate and clutch hydrauliC slave cylinder. '4 Install the angine mount nuts and tighten them securely. 15 Install the staner motor aod bracket. '6 Connect the cable and solenoid wire to the st8ner. '7 Connect the distributor wires. 18 Connecl the elfhaust pipe to the manifold and inst8111he olfygen sensor wire (il so &quipped). 19 Connect the nagative battery cable and body ground wire. 20 Inltall the air cleaner assembly. 21 FiU the engine to the correct level with the recommended oil. 22 Refer to Chapter 2A for lhe Initial stan-up and break-in procedure •.

28

28-14

Chapter 2 Part B 151 cu in four-cylinder engine

Notes

•

2C-l

Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines Contents Camshaft and bearings · Inspection and replacement. . . . . . . . . 59 camshaft and timing chain/sprockets - installation ...... 67 Camshaft - removal . . . . • . . . • • . . • . . . . . . . • . • • . • • . . • . • . . . . 51 Crankshaft - removal . . . . .. . ............... ~ . . . .. Chapt8f 2A CranKshaft - inspection . ......................... Chapt8f 2A

Crankshaft - installation and main bearing 011 clearance check .•

64

Cylinder head and rocker gear - Inslallation . . . . . . . . . . . . . . . . . 69 Cylinder head - cleaning and Inspection ............. Chapter 2A Cylinder head - disassembly . . . . . . . . . . . . . . . . . . . . . .. Chapter 2A Cylinder nead - reassembly ..•..•.. Chapter 2A Cylinder head - removal ...•.•.. ..•... .. . 48

Engine - installation . .. .. .. ...

. .. .. . .. ... ...

71

Engine · removal .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Engine block - c1eanli'lQ ' . . . . . . . . . . . . . . . . . . . . . . . . .. Chapter 2A Engirl6 block - inspection ... . . . . . . . . . . . . . . . . . . . . . Chapter 2A Engine disassembly - general Infotmation ........... Chapter 2A Engine mount flexible cushions· replacement. . . . . . . . . . . . . . 44 Engine overtlaul • general Information .............. Chapter 2A engine reblJllding alternatives. . . . . . . . . . . . . . . . . . . . Chapter 2A engine removal - methods and precautions . . . . . . . . . .. Chapter 2A External components - installation ........................ 70 External components - removal ..................... . .... 46 FlywtIeeI and starter nng gear - Inspection and servicing ...... 6t FlywheeVdnvepiate • installation ................ 65 FlywheeVdriveplate - removal ......................... 55

General Information . . . . . . . . . . . . . . . . . . . . . . .......... 42 Initial start-up and break·ln after ovemaul ............ Chapter 2A lubrication system· general in formation ................... 54 Main and connecting rod bearings - inspection ....... Chapter 2A Main and connecting rod bearings - seIec1iofl .............. 63 Oil pan • removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Oil seals - replacement ..... .. ......... . . . . . . . . . . . . . . . . . 62 011 pump and 011 pan - Installation ........................ 66 Oil pump - disassembly, Inspection and reassembly . . . . . . . . . . 60 Oil pump - removal ........ .......................... 53 Oversize and undnze component designation .... .. ....... 43 Piston/connecting rod assembly - installation and bearing oil clearance check ........................... Chapter 2A Piston/connecting rod assembly - inspection ......... Chapter 2A Piston/connecting rod assembly - removal ... Chapter 2A Piston rings - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2A Repair operations possible with the engine In the vehicle Chapter 2A Rocker gear - Inspection and ovemaul .. . . . . . . . . . . . . . . . . . . . 56 Rocker gear - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 TIming chain and sprockets· inspection ........... 58 TIming cover. chain and sprockets· removal. . . . . . . . . . . . . . . . 50 Valve liftet'S· installation . . . . . . . . . . . . . . . . . . . . . . . .. .. 68 Valve lifters - descripllon and removal ..................... 49 Valve lifters· Inspection and ovemaul ..................... 57 Valves - serviCing ....... . Chapter 2A

Specifications

General Displacement Six-cylinder .................. . Four-cylinder ............. . Bore and stroke 150 co In engine ....................................... . 232 co in engine 258 co in engine ............. . ............. . Oil pressure

600 rpm . . . . . ....... _..... ................ . Above 1600 rpm .......• . ..... . ............ , .... .

232

Of

258 cu In

150 cu In 3.876 x 3.188 in 3.750 x 3.50 in 3.750 x 3.895 In 13 psi 37 to 75 psi

2C

2C·2

Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines

General (continued) Firing order Four-cylinder . ..... . . . Si)(-cyllnder . . .. . .. . . .

' -3-4-2 1-5-3-6-2- 4

FRONT

Four-cylinder engine

(0

Engine block Cylinder bore

Diameter

... . .. . ... .

Taper limit ................ . Out -af-round limit •.•..•..•.....•..........•. . ...•..•.... Deck warpage limit . . .

3.8751 to 3.8775 in a 001 in 0.001 in 0.002 in over 6 in

Pistons and rings Piston-la-bore clearance Starxlard ............................................. . Preferred .... . ..... . ............. . ..... . .......•..• .. .. Piston ring side clearance Compression Standard .....•.••.••.•..•..•• • •. • •• • • . •..•.. • . • • . . . Preferred ........................... . .. . .. . .. . .. . .. . Oil control Standard Preferred Piston ring end gap Compression ............................... . Oil control

q (2)

CD 0)

~

four-cylinder 0.0009 to 0.00 17 in 0.0012 to 0.0013 in

• 0.0017 to 0.0032 in 0.0017 In 0.001 to 00008 In 0.003 in

®®0®®@

0.010 to 0.020 in 0.010 to 0.025 in

Crankshaft Mainjoumal Diameter .................. . ....... .. .... . .. . . Taper limit .•. Out 01 roond limit Main bearing oil clearance Standard . .• . Preferred ...... . ............ . ..... . ...... . . .. . Connecting rod joumal Diameter ..... . .. . Taper limit . . . . Out-ol-round limit . . . . . .. . . . . . Connecting rod bearing oil clearance Standard ........................ . Preferred ..•.....•..•..•.••.. Connecling rod end play Crankshaft end play

2.4996 to 2.5001 In 0.0005 in 0.0005 in 0.00 1 to 0.0025 in 0.002 in 2.0934 to 2.0955 in 0.0005 in 0.0005 in

®®0®®@

Inline six-cyflnder engine (1975·1986)

2.029 to 2.030 2.019 to 2.020 2.009 102.010 1.999 to 2.000 0.001 100.003 0.265 in

In

in in in in

Zero (engine operating)

Cylinder head and valve train Head warpage limit ... . . . •..•.••..•.••.•.... Inlake valve seat angle .. . . .. •.....•.••. • ..•..•.•..• . Exhaust valve seat angle .......• . .... . . ... . Intake valve seat width . . . . . . ... ••.. Valve seal n.moutllmit •..•....•.••..•.•• . • . Valve guide inside diameter . .•.•.. • .••..•.•..•.. . .•..•. . • . .• . Intake valve face angle . . . . Exhaust valve lace angle . . Valve margin width •.•..•. . •.•..• . .. . Valve stem d iameter .•.••.•..•..•. . ...•.. Valve stem-to- guide clearance. Valve spring lree length Utter/tappet type . . .. . . .. . .... . Valve lash adjustment ... . ... .

•

0.001 to 0.003 in 0.0015 to 0.002 in 0.010 to 0.00 19 In 0.0015 to 0.0065 in

Camshaft Bearing joomal diameter Number' ... . .. . Number 2. Number 3 ..... . Number 4 ............... . Beari ng oil clearance •....•..•..•..•.••.•..• . .•....•.•• . •. . Lobe lift . .. . .•.......•...• •. . • .. • ..•.. End play

fnline siK-cylinder engine (1972-1974)

0.002 in over 6 in 44 .5" 44 S 0.040 to 0.060 in 00025 in 0.313 10 0.3 14 in

44' 44' 1/ 32 in minimum 0.311 to 0.312 in 0.001 to 0.003 in 1.82 in Hydraulic Z~O

Cyfinder location and distributor rotation

Chapter 2 Part C 150 cu in four~cylinder and all utter bore diameter ..... . . . . . . . . . . . . . . . . . .. . Ufter diameter . . . . . . . . ........ . Utter-to·bore clearance .... . .......................... . Pushrod diameter .............................. . Pushrod length .. . . . . .......... .

in~line

six-cylinder engines

2C-3

0.9055 to 0.9065 In 0.904 to 0.9045 in 0.001 to 0.0025 in 0.312 to 0.315 In 9.640 to 9.660 in

Oversize and undersize component code letter definition Code letter B All cylinder bores ..................... . ...... . M All crankshaft main beanng Journals P All connecting rod bearing tournals ...... . C All camshaft bearing bores ... . ....... .

0.010 In 0.010 In 0.010 In 0.010 in

oversize undersize undersize oversize

Six-cylinder engine Engine block Cylinder bore Diameter ..... Taper limit 1972 through 1981 1982 and later Out-ol-round limit 19721hrough 1981 ....... . 1982 and later ... Deck warpage limit ....

3.7501 to 3.7533 In 0 .005 In 0 .001 in

0.003 In 0 .001 In 0.006 in max.

Pistons and ring s Piston-to·cylinder bore clearance Standard .. Preferred . . .. . ..... . '; ' Piston ring side clearance 1972throu9h 1980 Compression (standard) ........... .. . . ........... . Compression (preferred) ............. . .....•.....• . 011 control (standard) . . . . ....• . ..•.. . ...... Oil control (prelerred) .........• . . . . ..•..•..•..•..• . 1981 and later Compression (slandard) Compression (preferred) Oil control (standard) Oil control (prelerred) .............................. . Piston nng end gap • Compression (all) ..... Oil control 1972 and 1973 only All others ...... .... . Piston pin diameter Piston pin'lo-piston clearance Standard ............. . .................. . .. . Preferred ....... .................. ............ ....... . .

.... .........

0.0009 to 0.0017 in 0.0012 to 0.0013 In

0.001510 0.003 in 0.0015 in 0.001 100.008 in 0.003 In 0.0017 to 0.0032 in 0.0017 In O.OCl1 10 0.008 in 0.003 in 0.010 to 0.020 In 0.01510 0.055 in 0.010 10 0.025 In 0.9304 100.9309 In 0.0003 10 0.0005 In 0.000510

Crankshaft Main journal Diameter 1972 through 1981 .... 1982 and later Taper limit . .. . ... Out·ol·round limit . . Main bearing 011 clearance 1972 and 1973 . . .. 1974 through 1980 Standard Preferred 1981 and later Standard Preferred Connecllng rod journal Diameter ....... . ........................... . Taper limil . . .. .... .......................• . .•..... . Out-ol·round limit . .. ..........................•..

2.4986 2.4996 0.0005 0.0005

to 2.5001 in to 2.5001 in in In

0.001 to 0.002 In 0.001 to 0.003 in 0.0025 in 0.001 10 0.0025 In 0.002 In 2.0934 to 2.0955 In 0.005 In 0.0005 In

2C

2C-4

Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines

Crankshaft (continued) Connecting rod bearing oil clearar'ICe 1972 and 1973 ...............••.••..•.••.••. 1974 and 1975 Standard ....•.•..•.••.••... . Preferred .................. . 1976 through 1980 Standard Preferred 1981 and later Standard .................... . Preferred .... .... .. Connecting rod end play 1972 1973 through 1980 .•..•.. 1981 and later •.•..•.••.•..•... .. .••..•.•• . •• . Crankshaft end play •..•.••.•..•..•.••••. .

0.001 to 0.002 in 0.001 to 0.003 in 0.0025 In 0.001 100.0025 in 0.0015 to 0.002 in 0.001 to 0.003 In 0.0015 to 0.002 in 0.008 to 0.010 in 0.005 10 0.014 in 0.010 to 0.019 in 0.0015 to 0.0065 in

Camshaft Bearing journal diameter Number 1 ... . Number 2 .. . Number 3 .. . Number 4 .. . Bearing oil clearance .•• . Lobe lift 1972 through 1974 ............ . ........ . 1975 and 1976 . .... •..•..•.••• • •. • . .•.. • . 1977 through 1979 2321258 with 1 bbl. carn 258 with 2 bbL carb 1980 ..•..•..•..•... 1981 and later .•..•....... End play .. ...•....••.•..• .

2.029 to 2.030 in 2.019 to 2.020 in 2.009 to 2.010 In 1.999 to 2.000 in 0.001 100.003 in 0.254 In 0.232 in 0.232 in 0.248 in 0.248 in 0.253 in Zero (engine operating)

Cylinder head and valve train Head warpage limit .••.• •.. ... ... . ......•..•..•... (ntake valve seat angie .•..• .. . .. . . Exhaust valve seat angle ....•.••....•. Intake valve seat width . .. .....••.••.• .. . . Exhaust valve seal width .....•..•....... Valve seat runout limil . . . ...••....•....... Valve guide Inside diameter ....... .. .... ...•.••.. . Intake valve face angie .... ••.•..•..• . .. .... Exhaust valve face angle ..•. . . ...••.•..•.. Valve margin width .•... . . • . . • . . •• .•.. • ..•..•.. Valve slem diameter . .. ..•..•..•..•. •.. Valve stem-Io-guide clearance ..••.••. • ..•.. •. Valve spring free length 1972 and 1973 •..•... 19741hrough 1976 With rotatOfS ...••.•..•..•.. Without rotalors 1977 258 2 bbl. only ..... ..... . An others 1978 and later . • . . . . . • . . • . . . . . . . •. .•.. • ..•.. • .. • .. •. .• Ufter/lappet type ......... ....•.. • .. • Valve lash adjustment. . . . . . . • ..•..•.. •. .• ..•. . . UfIer bore diameter 1972 and 1973 ..•.•. . 1974 through 1980 ....•.••.••.• 1981 and later ...•.... Ufter diameter 1972 and 1973 19741hrough 1983 ..••...... Ufter·to-bore clearance 1972 and 1973 1974 through 1980 1981 and later

0.006 in max.

30" 44.5 0 0.040 10 0.060 in 0.040 to 0.060 in 0.0025 in 0.3735100.3745 in 29"

44" 1132 in min. 0.3715 to 0.3725 in 0.001 to 0.003 in Not available 2.00 in (approK.) 2.234 in (approx). 1.987 In (approx .) 2.234 in (approx.) 1.99 in (approx.) Hydraulic Zero Not available 0.905 to 0.906 in 0.9055 to 0.9065 in Not available 0.904 to 0.9045 in Not available 0.001 to 0.002 in 0.001 to 0.0025 in

•

Chapter 2 Part C 150 cu in four-cylinder and all in-line six-cylinder engines Pushrod diameter 1972.1973 and 1975 1974 1976 through 1980 1981 and tater ... Pushrod length 1972. 1973 and 1975 1974 1976 1977 through 1980 1981 and later

2C-5

Not available 0.294 to 0.303 In 0.312 to 0.313 In 0.312 to 0.315 in Not available 9.656 to 9.666 9.595 to 9.615 9.64010 9.660 9 .71010 9.730

In in In in

Oil pump Gear-Io,body clearance 1972 through 1980 1981 and later . Gear end clearance 1972 through 1976 and 1981 throu9h 1966 . . . . . . . 1977 through 1980 . • .. .. . •..•. .

0.0005 to 0.0025 in 0.002 to 0.004 in 0.002 to 0.006 in 0.002 to 0.008 In

Oversize and undersize component code letter definition Code B M P

letter All cylinder bores . . . . . . . . . • • . •• • .••... All crankshaft main beanng JOUrnals .. . .•••.. .•...•.•. All connecting rod beanng journals .. . C All cam shaft beanng bores ....... .

Torque specifications (atl models) Camshaft sprocket bolts Carburetor mountmg nuts Connecting rod cap nuts Cylinder head bolts 1972 1973 through 1980 1981 and laler ...... ... .•..•••.••.. Crankshaft pulley-Io-damper bolt ..........•..•..•.•• • , . Exhaust manifold bolls . . . . . . . . . .. ".,. Fan and hub assembly bolts ........ . .. , . " " , •. Dnveplale-to-torque converter bolts •.•••.... Flywheelldriveplate-to-crankshaft bolts. •• • ....•.•••. Intake manifold bolls ..••.••....• MaIO beanng cap bolts . Oil pump cover bolts .. Oil pump mounllng bolls Short Long 011 pan bolts 1/4 x 20 5116 x 18 . Bndged rocker pivot boll Rocker arm shaft bolts VibratIOn damper boll Ig721hrough 1976 1977 and laler Water pump bolls.

.

.......

42

General information

The In·line six·cylinder engines. used from 1972 through 1986. displace 232 or 258 cu In and are equipped With either a one-barrel or two-barrel carburetor. Beginning In 1984 the 150 cu in four-cylinder. manufactured by AMC. replaced the GM 151 cu in fOl.lr·cylinder as the standard engme. The new lour·cylinder IS based on the Six-cylinder engine design and the maJonty 01 the engine operations 81e IdentiCal to the six-cylinder, The engln'es 81e constructed of cast Iron. With a removable cylin· der head. Intake and exhaust manifolds. The crankshaft IS supported In tile block by live (four-cylinder) or seven (six-cylinder) main bearings.

0.010 in oversize 0 ,010 in undersize 0.010 In undersize 0.010 in oversize Ft-Ibs 45 to 55 12to15

33 80 10 85

105 85 20 to 25 20 to 25 15to 25 20 to 25 10010110 20 to 25

80 6 8 to 12 15 to 18 5 t09 10to 13

"

21 50 to 60

eo

10 to 15

The piwn bearing insens for the crankshaft and connecllng rods are removable. The valves are mounted in the cylinder head and are actuated by a camshaft located In the block via puSh rods , rocker arms and hydraulic lifters. Depending on the year of production. the rock8f arms are mounted in either of two ways . On 1972 and 1974 six-cylinder models the rocker arms operate on a common shaft. All oth8f models use a bridged rocker arm pivot, which Is attached to the cytinder head by cap screws. The camshaft Is driven from the crankshaft by a chain. The distnbl.ltor IS dnven by a gear on the camshaft. which In tum dnves the poSItive displacement oil pump. Along with the cylinder head and manifolds. the watOf pump. tim· 109 chain cover and belihOl.lslng can be unbOlted from the block.

2C

2C-6

Chapter 2 Part C 150 cu In four-cylinder and all in-line six-cylinder engines

""'"

FII ...... ( SUPPORT

COD GEAII

~@

Fig. 5.32 1978 through 1986150 cu in four-cylinder, in-line six-cylinder and V8 distributo r co mponents (sec 20 and 22)

lusing a washer IS a sp8cer on the lOP of the distributor shalt) or with two screwdrivers lused to lever the wheel off!. Remove the pin from the wheel. . 12 On four-cylinder and Six-cylinder engines, remove the pick-up coil retainer and washers from the base plale pivot pin. '3 On va engines. remove the snap-ring which retains the pick·upto the shaft. Remove the vacuum advance mechanism and move it out 01 the way. , 4 Remove the harness tab ground screw and separate the pick-up assembly from the distributor. 'S To install the pick-up assembly, place it in position. On four-cyli~ der and six-cylmder engines, insert the pick-up coil pin into the hole;'

Chapter 5 Engine electrical systems

the vacuum advance mechanism link. On VB engines, attach the vacuum advance mechanism lever and retainer to the pick-up coil pin. 16 On four-cylinder and six- cylinder engines, install the washers and retainers on the pivot pin so the pick-up coil is secured to the base plate_ On VB engines, install the snap-ring. n Place (he wiring harness In tha oistfiDutor nousing slot and install the ground screw through the tab. 18 Position the triggar whael on the distributor shaft with tha long portion 01 the teeth fecing up. Aher aligning the trigger wheel with the slot in tha shaft, insen tha retaining pin into the locating groove and tap it into place with a small drift punch and hammer. 19 Install the rotor and cap.

CAP _ _ ' -

CENTRIFUGAL _ _ _ I ADVANCE MECHANISM

151 cu in four-cylinder models " _ _ _ _ _ TRIGGER ... WHEEL

MAIN _ _ _ _--oj SHAFT

SNAP RING

20 Remove tha distributor. 21 Mark the relativa location of the distributor gear on the shaft, drive out tha roll pin and ramove the gear. 22 Remove the distributor shaft, complete with the rotor and advance weights_ 23 Ramove the snap-ring on tha top of the pick-Up coil, disconnect the wire from the module and remove the pick-up coil and plate assemblv_ The three screws should not be removed. 24 Installation is the reverse of ramovel. Be sure to align the distributor gear with tha mark made during removal.

21

VACUUM AOVANCE MECHANISM

•

ELECTRONIC MOOULE-TOIGNITION COIL CONNECTOR

IGNITION COIL CONNECTOR

•

1980 through 1983 four-cyHndat distributor componant layout ISec 20 and 22)

Conventlona] distributor - check

1 Remove the distributor cap and rotor. 2 Rotate the crankshaft until the point rubbing block is on ana of the high points of the cam. Grasp tha distributor sheft firmly and move it back-and-forth while obsarving the points. If there is enough play in the shaft bushing to allow the points to open, the distributor Is bad IV worn and should be raplaced with a new or rebuilt unit. 3 As a furthar test, connect a dwell metar as dascribad in Chapter I. Start the engine and observe the dwell mater raading , then rev up the angine. If the dwell varies more than two or threa degrees as engine spe&d increases, the distributor is worn and should be replac&d with a new or rebuilt unit.

22

Fig_ 5.33

5-13

Electronic distributor - check

1 Remova tha distributor cap and rotor . 2 Grasp tha distributor shaft firmlv and move it back-and-forth. If there is perceptible movement, the bushings are worn and the distributOf should be replaced with e new or rebuilt unit.

5

6-0

Chapter 6

Emissions control systems

Content. Air Injection (AU system.

. .................. .

Catalytic convener .. Evaporative Contro~System lEeS) Exhaust Gas Recirculation (EGR) system Feedback carbure tOl .

6

•3

General information . . .. . .. Positive Crankcase Ventilation IPCV) syst em

Spark con trol system Thermo-controlled Air Cleaner (TA C)

7

1

2 5

,

9

Speclfic.tlons

T orqu8 specific ations Air injection pump mounting bolts F-head four-cylinder

V6 In-line six-cylinder V8 Air inJection pump adjusting bolt (ell) Air rO!flction manifold screws F·helld fouf-cylinder

V'

Ft-Ib.

Nm

30 to 40 30 to 40

40 to 54 40 to 54

20 20 20

27 27 51

29 to 35 25 to 30

•

40 to 47 34 to 40

In-line sill-cylinder

1972 through 1974 . 1975 through 1983 V8

15 20 38

20 52

13 13

17 17

27

EuR valve ISO cu In foul-cylinder and In-line six-cylinder ...

VB

. . . . . . . . . . .•.••.••...

151 cu In four-cylinder Ollygen sensor 150 cu In four-cylinder and in-line sill-cylinder ..... 151 cu in lour cylinder .•.. , ..•

1

•

9

31

'2

20 to 25

27 to 34

General Information

To prevent pollution of the atmosphere, a number of emissions con· trol systems Ille installed on these models . The combination of sYltems used depends on the year in which the vehicle was manufactured, the locale to which it was originally delivered and the engine type. The svstems end enpine combi nations Include: Positive Crank~se Ventilation (PCV) system - all engines except pre-1960 models Fuel Evaporattve Control System (ECS) - all engines except pre-1960 models Exhaust Gas RecIrCulation (EGR) system - all engines except pre-l960 models AIr l"Iection (AJ) system - all engines except early models Spark control system - all later in-line six-cylinder, VB and lour-cylinder engines Thermo-controlJed Air Cleaner (rAC) - eillarer model engines Calalytic converter - most engines efter 1974 Feedback carburetor and oxygen sensor - 1980 through 1986 Callfomia mOdels

The Sections In this Chap ter Include general descriptions, checking procedures (where possibleland component replacement pr ocedures (where applicable) for each 01 the sySiems listed above. Before assuming that an emiSSions control system is malfunctioning, r..' .;:lk The fuel and Ignition systems carefully. In some casel, speciII tools and equipment, as welln specialized training, afe required to accurately diagnose the causes of a rough-running or dillicult·to·ltaft engina. II checking and servicing bacoma too difficult, or if a procedure is beyond tha scope o f the homa mechanic, consul t your dealer or a properly equipped shop. This does nOt necessarily mean, however. mit the emissions control systems are all particularly difficult to maintain and rapair. You can quickly and a,sily perform many checks and do most IiI not ail) of the regular maintenance at home with common tuneup and hand tools. Note: The most frequent clIUse o f emissIOns problems is simply a loose or broken vacuum hose or w iring connec tion. Therefore, e/ways check rhe hose and wiring connections first. Pay close anentian to the special preceUlJons outlined In this Chapt" Iparticularly those concerning the catalytiC converter, feedba ck ewburetor and oxygen sensorf. It should be noted that the illustrlltion. ot the various systems may nOt ellaetly match the system Installed on your particular vehicle Idue to changes made by the manufecturer during production or from year-to·yearL

6-1

Chapter 6 Emissions control systems 2 PositivI Crinkclsi Ventilation (PCV] system

General description 1 This system is designed to reduce hydrocarbon (He] emissions by routing blow-by gases (fuellair miXUJre that escapes from the combustion chamber past the piston rings into the crankcase) from the crankcase to the intake manifold and combustion chamber where they ere burned during engine operation. 2 The system is very simple and consists of rubber hoses and a small replaceable metering valve (pCV velve). Refer to Chapter 1 for illustrations of the PCV valve location.

Checking and component replacement 3 Rough idling is the most common symptom of a defective PCV valve. 4 Remove the valve and inspect it for a build-up of oil sludge.. Shake the valve to see if it rattles, which is an indication that it is not sludged up (photoL If there is a sludge build-up. clean the valve with solvent and blowout the hose with compressed air. 5 With the valve installed and the engine running, pinch off the hose and see if the idle speed drops about 50 rpm. If it does not. replace the valve with a new one. 6 Replacement of the PCV valve is described in Chapter 1.

3 Evaporative Control Sy8tem IECS)

General description 1 This system is designed to trap and store fuel that evaporates from the carbu retor and fuel tank which would normally enter the atmosphere and contribute to hydrocarbon (HCI emissions. ., 2 The system is quite simple and consists of a charcoal-filled canister and (depending on the model and yearl a purge valve. a manifold vacuum purge line, a carburetor vacuum line. a liquid check valve in the fuel line and a relief valve In the fuel tank filler cep. 3 On the earlier versions of this system there are only two hose connections to the canister; one connected to the fuel tank vapor line and tha other to the air cleaner. The fuel vapors are drawn from the canister to the air cleaner and into the engine by the vacuum developed by the air passing over the canister hose tube located in the snorkel. On later models, when the engine is off and a high-pressure condition begins to build in the fuel tank Icaused bv fuel evaporationL thll charcoal in

2.4

The PCV valve should rattle when shaken beck-and-fortrl

the canister absorbs the fuel vapor. On some models, the vapor from the carburetor also enters the canister. When the engine is started cold, the charcoal continues to absorb and store fuel vapors. As the engine warms up, the stored fuel vapors are routed to the intake manifold where they are inducted and burned during normal engine operation. As the engine vacuum increases, the secondary purge circuit opens so the vapors are purged at a higher rate. A liquid check valve incorporating a float and needle valve allows the free passage of vapors (but not liquid fuel) between the fuel tank and canister. The fuel tank filler cap features a calibrated two-way relief valve which allows outside air to enter the fuel tank and relieve the high vacuum.

Checking 4 Checking the canister, replacing the filter pad and inspecting the lines and hoses are routine maintenance procedures, Refer to Chapter 1 for details. 5 If liquid fuel is found in the canister, replace the check valve with a new one. 6 To check the filler cap and relief valve. remove the cap and inspect

CAIIBUIIETOII

8OW' ,,~

AIR CLEAIliER SIIIORKEL HOSE-TO·FUEL VAPOR STORAGE CAIliISfER

VACUUM

FlLTEII

SIGNAL

Fig. 6.2 Fig. 6,1

Early model ECS system component locetion end layout (Sec 3]

Typical later model ECS system component layout (SI(: 3)

6

6-2

Chapter 6 Emission control systems

the cap and filler neck for luel stains, indicating luel leakage. 7 lDok for 8 damaged Of deformed gasket and make SUfe the felief va lve Is nOI stuck. If tha gasket end valve are not In good condition, replace the cap with 8 new one.

4 Catalytic convener

General description 1 The catalytic COffl'8fter is designed to reduce hydrocarbon !HC'and carbon monoxide (CO) pollutants in the exhaust. The converter oxidize. Ihese components ,nd converts them to water end carbon dioxide. 2 The converter is located in Ihe ...haust system and closely resembles II muffler. Two types 01 converters are used; II conventional

Component replscement e Repl8'Cement Ind maintenence of the chercoel cenister, filter ped and lines Ire covered In Chapter 1. 9 Replacement of the ~quid check valve is very streight forward alnea II only Involves disconnecting the hoses and clemps from the fautty part, unbolting Jt and Installing the new ona. Mark the hose connec· tiona before removal to avoid milcing them up.

oxidizing catalyst (CDC) 80d 8 three-way ca talyst (TWCI. The coe converter controls the He end CO pollutants when the exhaust gas II forced over the trllated pellets and is sometimes celled B two-way cltaly81

TOC14 ... RCO ... L C.t.NISTlII

"

'ull OUTlET LI .. E TO

a"'UGE

LIOUIO CH(CIt V... LVE /

r-.J('~~~~'" l"~'

ROLLOVER CHECIt V ... LVE

FUEL T ..... 1t .~.

Vf"T LINts

Fig. 6.3

ECS system fuel vapot control component IIYOut (Sec 31

HANGER _ _ _ _ SUPPORT , ~ _ -

••

~

III ... CIt£T HANGEII

•

,•• u~ro.

~

\:i.t

IIIIACIt£T

,

CATALYTIC CONV(IITlII EXHAUST

""

o

~ Fig. 6 .4

MUfFLER

, CONVEIlTEII AIIIINJECTIOI
•

;¢. /'