Plymouth Pl2 Manuals

Manuals and User Guides for Plymouth Pl2. We have 1 Plymouth Pl2 manual available for free PDF download: Service Manual

Plymouth Pl2 Service Manual

Plymouth Pl2 Service Manual (220 pages)

PASSENGER CARS

Brand: Plymouth | Category: Automobile | Size: 11.91 MB

Table of Contents

Table of Contents
4
Fof1Eword
9
General Data and Specifications
13
Car Serial Numbers and Engine Numbers
14
Car :Serial Numbers and Engine Numbers
14
- Maintenance
  15
- Importance of Lubrication and Maintenance
  15
- Engine Oil Recommendations
  15
- Checking the Engine Oil Level
  16
- When to Change Engine Oil
  16
- Cleaning of Carburetor Air Cleaner
  16
- Lubrication of Transmission
  16
- Lubrication of Rear Axle
  17
- Lubrication of Front Wheel
  17
- Lubrication of Steering Gear
  22
- Lubrication of Water Pump
  22
- Lubrication of Universal Joints
  22
- Chassis Lubricant Fittings
  22
- Lubrication of Starter
  22
- Lubrication of Generator
  23
- Lubrication of Distributor
  23
- Lubrication of Hand Brake Linkage
  23
- Lubrication of Pedals and Linkage (Brake and Clutch)
  23
- Lubrication of Springs with Metal Covers
  23
- Lubrication of Powermatic Shift
  24
- Cleaning and Lubricating Power Cylinder in Air Cleaner
  24
- Cleaning and Oiling Crankcase Oil Filler Pipe Air Cleaner
  25
- Replacement of Oil Filter
  25
- Maintenance of Rubber Parts
  25
- Maintenance of Oilite Bearings
  25
- 6. Servicing Batteries
  26
- Recommended Tire Pressures
  26
  - Engine will Not Turn
    27
  - Engine Turns but will Not Start
    27
  - Engine Does Not Develop Normal Power
    28
  - Eng~Ne Ru?S Unevenly
    29
  - Engme Notses
    29
  - Low or no Oil Pressure
    30
  - Excessive Oil Consumption
    30
  - Excessive Fuel Consumption
    30
  - Engine Overheats
    30
- Improper Generator Charging Rate
  31
- Lights
  31
- Improper Clutch Operation
  31
- Difficult Gear Shifting
  32
- Noise or Play in Drive Line
  32
- Noisy Rear Axle
  32
- Brakes
  32
- Steering
  33
  - Data and Specifications
    34
Front Axle
35
- Front Wheel Alignment
  35
- Checking King Pin Inclination
  35
- Checking Camber
  36
- Checking Caster Angle
  37
- Adjusting Camber and Caster
  38
- Measuring Toe-In
  39
- Adjusting Toe-In
  39
- Measuring Toe-Out on Tw·ns
  40
- Location of Pitman Arm for Proper Toe-Out on Turns
  40
Removal of Steering Knuckles and Bushings
41
- And Bushings
  41
Removal of Upper Control Arm
42
Installation of Upper Control Arm
42
Installation of Upper Control Arm Bushings
42
Removal of Lower Control Arm and Front Spring
42
Installation of Lower Control Arrri and Front Spring
43
Removal of Tie Rods
43
Installation of Tie Rods
43
Rear Axle
53
Removal of Rear Axle Housing
58
Installation of Rear Axle Housing
58
- Removal of Rear Axle Assembly
  58
Installation of Rear Axle Assembly
58
Section V-Body
59
Replacement of Window Lift Regulator
63
Removal of Front Door Latch and Remote Control
67
Removal of Rear Door Glass
67
- Removal of Rear Door Window Regulator
  68
Removal of Rear Door Latch and
68
Replacement of Rear Quarter Window
68
- Replacement of Ventilator Window (Rear Side Quarter)
  69
Replacement of Rear Window
69
- Glass
  69
Removal of Seat Back Cushion
70
- Adjustment of Front Seat Guide
  70
Installation of Windshield Glass
72
- Adjustment of Hood Striker Plate and Lock
  74
Adjustment of Hood Lock Control Cable
75
Brakes
81
- Bleeding Brake System
  81
  - Removal of Brake Shoes
    82
  - Installation of Brake Shoes
    82
- Replacement of Brake Lining
  82
- Removal of Wheel Cylinder
  82
- Installation of Wheel Cylinder
  83
Assembly of Master Cylinder
85
Adjusting Hand Brake
87
Replacement of Hand Brake
87
Replacement of Hand Brake Lining
87
Clutch
89
- Description
  89
  - Adjustment of Clutch Pedal Free Play
    89
- Adjustment of Over-Center Spring
  89
- Replacement of Over~Center
  89
  - Data and Specifications
    90
- Removal of Clutch
  93
- Installation of Dutch
  93
- Disassembly of Clutch
  93
- Assembly of Clutch
  94
- Adjustment of Clutch Release Levers with Fixture
  94
  - Clutch Fixture Spacers and Feeler Gauges
    95
    
    Fixture
    95
Cooling System
97
Section VIII-Cooling System
97
- Adjustment of Fan Belt
  97
- Replacement of Fan Belt
  97
  - Replacement of Engine Water Thermostat
    97
  - Replacement of Water Distributor Tube
    97
- Replacement of Water Pump
  97
  - Data and Specifications
    98
- Disassembly of Water Pump
  100
- Assembly of Water Pump
  100
- Water Temperature Indicator
  101
- Removal of Radiator Core
  102
  - Removal and Installation of Radiator and Fender Unit
    102
Engine
103
Section IX-Engine
103
- Data and Specifications
  103
- Description
  105
- Engine Tests and Adjustments
  105
  - Engine Tune-Up Chart
    106
Engine Tune-Up
107
- Cy Iinder Head Installation
  109
- Replacement of Valves and
  109
  - Adjustment of Valve Tappet Clearance
    111
  - Reconditioning of Exhaust Valve Seat Inserts
    112
- Replacement of Exhaust Valve Seat Inserts
  112
- Replacement of Valve Stem
  112
  - Removed)
    112
Replacement of Valve Tappets
112
Checldng Valve Timing
112
Replacement of Timing Gear Case Cover and Oil Seal
112
Replacement of Timing Chain and Sprockets
113
Replacement of Camshaft
113
- Replacement of Camshaft
  114
  - Bearings
    114
- Replacement of Connecting Rod and Piston Assembly
  114
- Reconditioning of Cylinder Walls
  114
- Fitting Pistons
  114
- Replacement of Piston Rings
  115
- Replacement of Piston Pins (Pistons Removed)
  116
- Replacement of Connecting Rod Bearings
  116
- Replacement of Crankshaft (Main) Bearings
  117
- Checking Crankshaft End Play
  117
- Installation of Crankshaft Bearing Oil Seals
  118
- Replacement of Flywheel
  118
- Engine Oiling System
  118
- Removal and Installation of Oil Pan and Strainer
  118
- Removal and Installation of Oil Pump
  119
Section X-Exhaust System
120
Section XI-Frame
121
- Frame Alignment
  121
  - Frame Alignment Diagrams
    123
Fuel System
127
Section XII--Fuel System
127
- Description of Carburetor
  127
- Disassembly of Carburetor
  127
- Assembly of Carburetor
  127
- Adjusting Idle Speed of Carburetor
  127
- Accelerating Pump Setting
  127
- Replacement of Main Metering Jet
  127
- Adjustment of Carburetor Float Level
  127
  - Data and Specifications
    128
  - Cleaning Carburetor Air Cleaner
    129
  - Description of Fuel Pump
    129
- Disassembly of Fuel Pump
  129
- Assembly of Fuel Pump
  129
- Testing Fuel Gauge
  132
  - (Dash Unit)
    132
  - Data and Specifications
    134
  - Description
    135
  - Disassembly of Generator
    135
  - Removal of Field Coils
    138
  - Installation of Field Coils
    138
  - Assembly of Generator
    138
Generator
139
- Testing Generator on Test Stand
  139
- Testing Generator on Engine
  140
Generator Regulator
141
Section XIV-Generator Regulator
141
- Regulator (1940-42)
  141
- Data and Specifications
  142
- Testing and Adjusting Generator
  143
- Testing and Adjusting Cut-Out Relay ( 1936-39)
  144
- Testing and Adjusting Circuit
  144
  - Breaker and Voltage Regulator
    144
- Description
  145
- Disassembly of Distributor
  145
  - Data and Specifications
    146
Ignition System
147
- Assembly of Distributor
  147
- Spark Plugs
  149
  - Data and Specifications
    150
Section XVI-Lighting and Wiring
151
- Description of Lights
  151
- Aiming of Headlights
  151
- Replacement of Light Bulbs
  153
- Description of Wiring
  155
  - Wiring Diagrams
    156
Starting Motor
167
Section XVII-Starting Motor
167
- Data and Specifications
  167
- Description
  167
- Replacement of Starting Motor Brushes
  167
- Disassembly of Starting Motor
  167
- Replacement of Starting Motor Field Coils
  169
- Assembly of Starting Motor
  170
- Testing Starting Motor
  171
  - Data and Specifications
    173
- Description
  173
- Testing Shock Absorber Operation
  173
Shock Absorbers
174
- Refilling Shock Absorbers
  174
- Disassembly of Shock Absorbers
  174
- Assembly of Shock Absorbers
  175
- Installation of Shock Absorbers
  177
Springs
179
Section XIX-Springs
179
- Front Spring Height
  179
- Installation of Front Spring
  179
- Adjustment of Front Spring Shackles
  179
- Inst~Ll~Tion of Steering Shock Ehmmator
  179
- Installation of Rear Spring
  179
  - Data and Specifications
    180
    
    Shackles
    180
- Adjustment of Rear Spring Bolts
  181
- Spring Clip Maintenance
  181
Section XX-Steering Gear
182
- Description
  182
- Adjustment of Worm Bearings
  182
- Adjustment of Roller Tooth and Worm
  182
- Removal of Horn Button ( Wi1Th Blowing Ring)
  183
- Removal of Horn Button (Without Blowing Ring)
  183
- Removal of Steering Wheel
  185
- Disassembly of Gearshift Control
  185
- Removal of Steering Gear
  186
- Installation of Steering Gear
  191
Alignment of Steering Gear in Frame
192
Alignment of Steering and Front Wheels
192
Disassembly of Steering Gear
193
Assembly of Steering Gear
193
- Data and Specifications
  194
- Description
  195
- Replacement of Transmission
  195
Transmission
197
Adjustment of Gearshift Control Rod (Manual Shift)
206
Adjustment of Gear Selector Rod (Manual Shift)
207
Adjustment of Powermatic Shift. 205 13. Lubricating Powermatic Shift
207
Cleaning Power Cylinder Air Cleaner
209
- Propeller Shaft
  210
- Description
  210
- Replacement of Universal Joint (Ball and Trunnion)
  210
- Replacement of Universal Joint Boot (Ball and Trunnion)
  210
  - (Cross and Roller Type)
    213
  - Data and Specifications
    214
Wheels and Tires
215
Section XXIII-Wheels and Tires
215
- Adjustment of Front Wheel Bea:rings
  215
- Adjustment of Rear Wheel Bearings
  215
- Installation of Front Wheel Bearings
  215
- Removal of Tires
  215
- Installation of Tires
  216
- Rotation of Tires
  216

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