EXHAUST SYSTEM
Contents
1. GROUP 11 EXHAUST SYSTEM CONTENTS Page Page DESCRIPTION ieie 3 552 een d Rag EE Eeer 1 SERVICE PROCEDURES 1 SERVICE DIAGNOSIS 1 TIGHTENING REFERENCE In Rear of the Manual Description Long life aluminized and stainless steel muffler components are used on all models Mufflers on AC 1 AC 2 and AC 3 models are supported at the rear by double strap hangers L type hangers are used to support the tail pipes on all models Figs 1 2 3 and 4 Ball joint connections which allow more accurate alignment of the exhaust system are located in the exhaust pipes forward of the mufflers on all models Figs 1 2 3 and 4 The exhaust manifolds on all engines incorporate a thermostatic heat control valve to direct the ex haust gases to a heat chamber beneath the carburetor mounting flange to help vaporize the fuel The heat control valve is located in the right hand manifold Figs 6 and 7 SERVICE DIAGNOSIS Condition Possible Cause Correction EXHAUST SYSTEM EXCESSIVE EXHAUST a Leaks at the pipe joints a Tighten the clamps at the leaking joints NOISE b Burned or blown out muffler c Burned or rusted out exhaust pipe d Exhaust pipe leaking at the manifold flange e Exhaust manifold cracked or broken f Leak between the manifold and cylinder block LEAKING EXHAUST GASES a Leaks at the pipe joints c Restriction in muffler or tail pipe ENGINE HARD T2. O WARM UP OR WILL NOT RETURN TO NORMAL IDLE NOISE IN MANIFOLD a Thermostat broken b Weak or broken anti rattle spring D MANIFOLD HEAT CONTROL VALVE RATTLE a Thermostat broken b Damaged or improperly installed gaskets a Heat control valve frozen in the open position b Broken weak or missing anti rattle spring b Replace the muffler assembly c Replace the exhaust pipe d Install a new gasket and tighten the exhaust pipe flange nuts to specifications e Replace the manifold f Tighten the manifold to cylinder block nuts to specifications a Tighten the clamps at the leaking joints b Replace gaskets as necessary c Remove the restriction if possible or replace as necessary a Free up the manifold heat control valve sol vent number 1879318 a Replace the thermostat b Replace the spring a Replace the thermostat b Replace the spring SERVICE PROCEDURES EXHAUST PIPES MUFFLERS TAIL PIPES Removal 1 Raise the vehicle on a hoist and lubricate the clamp nuts and bolts with penetrating oil to loosen the rust and dirt 2 Remove the clamps from the exhaust pipes mufflers and tail pipes 11 2 EXHAUST SYSTEM e Va M K X F Lit AR STATION WAGON Se SSBALL JOINT oe 25 gt xi d s CLAMP VIEW IN CIRCLE A 1 lt 2 S NUT VIEW IN CIRCLE B NK947 Fig Exhaust System Single AC 1 AC 2 AC 3 STATION
3. WAGON SAME AS MAIN VIEW RS EXCEPT_AS_SHOWN N gt N T BOLT Be Deg CLAMP ZA K e EE B j N ly nee Ku Ion XT N gt Re 4 e es N C R MUFFLE A E P Ad WASHER DOUBLE HANGER VIEW IN CIRCLE B NK948 Fig 2 Exhaust System Dual AC 2 AC 3 EXHAUST SYSTEM 11 3 TORSION BAR BE POSITIONED TO PROVIDE MIN CLEARANCE AS SHOWN BY ARROWS BRACKET SUPPORT NK1092 TAIL PIPE BOLT NUT N P WASHER Kee HANGER NK1093 Fig 4 Exhaust System Dual AY 1 Convertible Models 11 4 EXHAUST SYSTEM 3 Disconnect the ball joints in the exhaust pipes 4 Disconnect the exhaust pipe at the exhaust manifolds and remove the exhaust pipe 5 Remove the muffler extension pipe and the tail pipe assembly NOTE If only the muffler is to be replaced cut the extension at the muffler with a hack saw It is un necessary to remove the exhaust pipe The replace ment muffler is installed using a clamp at the front of the muffler Installation 1 Connect the exhaust pipes to the manifolds us ing new gaskets Tighten the nuts to 40 foot pounds 2 Adjust the hanger heights for proper alignment 8 Tighten U bolt nuts to 100 inch pounds 4 Tighten support clamp screws to 95 inch pounds 5 Align system at ball joints and tighten flange bolts to 20 foot pounds The inner surfaces of the flanges should be parallel to each other and perpe
4. ad ends If this precaution is not taken water leaks may de velop at the studs 1 Place the exhaust manifolds on the studs on the cylinder heads and install the nuts Tighten to 30 foot pounds torque 2 Connect the exhaust pipes at the exhaust mani folds Tighten the nuts to 40 foot pounds torque 3 Install the alternator on the right cylinder head and adjust the belt tension 4 Connect the spark plug cables to the spark plugs Manifold Heat Control Valve Inspect the operation of the manifold heat control valve and apply Heat Control Valve Solvent Part No 1879318 to both ends of the valve shaft every six months With the engine idling accelerate the engine and release quickly The counterweight should respond by moving clockwise approximately 1 2 inch and return to its normal position Removal All Models 1 Loosen the counterweight clamp bolt Figs 6 and 7 and remove the counterweight lock and stop from the end of the shaft exposing the thermostat 2 Unhook the thermostat from the pin and re move by sliding out of the valve shaft slot 3 If the valve shaft is frozen in the manifold ap COUNTERWEIGHT BOLT BUMPER LR THERMOSTAT 28 m LOCK N SHAFT RETAINER SPRING 63 x 432 A Fig 6 Manifold Heat Control Valve Rear Outlet Manifold ply manifold heat control valve solvent Part No 1879318 and allow to stand several minutes Loosen by rotating the shaft back and forth un
5. ide Wrap the outer end of the thermostat counterclockwise and engage it under the stop pin Fig 8 3 Place the counterweight on the shaft with the shield in the upper position and insert the lock in the shaft slot 4 Center the counterweight on the shaft and turn the valve clockwise until the bumper passes the stop pin Fig 9 EXHAUST E a MANIFOLD COUNTERWEIGHT ASSEMBLY THERMOSTAT CLAMP BOLT e R 236 A Fig 9 Installing the Counterweight 11 6 EXHAUST SYSTEM 5 Press the counterweight on the shaft until it is seated Tighten clamp bolt to 50 inch pounds using Tool C 3380 Torque Wrench 6 Make sure the anti rattle spring on the opposite end of the shaft is in place Test operation of the valve MANIFOLD HEAT CONTROL VALVE REPLACEMENT Removal 1 Remove the alternator 2 Remove the exhaust pipe from the manifold 3 Remove the exhaust manifold from the engine 4 Remove the counterweight thermostat shaft clips and anti rattle spring 5 Cut the valve plate off of the shaft 6 Remove the shaft and press the bushings from the manifold Installation 1 Install the new bushings in the exhaust mani fold 2 Position the shaft into both bushings and check the shaft for freedom of turning Should the shaft fail to turn freely it will be necessary to hone the bush ings 3 Pull the shaft out far enough to position the valve plate on the shaft then slide shaft into position
6. in both bushings 4 Align the hole in the valve plate with the hole in the shaft and insert a drift into both holes to main tain correct positioning of the valve plate as it is be ing welded to the shaft 5 Remove the drift from the valve plate and shaft 6 Install the new anti rattle spring shaft clips thermostat and counterweight assembly on the shaft 7 Install the manifold on the engine assembly 8 Using a new gasket connect the exhaust pipe to the manifold 9 Install the alternator and adjust the belt tension 10 Start the engine and test the operation of the manifold heat control valve assembly Servicing Test the manifold heat control valve for proper op eration during engine tune up and apply Manifold Heat Control Valve Solvent Part No 1879318 to both ends of valve shaft
7. n dicular to the pipe axis 6 Adjust the converter housing bracket so that it is flat against the converter housing and in the proper contact with the pipe tab Tighten screw to 15 foot pounds INTAKE MANIFOLD NOTE Refer to the Engine Group 9 for removal and installation of the intake manifold With the manifold removed clean and inspect it as follows EXHAUST CROSSOVER PASSAGE WELL FOR AUTOMATIC CHOKE PRIMARY SECONDARY BORES BORES lt 4 3 5 EXHAUST CROSSOVER PASSAGE CARBURETOR NY 843 MOUNTING FLANGE Fig 5 Intake Manifold 1 Clean the manifold in solvent Blow dry with compressed air 2 Inspect the exhaust crossover passage and pres sure test for leakage into any of the intake passages Fig 5 3 Inspect the mating surfaces for parallelism 4 Use new gaskets when installing the manifold EXHAUST MANIFOLD Removal 1 Disconnect the spark plug cables from the spark plugs 2 Remove the alternator from the right cylinder head 8 Disconnect the exhaust pipes at the exhaust manifold flanges 4 Remove the nuts that hold the exhaust mani folds to the cylinder heads 5 Slide the manifolds off the studs and away from the cylinder heads 6 Clean the exhaust manifolds in solvent Blow dry with compressed air 7 Inspect the manifolds for cracks and distortion Installation NOTE If studs came out with the nuts install new studs applying sealer on the coarse thre
8. til the shaft turns easily Installation Rear Outlet Manifold 383 413 Cu In Engines 1 Position shaft in extreme counterclockwise po sition Fig 6 2 Place a new thermostat in the shaft slot with the outer end of the thermostat facing downward on the right side Wrap outer end of the thermostat clockwise and engage under the stop pin Fig 6 3 Place the counterweight on the shaft with the shield in the upper position and insert the lock in the shaft slot Fig 6 4 Center the counterweight on the shaft and turn the valve counterclockwise until the bumper passes the stop pin 5 Press the counterweight on the shaft until it is seated Tighten the clamp bolt to 50 inch pounds us ing Torque Wrench C 3380 EXHAUST MANIFOLD bh 4 at COUNTERWEIGHT THERMOSTAT ANTI RATTLE SPRING RETAINERS KR 234 B Fig 7 Manifold Heat Control Valve Center Outlet Manifold EXHAUST SYSTEM 11 5 EXHAUST MANIFOLD INSTALLED POSITION VALVE SHAFT FREE POSITION THERMOSTAT VALVE KR235 B Fig 8 Positioning the Thermostat 6 Make sure that the anti rattle spring on the op posite end of the shaft is in place Test operation of the valve Installation Center Outlet Manifold 383 413 Cu In Engine 1 Position shaft in extreme counterclockwise po sition Fig 7 2 Place a new thermostat in the shaft slot with the outer end of the thermostat facing downward on the left s
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