Opel 1973 Service Manual Download | Manualshive

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1973 OPEL SERVICE MANUAL

ENGINE

CONTENTS

Subject

DESCRIPTION AND OPERATION:

Engine Construction

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

Lubrication System ............................................................

DIAGNOSIS:

Excessive Oil Consumption ............................................
Noisy Valves and Lifters ..................................................

MAINTENANCE AND ADJUSTMENTS:

Valve Lifter Adjustment

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

MAJOR REPAIR:

Engine Removal and Installation ..................................

Engine Oil Pan Removal

and Installation

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

Manifold, Cylinder Head, Valve Train and

Lifters

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

Connecting Rod Bearings ................................................
Crankshaft Bearings and Seals ....................................
Piston, Rings and Connecting Rods ............................

Timing Chain Cover and Timing Chain ......................

Camshaft

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

Oil Pump Cover and Gears ............................................

SPECIFICATIONS:

Bolt Torque

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

General Specifications ......................................................
Engine Dimension and Fits

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

Page No.

2
4

6
6

7

8

DESCRIPTION AND OPERATION

ENGINE CONSTRUCTION

Engine Usage

The 1.9 liter engine is standard equipment on all 1973
Opel

Manta and GT models. This engine has

a compression ratio of

and operates

“regular” low lead grade fuel.

Engine Construction

The

is made of high-grade chromium

grey cast iron. The valve guides are cast

with

the head. The overhead camshaft is supported in four
bearings in the cylinder head.

Location of the

seats in

combustion chamber

is above the center of cylinder bore. The spark plug
is positioned in the center and near the highest point
of combustion chamber. This arrangement provides
for short flame travel, uniform combustion and

good

cold start prop&ties.

Exhaust valves

have seat

in-

serts of highly heat and water resisting material. The
head surface is alumetized and so are the seats of the

Alumetizing makes the valve heads

non- scaling and promotes long life. All engines have

The forged,

main bearing crankshaft has large-

diameter main and connecting rod bearing journals
with considerable overlap for vibration-free operat-
ion.

bearing shells are used for main and

connecting rod bearings. The crankshaft end play is
controlled by the rear main bearing.

cardiagn.com

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Summary of Contents for 1973

Page 1: ...Engine Mechanical and Mounts All Models Cooling System All Models Fuel System All Models Exhaust Systems All Models Carburetor And Throttle Linkage Emission Control Systems All Models 6A 2 6B 32 6C 36 6D 42 6E 44 6F 60 Tune Up All Models __ 66 65 cardiagn com ...

Page 2: ...on ratio of 7 6 1 and operates on regular low lead grade fuel Engine Construction The cyfinderhead is made of high grade chromium grey cast iron The valve guides are cast intergal with the head The overhead camshaft is supported in four bearings in the cylinder head Location of the vzllve seats in combustion chamber is above the center of cylinder bore The spark plug is positioned in the center an...

Page 3: ... diameter of the four bearings and journals being slightly smaller than the preceding Camshaft end play is controlled at forward end by the camshaft front bearing seat outer face in one direction and by the front bearing cover in the other direction A nylon bolt in camshaft forward end serves to adjust end clearance The camshaft is driven by an endless Duplex roller chain The crankshaft double spr...

Page 4: ...elpump is located at bottom left hand side of timing case and operated by a cam integral with distributor drive gear riveted to distributor drive shaft The aluminum alloy cast intake manifold with smooth walls provide better charge of cylinders especially at high engine RPM It is a four port manifold i e there are separating walls between all arms one for each cylinder An adapter for crank case ve...

Page 5: ... through the screen and pumps it through drilled passages in timing case to the full flow filter From there it passes to the cylinder block main oil gallery with a branch in tim ing case to no 1 camshaft bearing Drilled passages lead from the oil gallery to crankshaft main bearings and in the crankshaft from main bearings to connect ing rod bearings The camshaft front journal has a crescent shaped...

Page 6: ...assembly to correct for oil consumption NOISY VALVES AND LIFTERS If the preceding check indicates valve mechanism is abnormally noisy remove the rocker arm cover so that the various conditions that cause noise may be The noise level of the valve mechanism cannot be checked A piece of heater hose of convenient length properly judged where the engine is below operating may be used to pick out the pa...

Page 7: ... push rod ends for scoring Check push wire to spark plug This determines which cylinder rods for bends valve lifters and camshaft surfaces is at upper top center on the firing stroke Adjust the for scoring Replace faulty parts hydraulic lifters of the two valves for that cylinder at this time When they are adjusted turn engine so MAINTENANCE AND ADJUSTMENTS that another cylinder is at upper top ce...

Page 8: ...se 4 Remove upper and lower radiator hoses 5 Remove radiator and fan shrbud 6 Disconnect heater hoses 7 Disconnect brake booster vacuum hose 8 Remove air cleaner 9 Disconnect electrical connections and accelerator linkage 10 Remove console 11 Remove shift lever boot plate and shift lever 12 Raise car on hoist 13 Disconnect fuel line at pump 14 Remove front stone shield 15 Disconnect speedo cable b...

Page 9: ...old to avoid inter ference during engine lowering 6 Remove throttle linkage and carburetor 7 Disconnect heater hoses 8 Disconnect water valve bracket to manifold 9 Remove gear shift lever 10 Using suitable equipment lift up engine so that front engine mounts are somewhat relieved Figure 6A 1 1 Radiator Hose Clamp Location 11 Raise vehicle both front and rear end A two post axle type hoist IS recom...

Page 10: ... Using suitable equipment raise assembly into vehi c l e 3 Install components as removed in steps 1 thru 21 ENGINE OIL PAN REMOVAL AND INSTALLATION Removal Opel 1900 and Manta To remove the engine oil pan a device similar to the one illustrated in Figure 6A 14 can be made and used to support the front of the engine This particular device was made up using hardwood bolts and chain 1 Assemble chains...

Page 11: ...nta 1 Apply a light bead of sealer to the clean sealing surfaces of the oil pan and affix a new gasket 2 Bolt oil pan and gasket assembly to engine block 3 Roll front suspension and floor jack under car and raise into position careful to pilot the cross member to frame rail attaching bolts and steering shaft to their respective locations 4 Install cross member support to frame attaching bolts and ...

Page 12: ...lts in the sequence illustrated in Figure 6A 16 Torque bolts to 33 lb ft Figure 6A 16 Manifold Bolt Tightening Sequence 4 Connect parts removed in Steps 1 thru 8 above CYLINDER HEAD REMOVAL AND INSTALLATION Removal 1 Drain coolant from radiator and block Loosen drain plug on right side of engine to avoid coolant entering into cylmder bores Drain plug is located on the right rear of cylinder block ...

Page 13: ... bolts a final torque in the same sequence Torque to 72 lb ft cylinder head cold Use same procedure for cylinder head to timing chain cover bolts with final torque at 17 lb ft See Figure 6A 20 These torques apply to lightly oiled threads Figure 6A 20 Cylinder Head Bolt Tightening sequence 7 Slide camshaft sprocket with assembled chain onto camshaft and guide pin and fasten with bolts Install nylon...

Page 14: ...vidences of poor seating If a valve head must be ground until the outer edge is sharp in order to true up the face discard the valve because the sharp edge will run too hot J 22917 1 0030 O S J 22917 2 0059 05 J 22917 3 Ol 18 OS Figure 6A 22 Reaming Valve Guide CORRESPONDING VALVE STEM DIA SIZE IN VALVE GUIDE PRODUCTION 3553 3562 3538 3543 3524 3528 PRODUCTION AND SERVICE 3582 3592 3567 3572 3553 ...

Page 15: ...ew valve seals whenever valves are reconditioned 9 Lube valves with engine oil and reinstall valves valve springs caps and cap retainers using J 8062 Install valve spring with closely wound coils toward cylinder head See Figure 6A 24 2 Attach vise grip pliers to stud being removed and remove from cylinder head 3 Screw in new stud Seat tapered part of stud by striking stud end with a rubber hammer ...

Page 16: ...ce a piece of the plastic type gauge material Figure 6A 25 Checking Bearing Cleatance With Plastic Type Gauge lengthwise along the bottom center of the lower bear ing shell Figure 6A 25 view A then install cap with shell and tighten nuts to 36 lb ft Do not turn crankshaft with gauge type material in bearing 3 Remove bearing cap with bearing shell the flat tened piece of gauge will be found adherin...

Page 17: ... clearance with a plastic type gauge 4 When checking a crankshaft bearing with plastic type gauging material turn crankshaft so that oil hole is up to avoid dripping of oil on the gauge material Place paper shims in lower halves of adja cent bearings and tighten cap bolts to take the weight of crankshaft off the lower shell of beating being checked 5 If bearing clearance exceeds C03 it is advisabl...

Page 18: ...veral times last movement fore with the thrust bearing cap bolts finger tight 16 After bearing is installed and tested loosen all bearing cap bolts l 2 turn and continue with other bearings When bearings have been installed and tested tighten all bearing cap bolts to 72 lb ft 17 Replace rear bearing oil seals 18 Install pipe and screen assembly and oil pan Installation of Rear Bearing Oil Seals En...

Page 19: ...roughness or ridges which indicate excessive wear Check cylinder bores for taper and out of round with an accurate cylinder gage at top middle and bottom ofbore both parallel and at right angles to the centerline of the engine The diameter of the cylinder bores at any point may be measured with an inside micrometer or by setting the cylinder gauge dial at 0 and measur ing across the gauge contact ...

Page 20: ...tons with micrometer contacting at points exactly 90 degrees to piston pin Figure 6A 32 then select the smallest piston for the first fitting The slight variation usually found between pistons in a set may provide for correction if the first piston has excessive clearance If wear of cylinder does not exceed 005 honing is recommended for truing the bore If wear or out of round exceeds these limits ...

Page 21: ...ston grooves and for gap in cylinder bores how ever the flexible oil rings are not checked for gap The cylinder bores and piston grooves must be clean dry and free of carbon and burrs To check the end gap of compression rings place the ring in the cylinder in which it will be used and square it in the bore by tapping with the lower end of a piston Measure the gap with feeler gages Piston ring end ...

Page 22: ...ston pin bores and piston pins must be free of varnish or scuffing when being measured The piston pin should be measured with a niicrometer and the piston pin bore should be measured with a dial bore gage or an inside micrometer If clearance is in excess of the 001 wear limit the piston and piston pin assembly should be replaced 1 Lubricate piston pin holes in piston and connect ing rod to facilit...

Page 23: ...ots in rear main bearing cap and engine front cover Then install rubber strips in grooves in rear main bearing cap and engine front cover Install oil pan torquing bolts to 5 lb ft 14 Install Opel 1900 and Manta front suspension assembly GT Install engine suspension cross mem ber After installation of new pistons and rings care should be used in starting the engine and in running it for the first h...

Page 24: ...per operation and reusability 6 Install timing case rubber gaskets to cylinder block Stick on with grease as necessary Gaskets will somewhat overlap with oil pan gasket 7 Position timing cover onto guide pin in upper left corner of cylinder block and insert centering bolt through timing chain cover into lower right corner of cylinder block See Figure 6A 40A No sealing is required SA 40 4 Figure 6A...

Page 25: ...ifter Place lifters in a suitable hold ing fixture so that they may be reinstalled in original position 7 Install belts and torque to proper tension 45 lb ft 4 Remove cover from access hole on left side and Figure 6A 42 Installing Timing Chain Cover Oil Seal Replacing Distributor Drive Gear On Crankshaft 1 Remove fan belt 2 Remove fuel pump Plug end of fuel line with a suitable stop 3 Remove spark...

Page 26: ...hing oil pump cover assembly to timing chain cover Remove cover assembly and slide out oil pump gears See Figure 6A 44 2 Wash off gears and inspect for wear scoring etc Replace any gears not found serviceable Discard pump covers scored by gear action If pump housing or distributor drive shaft bushing are worn this is only possible after a long service life the timing case together with all exchang...

Page 27: ...emove oil pan 2 Clean oil pan Make sure the gasket surfaces and pan and block are clean Figure 6A 47 Installation of Pipe and Screen Assembly 4 Clean the screen and housing thoroughly in sol vent and blow dry with air stream Installation of Oil Pump and Screen Assembly Install by reversing removal procedures paying par ticular attention to the following points 1 Make sure oil pump pipe flange gask...

Page 28: ...0 MM Head 30 Lb In Torque Lb Ft GENERAL SPECIFICATIONS Type No of Cylinders Valve Arrangement I nlinzai Bore and Stroke Piston Displacement Cu In 3 66 x1 Compression Ratio ô 7 6 1 Octane Requirement Firing Order Regular Lo Cylinder Block Material Cast Iron Crankshaft Bearings Number and Type 5 Removable Steel Backed In Metal Babbitts Bearing Which Takes End Thrust 5 Connecting Rod Bearing Material...

Page 29: ...roove _ 0013 OO24 In Oil Control Ring Side Clearance in Piston Groove __ __ _ 0013 X024 In Piston Ring Gap No 1 Compression Ring 014 022 In No 2 Compression Ring _ ___ __ 014 022 In Oil Control Ring ___ ___ _ 015 055 In Piston Pin in Connecting Rod ____ ___ _ __ Press Fit Intake Exhaust Valve Spring Pressure Valve Closed _______ ___ 1 57 In at 93 Lbs 1 36 In at 97 Lbs Valve Open 1 18 In at 182 Lbs...

Page 30: ...s Placed in V Blocks so That Main Bearing Journals Next to Each Other Are Supported 0005 In Max Permissible Runout of Crankshaft to Flywheel Contact Area 0008 In Crankshaft End Play GOl7 CO61 In Main Bearing Clearance ooO9 I25 In Connecting Rod Bearing Clearance ooO6 0025 In Connecting Rod End Play on Bearing Journal 0043 0095 In Connecting Rod Bearing Length 7785 7992 In Crankshaft Thrust Bearing...

Page 31: ...ENGINE MECHANICAL AND MOUNTS 6A 31 cardiagn com ...

Page 32: ...eater is in operation before engine has reached full operating temperature MAINTENANCE AND ADJUSTMENTS Checking and Filling Cooling System The coolant level should be checked only when the engine is cold and only enough coolant should be added to bring the level halfway between core and tank top It is unnecessary and undesirable to remove the radiator cap and check the coolant level each time the ...

Page 33: ...ing System Protector and Water Pump Lubricant or equivalent be added to the cool ing system as soon as possible If any other cooling System protector is used be certain it is labeled to indicate that it meets General Motors Specification GM 1894 M It should be recognized that this is only a temporary measure The manufacture intends that permanent type coolant solution be used year around in the co...

Page 34: ...r cap then remove lower radiator hose and drain radiator coolant into suitable con tainer 2 On vehicles with automatic transmission unscrew oil lines from connectors on lower radiator tank and plug lines On GT models with automatic transmis sion the lines have to be disconnected at the coupling before removing from the tank It is essential that no dirt enters the oil lines When unscrewing oil line...

Page 35: ...IES Cooling System Type Liquid Filler Cap Type Pressure _ _ __ _ _ Water Temperature Control Thermostat Open At __ __ _ __ Cooling System Capacity Fan Drive Cooling With Circulating Pump 13 2 15 2 PSI Thermostat and Bypass 189 F 6 Qts Water Pump Shaft cardiagn com ...

Page 36: ... eccentric the lighter diaphragm spring will push the diaphragm to replace any fuel used in the carburetor The diaphragm seldom operates through a full stroke under normal driving conditions the dia phragm moves only a few tenths of an inch Fuel pump pressure is determined by the compres sion of the diaphragm spring Low pressure or pres sure leak down generally indicates a leaky diaphragm or check...

Page 37: ...ng In this way the fuel vapors escaping to the outside during engine idle are collected by the activated carbon container and fed into the combustion chambers 5 The vent lines are connected to the upper part of the activated carbon container Fresh air enters through a foam rubber filter at the lower part and flows together with the fuel vapor to the carburetor Metered bores in the hose fittings of...

Page 38: ...ing a Strainer must be properly seated with projections facing upward b A new cap gasket must be positioned over strainer c Sealing ring must be in place on cap retaining screw 6 Reconnect fuel supply line Start engine and check for leaks EVAPORATION CONTROL SYSTEM Proper performance of the system requires the use of a non vented fuel tank cap hose connections be leak free and all hoses routed cor...

Page 39: ...off tiller cap and unscrew tiller neck from side panel Pull off fuel tank hose and plug connect ing tubes on tank See Figures 6C 4 and 6C 6 3 With a jack and suitable support wooden board 12 x 12 support fuel tank and unscrew strap Lower fuel tank See Figure 6C 7 Installation 1 Raise tank into position and install strap 2 Install 4 filler neck to side panel attaching screws and filler cap Figure K...

Page 40: ...ing brackets Spare tire hold down and support attaching brackets are attached to the rear wheel house panel and are Figure 6C 1 1 Tank Vent and Filler Hoses Figure 6C 9 Spare Tire Hold Down and Brackets G T FUEL SYSTEM Figure 612 10 Support Attachments Figure 6C 12 Exploded View of GT Gas Tank cardiagn com ...

Page 41: ...tic line place the line in hot water to make it flexible Using the old line as a pattern form the new line Let the line cool com pletely then route it in the same location as the old line To prevent chafing against the underbody nine 9 rubber grommets are placed at points on the line between the fuel tank and the fuel pump When re placing fuel gauge tank units coat gasket on both sides and first t...

Page 42: ...r damper rings for muffler and tail pipe hanger and replace as necessary 1 Coat I D of rear muffler inlet neck and O D of center exhaust pipe outlet rear of pipe with exhaust sealer compound several brands are currently avail able on the market 2 Insert center exhaust pipe into rear mufIler and tighten clamp 3 Coat I D of front muffler outlet neck and O D of center exhaust pipe inlet front of pipe...

Page 43: ...ST SYSTEM KEJ 1 2 3 4 5 6 7 DESCRIPTION MUFFLER FRT W CTR EXHAUST PIPE FRT EXHAUST MUFFLER RR W TAIL PIPE BUMPER MUFFLER SUSPENSION RR BOW MUFFLER SUSPENSION RR BRACKET MUFFLER SUSPENSION RR DAMPER RING MUFFLER SUSPENSION FRONT AND REAR 6D 5 Figure 6D 2 GT Exhaust System cardiagn com ...

Page 44: ...ani fold The secondary barrel does not have a choke valve or an accelerator pump See Figure 6E 2 The throttle valve of the primary barrel is opened through the throttle linkage When the primary throttle valve is almost open at approximately half of the maximum engine RPM the secondary throttle valve is opened by vacuum applied through a vacuum diaphragm case See Figure 6E 3 The sec ondary throttle...

Page 45: ...e valve spindle through a pull rod The vacuum which develops below the throttle valve takes effect on the diaphragm through a vacuum passage See Figure 6E 4 As soon as the engine starts this vacuum pulls the choke valve slightly open the amount of choke valve opening depends on the amount of vacuum which depends on the engine load Therefore with a light engine load the choke valve will open slight...

Page 46: ... line connecting tube 13 Carburetor cover gasket 14 Leaf spring 15 Float amber 16 Pressure reduction valve 17 Pump lever 18 Diaphragm 19 D iophragm spring 20 Ball valve suction valve 21 Float 22 Pump connecting rod 2 3 Metering iet 2 4 Emulsion tube 25 Bore without function 2 6 Throttle valve 2 7 Intermediate lever 28 Main venturl 29 Vacuum passage for automatic choke 30 Throttle valve body 31 Gas...

Page 47: ...tendency the fuel level drops in the emulsion tube bore and more emulsion tube transverse bores are exposed Air from the high speed air jet Figure 6E 2 enters the emulsion tube through these trans verse bores and mixes with the fuel The more the fuel level drops the more the transfer bores are ex posed This causes the air fuel ratio to remain con stant over the whole engine speed range See Figure ...

Page 48: ...is moved inward by the pump con necting rod and the pump lever Fuel is injected into the primary bore through the injector tube The amount of fuel is determined by the pump stroke The inlet ball valve in the pump chamber prevents fuel from flowing back into the float chamber during the pressure stroke of the pump The outlet ball valve prevents air from being drawn into the injector tube during the...

Page 49: ...et check ball 4 Defective accelerator pump pressure relief valve 5 Defective accelerator pump diaphragm 6 Maladjusted accelerator pump linkage Condition II Hard Start Afier Hot Soak Correction Perform Steps l 4 in Condition I Condition Ill Hard Start When Engine Is Cold Correction 1 Align groove on choke cover with pointer on choke housing See Figure 6E 17 2 Set fast idle 3 Replace distributor poi...

Page 50: ...through the system 4 Ad just idle mixture screw until highest R P M is obtained Alternately adjust idle mixture screw and air speed screw until R P M is obtained that is 50 R P M higher than the desired final setting This is to be accomplished with the idle mixture screw at best idle 5 Turn idle mixture screw clockwise lean until a decrease of 50 R P M is obtained The idle R P M will n ow be withi...

Page 51: ...ng Fast Idle Speed a Unhook accelerator pedal return spring b Remove lock spring at upper end of vertical con trol rod and detach rod c Lengthen or shorten control rod so that wide open throttle is obtained at the carburetor when ac celerator pedal is l 4 l 2 from floor mat d Reinstall rod lock spring and pedal return spring Opel 19W and Manta Series The carburetor bowden control wire is properly ...

Page 52: ...4 Disconnect throttle linkage by removing lock pin and unsnapping ball socket from ball on end of throt tle shaft 5 Remove carburetor by removing four nuts and lockwashers Install in reverse order noting the following 1 Prior to carburetor insta lation place a new gasket on intake manifold 2 Make certain that all nuts and screws on the car buretor are securely tightened 3 Make sure that choke hous...

Page 53: ...ol wire is kinked or damaged in any way it must be replaced 1 Feed ball and plastic bushing from engine com partment through opening in dash panel and hook in accelerator pedal lever See Figure 6E 19 2 Lightly pull wire core so that the plastic bushing slips into bore of accelerator pedal lever 3 Hook bowden control wire in segmental disc and attach control wire to bracket Figure 6E 19 Installing ...

Page 54: ...ng from float chamber 9 Pull accelerator pump discharge nozzle assembly Figure 6E 23 Removing Vacuum Case Reduction Jet out of carburetor housing Nozzle is press fitted See Figure 6E 24 GATORPUMP ISCHARGE NOZZLE Figure 6E 24 Removing Accelerator Pump Discharge 10 Remove primary idle jets and secondary idle plug Remove primary and secondary high speed air jets 11 Remove primary and secondary main m...

Page 55: ... See Figure 6B28 18 Install gasket and shield between automatic choke cover and automatic choke body Figure 6E 28 Installing Vacuum Case Assembly 19 Install automatic choke cover so that the catch of the b metal spring is positioned onto bent end of the intermediate lever See Figure 6B29 Figure 6G29 Installing Automatic Choke Cover 20 Align and tighten automatic choke cover Choke valve should be n...

Page 56: ...g to push plunger against lever so that a zero clearance exists Then retighten the screws See Figures 6E 3 1 and 6E 32 27 Insert accelerator pump discharge nozzle so that the bent tube end points into suction channel of the primary barrel 28 Fill the bowl with fuel 29 With fuel in bowl slowly open the throttle and observe the accelerator pump pressure relief valve exhaust ports and where it seats ...

Page 57: ...ed in casting 36 Install new air horn gasket so that the holes in the gasket coincide with the screw holes in carbu retor housing See Figure 6E 35 34 Install leaf spring so that spring ends rest on float spindle See Figure 6E 34 37 On vent valve pay attention to cotter pin position and arrangement of washers 3 5 Screw in float needle valve together with copper 38 Basic adjustment of idle mixture a...

Page 58: ...ng valve lever Figure 6E 35 Installing Cover Gasket SPECIFICATIONS GENERAL SPECIFICATIONS Compression Ratio 7 6 to 1 Fuel Required Low Lead Fuel Tank Capacity Gallons Opel 1900 and Manta 11 9 GT 13 2 Fuel Gauge Type Electrical Fuel Pump Type Mechanical Fuel Pump Drive Eccentric on Camshaft Fuel Pump Pressure at 1950 RPM 3 1 to 3 7 psi Fuel Filter In Line Filter Carburetor Make a n d Type I Solex 2...

Page 59: ...CARBURETOR AND THROTTLE LINKAGE 6E 59 Figure 6E 37 Carburetor Specifications cardiagn com ...

Page 60: ...ystem The purpose of this law is to keep the atmosphere cleaner particularly in popu lous areas where these impurities add to the smog problem Basically excessive exhaust emissions are caused by incomplete combustion of the air fuel mix ture in the cylinders The basic components of the OECS on the 1 9 liter engines are 1 leaned out carburetion 2 heated air except GT and 3 tuned spark timing 1 The ...

Page 61: ...t 135 degrees the door will close tight not allowing any more warm air from the mainifold to enter the snorkel of the air cleaner Obviously if underhood temperatures rise above 135 degrees the air cleaner will no longer be able to control tempera ture and the inlet air temperature will rise with un derhood temperature The temperature door is moved by a diaphragm type vacuum motor When there is no ...

Page 62: ...the intake manifold and in the vacuum motor to drop Whenever vacuum drops below 5 inches the diaphragm spring will close the air door in order to get the maxumum outside air flow required for max imum acceleration The carburetor is set by the manufacturer for 800 850 RPM automatic transmission or 850 900 RPM manual transmission and 1 5 to 2 5 percent CO Figure 6F 3 E G R System EXHAUST GAS RECIRCU...

Page 63: ...ver and in stall a temperature gage such as J 22973 as close as possible to se r Keinstall air cleaner cover Let car stand idle for l 2 hour or more before proceeding to step 2 2 Start the engine Air door should open immedi ately if engine is cool enough When air door starts to close in a few minutes remove air cleaner cover and read temperature gage It must read 115 degrees plus or minus 20 degre...

Page 64: ...ng Sensor Assembly so that you can install new sensor in same position Then remove sensor 4 Install sensor and gasket assembly in air cleaner in same position as noted in Step 3 This is to elemi ate the possibility of interference with the air filter element See Figure 6F 4 5 Install sensor retaining clip Meanwhile support ing sensor around the outside rim to prevent damage to the temperature sens...

Page 65: ... each engine compartment Economical trouble free operation can better be as sured if a complete tune up is performed at first 4 months or 6 ooO miles of operation then at 12 month or 12 000 mile intervals The parts or units which affect power and perform ance may be divided into three groups 1 compres sion 2 ignition and 3 carburetion The tune up procedure should cover these groups in the order gi...

Page 66: ...ding number See Figure 6G 2 EXAMPLE After checking the compression pressures in all cylinders it was found that the highest pressure obtained was 182 psi The lowest pressure reading was 145psi By locating 182 in the maximum col umn it is seen that the minimum allowable pressure r __ MAXIMUM PRESSURE POIJNW W INCH 1 3 4 1 3 6 1 3 8 140 1 4 2 146 148 1 5 0 1 5 2 154 1 5 6 158 160 lb2 1 6 4 166 168 1...

Page 67: ...ction should be made with engine operating at normal temperature cooling system completely filled temperature control lever fully open and nor mal pressure in the system Normal pressure should be 13 2 to 15 2 psi Engine Lubrication System Inspect engine for evidence of oil leakage Correct any abnormal condition with sealastic or new seals and gaskets Battery 1 Inspect battery battery mount and cab...

Page 68: ... of Vacuum Start Advance 5 at 2 9 4 1 In Maximum Advance 1 5 at 4 5 5 0 In Vacuum Retard Engine Degrees at Closed Throttle 5 Condenser Capacity in MicroFarads 23 32 Breaker Spring Tension in Ounces 14 to 19 Breaker Point Gap in Inches 016 Dwell Angle in Engine Degrees 50 3 Firing Order l 3 4 2 Spark Plug or Coil Cable Max Resistance in Ohms 10 000 Spark Plugs Make and Model Production AC42FS Make ...

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