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Engine
M440
Service manual
Chrysler M440 Service Manual
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Contents
Identification
Service Bulletins
Data and Specifications
Operation
Preparation of New Engine for Operation
Pre-Starting Inspections
Starting and Stopping the Engine
Operating Precautions
Breaking in a New or Rebuilt Engine
Stopping the Engine
Warm-Up Period
Engine Data and Specifications
Rotation
Firing Order
Camshaft
Timing Chain
Cooling System Description
Proper Belt Tension
Raw Water Pumps
Removal of Water Pump
Removal of Impellers
Installation of Impellers
Installation on the Engine
Raw Water Cooling System Diagram
Fresh Water Cooling System Diagram
Fresh Water System
Servicing the Fresh Water Pump
Pump Disassembly
Assembly of the Pump
Selection of Lubricant
Materials Added to Engine Oils
Break-In Period
Full-Flow Oil Filter
Distributor
Flame Arrestors
Close Crankcase Ventilation System
Lubrication & Maintenance Schedule
Checking Operation of Exhaust Valve Rotators
Rocker Arms and Shaft Assembly
Cylinder Heads
Rocker Arm Assemblies
Rocker Arm Lubrication Holes
Valves and Valve Springs
Cylinder Head Tightening Sequence
Push Rods Installed
Valve Inspection
Refacing Valves and Valve Seats
Compressing Valve Spring
Installing Valve and Tool C-3973
Measuring Valve Guide Wear
Testing the Valve Springs
Intake and Exhaust Valve
Measuring Valve Stem Length
Hydraulic Tappets
Preliminary to Checking the Hydraulic Tappets
Oil Level too High
Oil Level too Low
Tappet Noise Diagnosis
Tappet Removal
Valve Timing
Installation of Oil Seal
Removing Vibration Damper Assembly
Removing Snap Ring
Installing Vibration Damper Assembly
Measuring Timing Chain Stretch
Alignment of Timing Marks
Camshaft Bearings
Camshaft and Sprocket Assembly
Removing Camshaft Bearings
Distributor Drive Shaft Bushing
Distributor Timing
Installation of Distributor
Piston Removal
Cylinder Bore Inspection
Holing Cylinder Bores
Pistons
Finished Pistons
Fitting Pistons
Fitting Rings
Piston Pin Removal
Measuring Piston Ring Clearance
Tool Arrangement for Removing Piston Pin
Removing Piston Pin
Connecting Rods
Installing Piston and Connecting Rod Assembly
Installation of Connecting Rod Bearings
Crankshaft Main Journals
Crankshaft Main Bearings
Measuring Main Bearing Clearance
Rear Main Bearing Oil Seal
Shim Stock Method
Upper Rear Main Seal Installation
Engine Oiling System
Oil Pump
Lower Rear Main Seal Installation
Side Seals Installation
Oil Filter Replacement
Servicing Oil Pressure Relief Valve
Measuring Outer Rotor Clearance
Measuring Clearance over Rotor
Carburetor & Fuel Pump Specifications
AFB Series Carter Carburetor
Disassembling the Air Horn
Main Body Disassembly
Removing or Installing Step-Up Pistons and Rods
Removing or Installing Accelerator Pump Jet Housing
Removing or Installing Main Metering Jets
Removing or Installing Primary Venturi Cluster
Removing or Installing Secondary Venturi Cluster
Ports in Relation to Throttle Valves
Accelerator Pump Test
Throttle Valve Identification
Assembling the Air Horn
Float Alignment Setting
Checking Float Alignment
Float Level Setting
Float Drop Setting
Checking Float Height
Checking Float Drop
Fast Idle Speed and Cam Position Adjustment
Accelerator Pump Adjustment
Secondary Throttle Lever Adjustment
Secondary Throttle Lock out Adjustment
Idle Speed Adjustment
Fast Idle Speed Adjustment
Fuel Pump
Fuel Filter
Testing Fuel Pump
Disassembling the Fuel Pump
Cleaning the Fuel Pump Parts
Reassembling the Fuel Pump
Carburetor
Poor Acceleration
Engine Backfires
Fuel Pump Noise
Fuel Pump Leaks
Electrical System Data and Specifications
Alternator Data and Specifications
Alternator Voltage Regulator Data and Specifications
Battery Visual Inspection
Battery Specific Gravity Test
Adjustment of Acid Gravity
Voltage Tests
High Plate Discharge Test of Battery Capacity
Test Procedure
Charging the Battery
Fast Charging the Battery
Starting Motor
Testing Starter Current Resistance and Current Draw
Starter Ground Circuit Test
Brush and Spring Replacement
Testing the Armature
Removing the Starting Motor
Testing the Starting Motor
Testing the Field Coils for Ground
Field Coil Replacement
Testing Armature for Ground
Testing Commutator Runout, Refacing and Undercutting
Bushing Replacement
Starting Motor Assembly
Alternator and Voltage Regulator
Construction and Operation
Rotor
Stator
Alternator Assembly
Rectifiers
Alternator Disassembled View
Alternator Rotor Assembly
End Housings
Pulley
Stator and End Shield Separated to Exposure the X Connector
Voltage Regulator
Wiring Diagram
Regulator Operation
Voltage Regulator Fusible Wires
Voltage Regulator Resistance Units
Service Procedures Testing the Alternator System
Field Circuit Resistance Test
Charging Circuit Resistance Test
Current Output Test
Voltage Regulator Test - Engine at Normal Operating Temperature
Regulator Mechanical Adjustments
Upper Contact Voltage Test
Lower Contact Voltage Test
Upper Contact Setting
Alternator Removal
Alternator Bench Test - Field Coil Draw
Testing Air Gap
Testing Alternator Internal Field Circuit for Ground
Removing or Installing Brush Terminal Cover
Removing or Installing Sealing Washers
Removing or Installing Brushes
Testing the Rectifiers with Tool C-3829
Positive Case Rectifier Test
Negative Case Rectifier Test
Testing the Rectifiers and Stator
Testing Stator for Grounds
Testing Stator Windings for Continuity
Removing a Rectifier
Removing Pulley
Disengaging Bearing Retainer from the End Shield
Removing Drive End Bearing from Rotor Shaft
Replacing Slip Rings
Removing or Installing Heat Sink Insulator
Removing Rectifier End Shield Bearing
Unsoldering Positive Lead at Slip Ring
Cutting Slip Rings for Removal
Rotor-Slip Rings Removed
Unsoldering Negative Lead at Slip Ring
Pressing Slip Rings on Rotor Sleeve
Ignition System
Installing Alternator
Testing with Secondary Circuit
Distributor Resistance Test
Distributor Point Dwell
Dwell Variation
Ignition Timing
Idle RPM Test
Distributor Removal
Shaft and Bushing Wear Test
Disassembly of the Distributor
Removing or Installing Cam Felt Wick
Assembling the Distributor
Installing Distributor Housing Upper Bushing
Installing Distributor Housing Lower Bushing
Burnishing Distributor Housing Bushings
Distributor Lubrication
Testing Distributor Advance
Testing Breaker Arm Spring Tension
Installing and Aligning Contact Points
Spark Plugs
Ignition Coil
Starter Fails to Operate
Starting Turns but Pinion Does Not Engage
Starter Fails and Lights DIM
Low, Unsteady Charging Rate
Low Output and a Low Battery
Burned or Pitted Distributor Points
Regulator Contacts Burned
Condenser Failure
Fouled Spark Plugs
Burned Spark Plugs
Hydraulic Transmission
Parts List
Transmission Hydraulic Circuit Diagram
External Views of ASII-72C
External Views of ASI-72
Transmission Oil Cooler
Control Lever Position
Front Pump Mounting
Lubrication Recommendations
Procedure for Filling Transmission with Oil
Procedure for Checking Oil Level
Oil Pressures
Transmission Operation
Neutral
Reverse
Shifting
Disassembly of Transmission
Oil Draining Procedure
Disassembly of Valve and Spring Assembly from Transmission
Removal of Front Pump Assembly
Disassembly of Drive Gear and Clutch Assembly
Disassembly of Forward Clutch
Removal of Rear Bearing
Assembly of Transmission
Assembling Oil Seal in Bearing Retainer
Installation of the Baffle in the Transmission Coil
Assembly of the Forward Clutch into the Ring Gear
Assembly of Forward Clutch Hub and Sealing Rungs on Drive Gear
Assembling Drive Gear and Clutch Assembly
Installation of Drive Gear and Clutch Assembly, Reverse Clutch
Plate, and Reverse Clutch Pressure Plate in Transmission Case
Installing Drive Gear and Clutch Assembly
Installation of Twelve Pressure Plate Springs and Three Dowel Pins
Installing Reverse Clutch Plates
Assembly of Reverse Clutch Piston into Adapter
Installing Thrust Washer and Reverse Clutch Pressure Plate
Assembling Sealing Ring
Assembly of Adapter and Reverse Clutch Piston Onto Transmission Case
Installing Reverse Clutch Piston in Adapter
Assembling Adapter and Reverse Clutch Assembly Onto Case
Mounting Adapter to Case
Assembly of Front Pump
Front Pump Parts for Assembly
Installing Pump Oil Seal
Pressing Pump Oil Sea into Housing
Mounting Front Pump on Transmission
Installing Pump Driven Gear
Installing Pump Drive Gear Key and Front Pump Gasket
Installing Pump over Seal Protector
Assembling Valve and Springs Assembly
Mounting Front Pump to Adapter
Exploded View of Valve and Spring Assembly
Installation of Valve and Spring Assembly in the Transmission Cable
Control Valve Assembly in Fixture
Installation of Snap Ring
Installation of Valve and Spring Assembly
Assembly of Shift Lever
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Data and Specifications
2
Cooling System Description
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