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M440
Chrysler M440 User Manual
200 pages
Manual
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2
Table of Contents
Contents
3
Identification
5
Service Bulletins
5
Data and Specifications
5
Operation
6
Preparation of New Engine for Operation
6
Pre-Starting Inspections
6
Starting and Stopping the Engine
6
Operating Precautions
7
Breaking in a New or Rebuilt Engine
7
Stopping the Engine
7
Warm-Up Period
7
Engine Data and Specifications
8
Rotation
9
Firing Order
9
Camshaft
9
Timing Chain
9
Cooling System Description
13
Proper Belt Tension
13
Raw Water Pumps
14
Removal of Water Pump
14
Removal of Impellers
16
Installation of Impellers
16
Installation on the Engine
16
Raw Water Cooling System Diagram
17
Fresh Water Cooling System Diagram
17
Fresh Water System
18
Servicing the Fresh Water Pump
18
Pump Disassembly
19
Assembly of the Pump
19
Selection of Lubricant
21
Materials Added to Engine Oils
21
Break-In Period
21
Full-Flow Oil Filter
21
Distributor
22
Flame Arrestors
22
Close Crankcase Ventilation System
22
Lubrication & Maintenance Schedule
24
Checking Operation of Exhaust Valve Rotators
27
Rocker Arms and Shaft Assembly
27
Cylinder Heads
28
Rocker Arm Assemblies
28
Rocker Arm Lubrication Holes
28
Valves and Valve Springs
29
Cylinder Head Tightening Sequence
29
Push Rods Installed
29
Valve Inspection
29
Refacing Valves and Valve Seats
30
Compressing Valve Spring
30
Installing Valve and Tool C-3973
30
Measuring Valve Guide Wear
30
Testing the Valve Springs
31
Intake and Exhaust Valve
31
Measuring Valve Stem Length
31
Hydraulic Tappets
32
Preliminary to Checking the Hydraulic Tappets
32
Oil Level too High
32
Oil Level too Low
33
Tappet Noise Diagnosis
33
Tappet Removal
33
Valve Timing
34
Installation of Oil Seal
35
Removing Vibration Damper Assembly
35
Removing Snap Ring
35
Installing Vibration Damper Assembly
35
Measuring Timing Chain Stretch
36
Alignment of Timing Marks
36
Camshaft Bearings
37
Camshaft and Sprocket Assembly
37
Removing Camshaft Bearings
37
Distributor Drive Shaft Bushing
38
Distributor Timing
38
Installation of Distributor
38
Piston Removal
39
Cylinder Bore Inspection
39
Holing Cylinder Bores
39
Pistons
40
Finished Pistons
40
Fitting Pistons
40
Fitting Rings
40
Piston Pin Removal
41
Measuring Piston Ring Clearance
41
Tool Arrangement for Removing Piston Pin
41
Removing Piston Pin
41
Connecting Rods
42
Installing Piston and Connecting Rod Assembly
42
Installation of Connecting Rod Bearings
42
Crankshaft Main Journals
43
Crankshaft Main Bearings
43
Measuring Main Bearing Clearance
44
Rear Main Bearing Oil Seal
44
Shim Stock Method
44
Upper Rear Main Seal Installation
44
Engine Oiling System
45
Oil Pump
45
Lower Rear Main Seal Installation
45
Side Seals Installation
45
Oil Filter Replacement
47
Servicing Oil Pressure Relief Valve
47
Measuring Outer Rotor Clearance
47
Measuring Clearance over Rotor
47
Carburetor & Fuel Pump Specifications
48
AFB Series Carter Carburetor
49
Disassembling the Air Horn
49
Main Body Disassembly
50
Removing or Installing Step-Up Pistons and Rods
50
Removing or Installing Accelerator Pump Jet Housing
50
Removing or Installing Main Metering Jets
51
Removing or Installing Primary Venturi Cluster
51
Removing or Installing Secondary Venturi Cluster
51
Ports in Relation to Throttle Valves
51
Accelerator Pump Test
52
Throttle Valve Identification
52
Assembling the Air Horn
53
Float Alignment Setting
53
Checking Float Alignment
53
Float Level Setting
54
Float Drop Setting
54
Checking Float Height
54
Checking Float Drop
54
Fast Idle Speed and Cam Position Adjustment
55
Accelerator Pump Adjustment
55
Secondary Throttle Lever Adjustment
55
Secondary Throttle Lock out Adjustment
56
Idle Speed Adjustment
56
Fast Idle Speed Adjustment
56
Fuel Pump
58
Fuel Filter
58
Testing Fuel Pump
58
Disassembling the Fuel Pump
59
Cleaning the Fuel Pump Parts
59
Reassembling the Fuel Pump
59
Carburetor
60
Poor Acceleration
61
Engine Backfires
61
Fuel Pump Noise
61
Fuel Pump Leaks
61
Electrical System Data and Specifications
63
Alternator Data and Specifications
63
Alternator Voltage Regulator Data and Specifications
64
Battery Visual Inspection
66
Battery Specific Gravity Test
66
Adjustment of Acid Gravity
67
Voltage Tests
68
High Plate Discharge Test of Battery Capacity
68
Test Procedure
68
Charging the Battery
69
Fast Charging the Battery
70
Starting Motor
71
Testing Starter Current Resistance and Current Draw
71
Starter Ground Circuit Test
71
Brush and Spring Replacement
73
Testing the Armature
73
Removing the Starting Motor
73
Testing the Starting Motor
73
Testing the Field Coils for Ground
74
Field Coil Replacement
74
Testing Armature for Ground
74
Testing Commutator Runout, Refacing and Undercutting
74
Bushing Replacement
75
Starting Motor Assembly
75
Alternator and Voltage Regulator
76
Construction and Operation
76
Rotor
77
Stator
77
Alternator Assembly
77
Rectifiers
78
Alternator Disassembled View
78
Alternator Rotor Assembly
78
End Housings
79
Pulley
79
Stator and End Shield Separated to Exposure the X Connector
79
Voltage Regulator
80
Wiring Diagram
80
Regulator Operation
81
Voltage Regulator Fusible Wires
81
Voltage Regulator Resistance Units
81
Service Procedures Testing the Alternator System
82
Field Circuit Resistance Test
82
Charging Circuit Resistance Test
82
Current Output Test
84
Voltage Regulator Test - Engine at Normal Operating Temperature
84
Regulator Mechanical Adjustments
86
Upper Contact Voltage Test
86
Lower Contact Voltage Test
86
Upper Contact Setting
86
Alternator Removal
87
Alternator Bench Test - Field Coil Draw
87
Testing Air Gap
87
Testing Alternator Internal Field Circuit for Ground
88
Removing or Installing Brush Terminal Cover
88
Removing or Installing Sealing Washers
88
Removing or Installing Brushes
88
Testing the Rectifiers with Tool C-3829
89
Positive Case Rectifier Test
89
Negative Case Rectifier Test
90
Testing the Rectifiers and Stator
90
Testing Stator for Grounds
91
Testing Stator Windings for Continuity
91
Removing a Rectifier
92
Removing Pulley
92
Disengaging Bearing Retainer from the End Shield
92
Removing Drive End Bearing from Rotor Shaft
92
Replacing Slip Rings
93
Removing or Installing Heat Sink Insulator
93
Removing Rectifier End Shield Bearing
93
Unsoldering Positive Lead at Slip Ring
93
Cutting Slip Rings for Removal
94
Rotor-Slip Rings Removed
94
Unsoldering Negative Lead at Slip Ring
94
Pressing Slip Rings on Rotor Sleeve
94
Ignition System
97
Installing Alternator
97
Testing with Secondary Circuit
98
Distributor Resistance Test
98
Distributor Point Dwell
99
Dwell Variation
99
Ignition Timing
99
Idle RPM Test
99
Distributor Removal
100
Shaft and Bushing Wear Test
100
Disassembly of the Distributor
101
Removing or Installing Cam Felt Wick
101
Assembling the Distributor
102
Installing Distributor Housing Upper Bushing
102
Installing Distributor Housing Lower Bushing
102
Burnishing Distributor Housing Bushings
102
Distributor Lubrication
103
Testing Distributor Advance
103
Testing Breaker Arm Spring Tension
103
Installing and Aligning Contact Points
103
Spark Plugs
104
Ignition Coil
105
Starter Fails to Operate
105
Starting Turns but Pinion Does Not Engage
105
Starter Fails and Lights DIM
105
Low, Unsteady Charging Rate
106
Low Output and a Low Battery
106
Burned or Pitted Distributor Points
106
Regulator Contacts Burned
106
Condenser Failure
107
Fouled Spark Plugs
107
Burned Spark Plugs
107
Hydraulic Transmission
108
Parts List
115
Transmission Hydraulic Circuit Diagram
117
External Views of ASII-72C
118
External Views of ASI-72
118
Transmission Oil Cooler
119
Control Lever Position
119
Front Pump Mounting
119
Lubrication Recommendations
120
Procedure for Filling Transmission with Oil
120
Procedure for Checking Oil Level
120
Oil Pressures
120
Transmission Operation
121
Neutral
121
Reverse
121
Shifting
121
Disassembly of Transmission
122
Oil Draining Procedure
122
Disassembly of Valve and Spring Assembly from Transmission
122
Removal of Front Pump Assembly
122
Disassembly of Drive Gear and Clutch Assembly
123
Disassembly of Forward Clutch
123
Removal of Rear Bearing
124
Assembly of Transmission
125
Assembling Oil Seal in Bearing Retainer
125
Installation of the Baffle in the Transmission Coil
126
Assembly of the Forward Clutch into the Ring Gear
128
Assembly of Forward Clutch Hub and Sealing Rungs on Drive Gear
131
Assembling Drive Gear and Clutch Assembly
132
Installation of Drive Gear and Clutch Assembly, Reverse Clutch
133
Plate, and Reverse Clutch Pressure Plate in Transmission Case
133
Installing Drive Gear and Clutch Assembly
134
Installation of Twelve Pressure Plate Springs and Three Dowel Pins
134
Installing Reverse Clutch Plates
134
Assembly of Reverse Clutch Piston into Adapter
135
Installing Thrust Washer and Reverse Clutch Pressure Plate
135
Assembling Sealing Ring
135
Assembly of Adapter and Reverse Clutch Piston Onto Transmission Case
136
Installing Reverse Clutch Piston in Adapter
136
Assembling Adapter and Reverse Clutch Assembly Onto Case
136
Mounting Adapter to Case
136
Assembly of Front Pump
137
Front Pump Parts for Assembly
137
Installing Pump Oil Seal
137
Pressing Pump Oil Sea into Housing
137
Mounting Front Pump on Transmission
138
Installing Pump Driven Gear
138
Installing Pump Drive Gear Key and Front Pump Gasket
138
Installing Pump over Seal Protector
138
Assembling Valve and Springs Assembly
139
Mounting Front Pump to Adapter
139
Exploded View of Valve and Spring Assembly
139
Installation of Valve and Spring Assembly in the Transmission Cable
140
Control Valve Assembly in Fixture
140
Installation of Snap Ring
140
Installation of Valve and Spring Assembly
140
Assembly of Shift Lever
141
Installation of Oil Strainer Assembly and Oil Drain Plug
141
Assembly of Neutral Switch Kit
142
Installation of Breather Assembly
142
Installation of Miscellaneous Pipe Plugs
142
Installation of Dipstick Assembly
142
Extra Equipment
143
Assembly of Neutral Switch
143
Neutral Switch Cam in Correct Position
143
Neutral Switch Correctly Assembled
143
Special Information and Instructions
144
Installation of Oil Filler Cap and Dipstick Assembly
144
Installing Backing Plate
147
Elimination of Regulator Valve Buzz
148
Drive Gear and Plug Assemblies
149
Pinion Cage and Output Shaft Assembly
149
Forward and Reverse Gear Transmission Case and Bushing Assembly
149
Adapter Capscrews
149
Selection of Reverse Clutch Plates
150
Drive Gear & Plug Assembly
150
Planetary Service Kits
151
Oil Collector Ring Kit
151
Transmission Case Service Bushing Kit
151
Output Shaft Service Bushing Kit
151
Selection of Output Shaft Coupling
152
Cooler Return to Transmission
152
Troublshooting Chart
157
Torque Specifications
158
Reduction Gear Assembly
161
Forward and Reverse Section Parts List
165
Parts Display for Forward and Reverse Section
165
Reduction Unit Parts List
166
Oil Circulation Variations
167
New Oil Circulation System
167
Identification of Oil Circuit System
167
Part Differences in Reduction Unit Designs
167
Right Side View of Current Production Transmission
169
Right Side of Transmission
169
Left Side View of Current Transmission
169
Transmission Installation Precautions and Operation
170
Reduction Planetary Retaining Ring Service Kit
178
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Chrysler M440 Specifications
General
Engine Type
V8
Displacement
440 cu in (7.2 L)
Bore
4.32 in (109.7 mm)
Stroke
3.75 in (95.3 mm)
Torque
480 lb⋅ft (651 N⋅m) @ 3200 rpm
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