5 F. OUR CAR \ WHETHE FINNING JO SHO YoU {80 Aston Marin Volante Poor fuel economy, hard starting, overheating, spongy brakes, lack of engine power .. . do any of these problems sound familiar? If you've experi- enced some or all of these headaches you know how frustrating and expensive they can be. How about excessive tire wear, a dead battery, a balky clutch or astumbling transmission? You can cure all these ailments and prevent them from happening again with PM’s comprehensive maintenance quide. Good car care is for everybody. This year don't leave it all up to your mechanic. MAY, 1980 138Mud Thg YOR) DSi hae a ees aire ihe kg is =a No Experience Needed. Now you can make professional-quality The ea: s Uoay repairs yourssll, Evenit you'venaver (béollet axplaina ovary step. aay Do done body work before. Its as easy as Easy makes body repair much simpler than other Does It standard methods. It’s even easier to Does It two-color-change system and remains sandable up to 48 h takes care of the tricky part for you. You'll get great-looking results much less than pay a professional. Easy Does It. One Tesecontctonge of the Durn family af yowhenit auto and home repair on snd products. 140CONTENTS A CARED-FOR CAR IS LIKE MONEY IN THE BANI‘! CAR CARE BY THE NUMBERS LUBRICATION EMISSIONS SYSTEM motor oil Servicing PCV valve 2. Replacingoilfilter Servicing EGR system 3. Servicing uindercart Otteremissions controls 4. Lubricating wheel bearings HAUST SYSTEM ENGINE Servicing heat riser 5. Adjusting valve clearan Servicing exhaust system 6. Testing cylinder compression 7. Testing vacuum COOLING SYSTEM 8. Replacing gaskets IGNITION SYSTEM 9. Testing sparkplug cables Servicingsparkplugs Servicing distributor Adjusting breaker points Setting dwellangle Repairingelectronic ignition (AMC, Chrysler) 15. Repaitingelectronic ignition (Ford, General Motors) 16. Setting ignition timing ELECTRICAL SYSTEM Testing chargingsystem Testing battery condition Servicingthe battery Testing starting system FUEL SYSTEM 21. Servicingautomatic choke 22. Servicingaircleaner 23. Adjusting carburetor jcarburetor filters 31. Servicing drive belts 32. Replacing hoses 33. Checkingthermostat 34. Checking forcoolant leaks 35. Flushing thesystem SUSPENSION Servicing tires Installing shockabsorbers Checking brak Road-testing brakes Replacing brake pads Replacing brake linings Bleedingbrakes Adjusting drum brakes Adjusting parking brake DRIVE LINE Adjusting clutch ‘Automatic transmi Replacing U-joints BODY SERVICE Repairing body dents Service weatherstripping Branarad by tha aeltors of Popular Mechanics with technical art by Dale Gustafson Fred Wolff Ed Lipski, Hank Iken, Fred Neinast and Gerhard Richter. Photography by Jerry Abramowite and Norman Blake. Design of tne Car Care Guide by Don Mannes. When Should You Change Engine Oil? How you drive determines how far and how often you should change your crankcase oll. It Is nearly’ Impossible to drive a car properly so that yearly Changes of oll would be sate for your engine. warm-ups, ort runs, taking kids to school, 1d those shor trips to the store tend to shorten tha life of your oil On top of that, today’s engines are smaller, work harder and run hotter. All'of these things help foul up engine ol, create var- nish, gum and sludge es they Use’ up the additives in the ‘motor ‘il. A quart of RISLONE with each oll ‘change and new filter will help get rid of power robbing deposits, and clean engines run better, longer and more econo- ‘mieally then dirty ones. Look for the big QUART red, yellow and black RISLONE For 40 years, motorists have been telling us that RISLONE really works! seg. seme ties Gresed ervaioe fr yaar Faerie es oa Case ras" tenet ERAT eal. SB kas THE SHALER CO. 21 Eat Jeferson St. [WAUPUN, WISCONSIN 52963, In Canada: Warren Pactagitg Co MAY 198) 141eo 7 Taal ra ccs ‘well-maintained beauties n Rileleels acct lial-1e Ml)acta a arene tsi Elyse ret ule nn (ele Pr ae Becta irt Deen immaculately Sonus Ores ieee Cee meee Rc pou eoctei alas Roe gu ter us ue Bis Gta a Cr MRA mated Cae Ru ey ee OR aR ee Ra ae eae CRU eer ees mee ee RR ee ur le Re ec ee ee eat ey and. strictly speaking. the only ua ie eC n RC Ue Ome CU IS MONEY IN THE BANIS! Cognets believe that maintenance Rea ee ee to keep your car looking jike the Pair e rie ema COO e eu aac eu eee ea ee Mireur ea oe Sa eet ats a ee eg eerie ieee ana cue a Ce eee CO rn ee nat ec en a ime a as CSR eu ne eee a eM uae eu Be aac Chanelle ia Ue Ce eR ee haobtehel Pe en eeewot ee Tey These fifty ways to love your car will keep it running like new long after the warranty runs out. Just perform the tasks outlined here at least once a year, or as often as called for in your service manual. aE. | a ine Instructions on the following pages a pe a show you how. Ee eee ras es Perera) Pret Paes eae are precy Er anit) Caer) SS Ee eae Eee Caer) Perera ors “ox eect) es ory Pea tee ated Eade ce eee bos PM art; Dale Gustation Ce aaaatnt Eee eee rery Me OE begs ncarers Dea ace pea aerate ey ordea eos pees enor Cees fiir presser Seats Pres attra riers aati rate Peseta cera Emer Sra eee Sata] Fae rs Foret BA Cea) eee Perenicd Porn Pisa cera ony Prema es ora coed ces reac Te eS aaa i otra Pea asa Ne Cee eR | 1s ae rant econ nea) Seed Sc ean pees Preae taeCAR CARE MONTH quality products featured in the CAR CARE GUIDE are included in these sale promotions. Car Care products to help keep your car in top-notch condition can be found at the Automotive Parts & Accessories Association Member Retailers listed on these pages. Many of these outlets are offering money-saving specials during “May ts Car Care Month.” Many of the ‘Watch your local newspaper for the spectal Car Care sections that contain car care information and announcements from your neighborhood Car Care Month Retailers. AAASTO PARTS | Aveltine's |" ae 7 me AeEas me Sas, wwe Ee, segs [KORE Bee SE | cece] morc | COAG |" Bee see | —_ 3X | sowoers auro [>= Pans MC. = Soo Cine a] |¢ °° ® ai / BUCHANAN SALES Ja la FOREST CITY ‘AUTO AUTO SUPPLY 1LNLOK, AUTO Plone’ Bare BSEAy JACKS ure suPeLy Mart LAR. TH| sus STATES Seer Fred! AWA, Teg Carfor the eighth consecutive year, POPULAR _car care information circulated during May will MECHANICS and the APAA are joining help keep your car in top running condition. forces as co-sponsors of “May is Car Care And by leading you to the special sales offered Month.” This ts a positive indication of the during Car Care Month, will save you money. success of the program anda measure of how _Not only will you “Drive a Happy Car” but you ‘meaningful it has become to automobile owners _will be a happler, well-fixed driver. and the manufacturers and retailers of car care ® products. fu ~ With the increasing emphasis being placed Ics - on the efiiciency and economy of automobile Suportard Car Cate Kriha yet! wai RETAIL MEMBERS R| Gs ne mn -— BE | SEXBRRERERE PEP SBBQSEREDESOR S$ 2393855 528% 2 5 ‘MURPHY'S ‘MART 3 3 ‘0. STORES RP QR QR THRIETY | ca AUTO PARTS auitie™ om Py -— Ro Tearry | mae ale wootworth] SRF, rs ey STORE kw A AL —=—=—=— cee ; ooh * ~ SE |RICHLIN g ure eR" 10,WA- ‘WONDER WORLD Surly __| (age END" ee | cm" vad, TRAK [moe |—a 2 oP “s 5 ALSTATES ‘EREBEREE EE ‘PERE 25: 2 5 ¥Zayre|~ Shoppers! city SP5RIZ9 pa Hgaihe seer PEPECYS | 1 os Fo = eal aENGINE OIL ORAIN PLUG. 1 1s ne meoiood ot your engine. By cchenging it regularly you can extend engine fe and avoid major repair. Fortunaie- ly, It iS one of the easiest maintenance tasks 1. Warmup the engine so the ilload of ity of wil drain from the pan, Heat thins all, alowing a ready flow. Conversely, cold oil Is thick. Some may remain in the engine. 2, Lift the frontof the caror eave all four wheels on the ground. Ifyou if the vehi- ‘de, support ts weight on safety stands, Do ‘ot work beneath a car which is supported only by a jack. Accidents happen. Engage the parking brake; place an automatic trans- rnission in Park and amanual transmission in (ear. you raise the front ofthe car, place hocks behing the rear tres to prevent rol 3. Place a drain pan (sixquartcapsc- ‘y) under the drain plug and loosen the plug with an adjustable, box, open-end or socket wrench. Whichever one you use, make sure It fits the plug snugly o avoid damaging the Plug. 4. Remove the loosened plug by hand. To avoid bumina your fingers, be ‘ready to draw your hand back quick as of begins flowing, Alow oil to drain completely ‘This takes about tee minutos. 5. Wipe the drain plug clean and chock 10 see has a gasket he plug has 2 gasket, the gasket must be kept in use to avoid an oll leak. However, o be effective, the casket must be in good coraiion. Ii isnt replace t ‘6. Thread the drain plug into the clipan (dont cross threads) and tighten by hand. Then, using a wrench, tghten the plug snugy. Do not overtighten. You may distort ‘he pan "7. Add fresh ello! tho corroct API clas- sification and SAE viscosty through the ot 148 POPULAR MECHANICS The ol drain plug on your car may not be in the ‘same spot ae shown. But it's always somewhere In the ollpan; the pan Is always under the engine. ‘engine, unt tne OpstCk stows the oll lovel at FUL. 8. Check around the clipan drain ‘plug for leaks. Tighion the plug there's leak Selecting the right oil The American Petroleum Institute (API) Classification system uses the symbols SE, 'SD and SC to designate of surable for auto- ‘mobile engine use. Symbols signity the abi- lty of oil 10 protect enginas of designated ‘Model years against wear, rust, corrosion, ‘sludge and othor detrimental factors caused by normal use. 'SE engine oil provides maximum protec: tion between manufacturer-recommended olchange periods for 1980 and all prior ‘models. SD engine oilis suggested for 1970 ‘and al older models, SC engine ols the sug- ‘gested choice for 1967 cars and all earlier modes. See thatthe canof ol you select bears the ‘symbal ofthe type oil you decide touse. The ‘symbol may be used by itsaf (SD, for exam- ple) or in conjunction with others, such as ‘SE-SD-SC. Ths means the olis intended for ‘SE use, but, obviously, also fulils the needs of SD and SC use. Consult your owner's manuaifor the cil vis- cosity to use. This is based on anticipated ambient temperature of an area. Viscosity, or weight, is @ numerical rating system esiablished by the Society of Auto ‘motive Engineers (SAE) that designates the resistance of cil to flow. Thick. slow-flowing ‘lls have high numbers; thin, ree-flowing ols have low numbers. The W following a num- ber means that viscosty was determined at (O° F. and the oll is intended for use in cold ‘weather. ltner@ is no Wi, was deter mined at 210° F., and the ol is intended for use in warm weather. on wut owo vers, out ao SAE OW: 40, have the ebilty to Change viscosiy as temperature changes, being ight enough to allow easy engine-staring in cold weather, Yet heavy enovgh 1 provide proper engine Pretecton at high temperatures. Remove the plug and let oll containing ‘contaminating deposits drain completely.‘The freezer. There's a Ford Granada in that block ofce - with Shell Fire Ice motor olin its crankcase. Af we chopped through the ie. we lhomed the key The engine started in four seconds. The oven. Same test car, same ShellF red Ie, towing a30-ton cranein the Mojase Desert 36 hours later The oil temperature kit 270°F (sell ‘above normal). Bit Shel Fire & ce protected the engine. From the freezer to the oven in 36 hours: The Shell motor oil that had to earn its name. ‘Take a new Ford Granada and askit to crank up fast. frozen ina huge block of ice. Then, after you've thawed it out, ask it to pull a 30-ton crane through several miles of Mojave Desert. Do that and you aren't just asking the car to perform. You're demanding peak performance from its motor cil. Afrozen Ford gets a quick start Shell Fire_& Ice® 10W-40 is an all- ‘season motor cil. And an all-season motor oil should be able to help cold engines start fast. Enter “the freezer.” First we built a special mold to hold our Ford Granada. Then we put it in a gigantic freezer at zero degrees and sprayed in gallon after gallon of water. Layer by layer, the water was frozen around the car. Inside the Ford's crankcase, the oil temperature dropped to well below freezing. When we removed the walls of the mold, the ice was so solid that it took us an hour with two pickaxes to hack our way into the passenger compartment, Finally, we turned the key. Immediately, the engine cranked, In four seconds, it started. We'd got- ten our Shell Fire & Ice All Season Motor Oil down to subfreezing, and it still helped the engine start fast. “The Oven” An all-season oil also has to protect when the going gets hot. And the going that gets an ail the hottest is tow- ing aheavy load. So after we'd defrosted our test car (236-hour task), we hooked itupto the crane we'd used tolift theice block out of its mold. The crane weighed in at over 60,000 pounds—the Ford Granada, a mere 3,500 pounds. We started towing. By the time we'd gone several miles. the oil tem- perature had hit 270°F. Well above normal. Did Shell Fire & Ice protect? We tore the Ford's engine down the next day for a closer look. And after care- fully examining its critical parts, our technical experts had the proof: ‘There was not one bit of abnormal engine wear. 36 hours after helping a cold engine start fast, the same Shell Fire & Ice Motor Oil had protected an extra hot engine. Gas-saving formula. Shell Fire & Ice All Season Motor Oil formulated to save gasoline. Your mileage will depend upon car and conditions. So change to Shell Fire & Ice 10W-40 Motor Oil today. Shell MAY 1980 149BYPASS VALVE FILTER \ ELEMENT) 9| Full-fiow, olbfilter bypass valves allow oil delivery, even If the filter clogs. he ol filter on your car's probably a ful- flow fiter. This means thal the oll pump delivers of through the fter before oils cis- buted 1 te engne, However, in the event that extremely cold weather causes the fiter to clog or the ol become too thick io flow through the fiter, a bypass valve will route oll around the fier ‘element to the enghe. This way, your engine will never starve for ol. Ot delivered to the engine through the bypass wil, of course, ‘contain abrasives and sludgy elements thal will accelerate engine wear Fitlers get cogged with sediment and par- tides if they are kept in use too long. There- fore, itis important that you replace ano fi- torat te tme tervals recemmended In your ‘owners manual. In many cases, tis sched- Ul cals for instaling anew fiter in anew car the first time the ollis drained and every sec- ‘ond ol change thereafter. I you use the vehi- ‘le under severe conattions, such as puling a taller, extensive shot-trip driving, idling for long periods, or criving in dusty areas, re- place the filer each time you change the ol 1. Place a drain pan under the oll Turn the oll-iter wrench counterclock- wise to loosen and remove the iilter. filter before adding fresh oil to the engine (se0 Changing Motor Oil, page 148). This will catch any of the fresh oll that may spill pending on its location on the engine. I i's ot accessible, youll have to get beneath the ‘car. Be careful thal you don't grab the fiter ‘with your bare hand. Since the engine was ‘warmed up prior to draining the oil, the fier ‘willbe hot. 3. Place anoll-filter wrench around the filter. If you are just row purchasing a ‘wrench, make sure that i's the right size, be- ‘cause not all wrenches fit afters. Be ready to tall the salesman the year, make and mod- el of your car and the cubic“inch displace- ‘ment of the engine. You'l also need ths in- formation if you want to purchase the correct frozen 'o the engine, remove the wrench and drive a chisel through the flter canister, but ‘waich out for hot ofthat may splatter. Then hitthe chisel wih a hammer to loosen the olé oll iter. 5. Hf old gasket material sticks to the filter seat on the engine afie: you have removed and discarded the iter, Scrape the eat clean and wpe with a dy lath. ‘6. Wash your hands, and then ip fin {ger into some ciean engine ol ang Wworcare the gasket of the new fiter.Alsolubricate the {iter seat on the engine. Lubrication assures Luanicare| ‘Apply oil to the gasket of a new filter to ‘secure 2 tight fit with the engine. that you will have a secure fit between the two. 7. Thread the filter by hand onto the engine. Be careful notto cross or strip threads on ‘the iter. When the gasket touches the filer seat on the engine, hand- turn the fiter another half to three-quarter tuto secue ‘In the past, manufacturers have wamed ‘not to tighten the fiter with a wrench, be- ‘cause the fiter may be dificul! to remove rex! time you have to replace it Some now ‘say to use a wrench to assure a tight, leak- [proof seal. Take the moderate approach. Tighten the fter by hand. After you have filed the crankcase with ol, star the engine ‘ana check eround the fiter for leaks. YOU findone, tightenthe fiter withthe wrench un- ti it stops, ™ 180 POPULAR MECHANICSThere’s areason somany sports It pulls hard, yet the 5-speed shift car enthusiasts who own a iruck, own into gear with a light, precise feel a Toyota SR-5 Sport Truck. Its more ine sports cars can't than just the presence of a 5-speed transmission, or bucket seats. Callit a jing, the way everything works to- gether Because ‘feel’ is what spots clean stop, but theres hardly a pip Cars, and the SR-S, are all about xm the tight ed cab.And Youll know what we mean the 3 standard AMIFM stereo radio moment you start the 2.2 liter engine. {ull carpeting, and blacked-ou! porty forking in harmony— e Toyola SR-5 Sport Truck shares with good sports PICKUP VAN & 4WD Magazin feeling, They put ith isted THE SR‘5 SPORT TRUCK. THE SPORTS CAR OF TRUCKS.LUBRICATION ‘STEERING UNKAGE Joints. UPPER AND LOWER EONTROL ARM A typical manufacturer's diagram of A. _steering and suspension is above. For ey G) body lubrication, see chart below. Up eacaisse artanence ets oh tricaling suspension ball joints and steering linkage ftings and, it called for, uni- versal pints and the clutch cross shaft. Con- sult the lubvicaton diagram for your particular ‘model (see sample, atove). ‘Some manutacturers print such a diagram in he car's service manual whie others pro- vide it as a separate service pamphlet. The diagram phponts lubscation fittings. It its ro! available, you will have to search for these fittings. How often should a vehicle have a grease job? Consult the maintenance guide in your ‘owner's manual. However, ke@p in mind that the interval given is a minimum recommen- dation and assumes ideal cvieg conditions. Ifyou érive frequertly in cold, snow, rain, ex- treme heator dusty areas, the car will beneft from more frequent lubrication. ‘You need a hand-operated grease gun, which should come with an extension adapt fr to permit easy access to lubricating fi tings. Newer grease guns accept cartrdges of grease s0 that you don't have to pack the (gun wih grease from a buk contaner. Generally, manufacturers recommend {grease containing molybdenum disulphide (so-caled "moiy” grease) for its long-lasting ‘qualties. To provide even greater protection, the grease should be water-resistant Ball joints, steering linkage To properly lubricate bal joints and stoer- ing linkage, do the folowing: 152 POPULAR MECHANICS 4. Raise and securely support the front of the ear. 2. Find grease fittings and wipe them clean. Some ball joints may have metal or rubber plugs rather than grease fit- lings. Remove plugs and insert fttings. After ‘greasing components, you can either leave ftings in place or reinstall plugs. 3. Engage each grease fitting, in turn, with the grease gun. Pump the ‘Labicating Point Hood iach Hood hirges Vent vandow oaton Door stk plate Door iter Keynole Trurk i hinges Trurk i lock Stop lubricat- ing when the tall pint is ful follow these tips 1 Ball joints of American Motors and Ford ‘cars should be lubricated until the rubber ‘boot of the ball joint begns sweling. Youcan ‘see the sweling begin, or you can place your hand on the boot and stop lubricating when you feel the rubber boot stating to swell all joints of Chrysler and General Motors ‘cars expel grease through bleed holes at he ‘base of the bal joint when the component has received ample grease. IH I'grease begins cozing betwoon the tip of the grease gun and grease fiting as you start {o lubricate a joint, stop pumping the grease gun. The fiting is probably Docked and shoud be replaced. Trying to force grease into _@ blocked fiting will only make a mess. Lubricating universal joints Many Usjoints, as thay are called, are sealed and can't be greased. Ifthe joints on the criveshat of your car do require lubrea- tion, put he car on salety stands at each ofits four comers. Place the transmission in neu- tral and release the parking brake. This pro- cedure assumes that you car't borrow the lit at a neighborhood service station for the few ‘minuies it takes to do this jod. Tum the driveshaft by hand and find grease fitings. Wipe fitings off, atach the ‘grease gun and apply grease until lubricant flows from the joint. Then wipe of the excess lubrieant Body lubrication Lubricating body points is usually when the undercariage is Char (le) indicates these ‘ints gests the type of lubricant you sho to each,A far sight better- GE halogen headlights. GE Power Plus™ halogens are a far sight better for night driving than ordinary headlights. Compared to conventional headlights, they have twice the candlepower on high beam and can throw the light up to 25% further down the road, GE halogens can cut through the dark and drizzle, take charge of the road and pull it into focus. GEhalagen Orainary Reealght, Sealed Bear Readight Install a pair of GE Power Plus halogen headlights today. They're a far sight better for night driving. Available wherever quality auto products are sold. WE DRING GOOD THINGS TO LIFE. GENERAL @ ELECTRIC MAY 1980 153S-KTooLs CTORY PECIALS ~ SAVE $3508" Over 50% S-K 21 pe. 1/4” Dr. Socket Set #4921-80 Only *34* Rick Mears— Jim McGee— driver mechanic and American-made S-K Tools Chie mechanic Jim McGee says, “lused 5-« Tools extensively in preparing our winning car.” Fight now take advantage savings on his and otter crampiorshie ‘qual S-K Tools sets. They'rea ‘atauto parts and hardware stores. CHECK OUR GOLDEN WARRANTY HAND TOOL OVISON DRESSER NOUSTRES. NC 5201N Wer Rs. Fomin Parkin 60% Conran 1960 ORESSER MOUSTRES, LUBRICATION 4. Lubricating wheel bearings It the car has arear ditfer- ential, service the front wheel bearings. iit has @ front ne, service the rear bearings. Follow ‘manufacturer's schedule for the proper bearing- corTeR WHEEL IN BEARING ApvesTING: GREASE car 4. Jack up the car and support the fend jou're working on with jack stands. Fe- move wheel covers. 2. Use chalk to seribe a line from the whee! onio the hub, if the wheel has disc brakes. These marks will alow you to put the wheel back in place so wheel balance is maintained. 3. Loosen caliper retaining bolts, if the wheel has disc brakes, and remove the ‘caliper trom the disc; support ne caliper on a suspension member io keep stress off the brake hose. 4. Remove grease cap. acastaliaiod lockrut ison the spindle, take it off. 5. Straighten the cotter pin, pul it out and throw it away. Remove the wheel- bearing adjusting nut and washer. Important: Al parts to be saved should be put on a sheet of clean, Int-ree paper. 6. Grasp the disc or the tire of a whee! equipped with drum brakes. Free the outer whee! bearing by pling disc, or whee!- ‘arde-tre assembly, toward you, and pushing ‘back. Bearing will drop on spindle. 7. Remove the disc or wheel-and- tire assembly and lay it face up on clean paver. Insert a brass drift or softwood dow Into the hub so it contacts the race of thei ‘ne: wheel bearing, The race is the metal pat that surounds the rollers. Tap the innerbear- ul of the disc or wheel. The grease re- {ane (seai) wil also fal tree. Throw it away. Remember which is the inner and which Is the outer bearing, 8. Wash bearings in a grease-cut- ting solvent, working solvent between rolers with a clean, sof-bristle paintbrush. Use trichloroethyiene as the solvent. tis not flammable. Important: Handle a bearing by its race to avod ditying it. ‘9. Replace the bearing It itis dam- ‘aged (cracked, chipped or blackened). Ii locks okay, spin it slowly to see if it rotates 154 POPULAR MECHANICS‘Avoid contaminating a bearing by holding it by its metal outer edge, the race. smoothy. Discard the bearing i rollers feel ‘rity orbind as they are rotated. Don't wory, you carit overlubricate a bearing. Ifa whee! bearing packing toolis not available, puton 2 paar of dean rubber gloves and scocp whee!- bearing grease into your palm. Kneod bear: ing into grease, coating all surfaces. 10. Clean the inside of the disc or wheel hub with trchioroothyione after bearings are greased. Allow hub to dry; coat surface with tin layer of bearing grease. 11. Turn the disc or wheel-assom- bly face down and put the inner bearing inside he hub. Place new seal over the bearing Using a grease-sea installing tool or a soft brass dri, tap the seal into ts seat 12. Clean the wheel spindle and ju bricate t with grease. Put the disc or whee Remove the Inner bearing and the grease Seal by tapping a soft ariftwitn a hammer. andstire assembly, back on the spindle, 13, Place the outer wheel bearing In the hub, and install the washer and Wheel-bearng adjusting nut. 14, Tighten the wheel-bearing ad- Justing nut to manutacturer's specs with & torque wrench as you spin the wheel. When the corect lorque measurement is ebtained, remove the wrench and see that the wheel revolves freely. fit does not, back off the nut about one-half tur. Test wheel spin again. 15. Replace tellated locknut, 16. Reinstall the caliper of a disc brake unit, and reinstall the wheel (line up wheel end hub chak marks), ™ eco ital a ee ea ere eee Beg read line number 8 — eee ae eee et Ceara eLe aos Aner aa ea ea) your car can be a per Ce) fetta feet56 Cet ATU Ta) FLANEPROOF COATING ENGINE ENAMEL SPEREX wr vie SUPE ump tse fiat POPULAR MECHANICS CARE GUIDE FEELER GAUGE To set vaive clearance on GM ‘he engine, use an Allen wrench fo turn adjusting nut ‘on the tappet. The feeler de- termines when correct clear- ance is reached. he valves in most US.-bult cars don't have to be adjusied, since valve ciear- ance from the seat is maintained by hydraulic valve lifters. An exception is the 2000-co Ford engine in the Pinto and Mustang Il and Mercury Bobeat and Capi. These valves are contvolled by an over- head cam (ohc). Cam lobes of the camshaft press agains! fingers which, in turn, press against valve springs. The gaps between the ‘cams and fingers should be measured and adjusted, if necessary, every 12 months or 12,000 mies, whichever comes frst ‘Another exception to the use of hydraul- cally activated valves isthe four-cylinder en- {Qne used in Chevrolet Vega and Monza and Fontiac Astreand Surbirdirom 1971 through 1975. ‘The gap between the cams of the cam- shaft and tappets should be measured and adjusted, if necessary, every 24 months or 30,000 mies, ‘There are cther cars, mostly imported, that use adjustable valves. Although the task is done similarly on foreign cars, valve-clear- ‘ance specications difer rom angine to en- ‘gne. So consult the manufacturer's service ata, Ford valve adjustment 1. Remove the air cleaner. Label the sparkplug cables $0 that you can reattach them!o the correct plugs when finished. Re- ‘move the cables from sparkplugs and then remove the sparkpluge. 2. Remove valve-cover bolts andi the valve cover off the engine, being careful that dirt doesn't fall into the engine. Discard the valve-cover gasket. Use anew one. Note that there are eight cams. ach one serves a valve, and each cam finger has an adusting rut ENGINE , 5. Adjusting valve WAENCH 3. Put the transmission in weurnat and attach a large wrench to the nut in the Center of the crankshaft pulley. Turn the nut Clockwise so that the pulloy rotates clocowice ‘nti the lobe (high spot) ofthe No. 1 cam is straight down, pressing on the cam finger. This compresses the No. 1 valve spring, 4. Disengage the cam retaining springs from the grooves of cam fingers No. 6 and 7 using needle-nose pliers. The springs must be free of the finger. 5. Slide afeeler gauge of correct size between cam No. 6 and cam finger No. 6, and then between cam No. 7 and cam finger No. 7. The feeler gauge should fit without force. iit doesn't (gap tends to decrease as valve parts wear), an adjustment is neces- sary. Valve adjustment for this engine shoud bbe done in the folowing sequence: Depress valve Measure and adjust, it (00 Stop 1)” neceasary. pap of came Not No.2 No.3 No.6 6. Loosen the locknut to make an adjustment. Then turn the adjusting nut uti you can ft the specited size feeler gauge Between the cam and camifinger. Turning the adjusting nut clockwise increases gap; coun- terciockwise decreases gap. The adjustment isecorrect when the gauge just fits the space ‘and offers alight resistance as you move itn and out 7. Tighten the locknut. Recheck the adjustment ard put the retaining spring back In the aroove on the cam finoer. Check the other adjustments. 8. Install a new gasket and replace the cam cover when you have finished. Re-clearance place the two front bols first; then replace ‘ear bots. Tighten bolts securely GM valve adjustment 1. Remove the air cleaner, spark: plug cables and sparkplug 2. Remove the valve-cover bolts ‘and the valve cover. Discard olé gasket 3. Place the transmission in weu. ‘rrat and engage the crankshaft pulley nut with a large wrench. Turn the crankshaft pul ley clockwise until the timing mark is al the ‘migway point of the timing scale. 4. Measure the gap between the ‘cams and tappets of No. 1, 2,3 and 6 cams. The gap at No. 1 and'3 should be be- tween 0.012.and0.018 inch. Thegap at No.2 land 6 should be between 0.027 and 0033 Inch. With this engine, gap increases as vahe parts wear. 5. Rotate the tappet until the ad- Justing screw comes Into view, i the ‘adjustment doesnt fall within spectied surpstn a Fat FABRE a Ford ohc engine (top) uses cam finger be- tween lobe and valve stem. GM (above) uses tappet between lobe and valve. bounds. Insert aYe-inch Allon wrench nt tho adjusting screw and select a feeler gauge that wil let you turn the screw at least one complete revolution. More revolutions are acceptable; less than one is not. With the feeler gauge in place, tum the adjusting screw clockwise to increase gap. 6. Rotate the crankshaft pulley 180° when you are done increasing the caps at came No. 1, 2, Sand 6. The timing mark should be in & postion opposite the timing scale. Now measure and adust cams No. 4, 5, 7 and 8. Cams No. 4 and 7 should mea- sure between 0.012 and 0.018 inch. and Cams No. 5 and 8 should measure between 0.027 and 0.033 inch &. Refit the valve cover. = PM Son Of A Gun!®... The Penetrating Protector. Ithelps protect vinyl, rubber and Pee at eens Prater! Son Of A Gun! penetrates surfaces and leaves a rich, lustrous protective coating. element canoes panels, vinyl top, tires and bumpers with Son OfA Gun! from STP. Protect Vinyl, Rubber, Leather... aN ALY a. May 1980 187GAS SAVERS ree ee ELECTRONIC WATER INJECTION. SYSTEM “Ends spark knock E 4 instal yourseit <3CD~, HALOGEN FOG & DRIVING LIGHTS MORE GAS SAVERS! Electronie fenitign Conversion it "6.8 Cyl except Mopar ‘Cutout (euts oft aye ranee Curve iit ‘aire act (onring ONLY) ‘Ford, Gi, Mopar LED Diitat Clock ‘Our Catalog specializes in many Gas Saver & its ¥ourself items, Performance parts for a Firestik DON'T TAKE NO FOR AN ANSWERI! we s WIRE-WOUND AND MOST -D ANTENNA IN THE WORLD! po ‘Svar Gry Bac Fedo Whe nite Communications Maria Since 1962. Eee aaeolad POPULAR MECHANICS 158 she compression and vacuum tests are diagnostic procedures for determining ‘engine condition. The compression test de termines whether piston-ring valve or eylin- derchamber wear have progressed to a point where sealing quaitieshave been ham- ered. permitting loss of compression. if ‘compression is ost, engine performance su fors. Most notably, there is loss of power. ‘The compression tester (gauge) needed to do this job is available in two forms: push-in ‘and screw-in. The pushin ype, whieh gener: ally costs less than the screw-in type, has to be heldin place withboth hands, This doasn’t allow you to use a remote-control starter ‘switch for cranking the engine: someone has to be available to tur the ignition inside the Car. If the pustrin compression gauge is not held firmly, there is a loss of pressure trom ‘round the gauge nozzle, which produces an ferroneous reacing. The screw-in compres: sion gauge allows you to avoid this prob- lem 4, Check that battery voltage is within acceptable hounde and that on: gine oil is at the Fut mark on the dipstick ‘Warm up engine. Then tur it of 2. Remove sparkplugs. 3. Ground the ignition system to avoid possible damage thal cranking might ‘cause. For all systems other than the Gener- al Motors High Energy ignition (HEN), remove the high voltage cable from ether the coll towor oF the center towor of the distributor. Using a jumper wire with aligator clips sol ‘dered to each end, connect one cip to the ‘metal terminal of the high-voltage cable. ‘Connect the other clip to a clean metal spot ‘on the engine, such as'@ bolthead or the al temator bracket. lithe car is equipped with the HEI system, 6. Testing cylinder compression To test compression, remove all sparkplugs and jam open throt- Ue plates. Test must be per- formed with @ warm engine. Spaneeugs {disconnect the main hamess connector rom the distributor cap to prevent damage. ‘4. Be certain the choke plate Is wide open when the engine is warmed up. To make sure, remove the carburetor air cleaner. Then wedge the carburetor throttle ‘lata(s) in the wide-open position. To do this: I Have an assistant stin the car tohold the ‘accelerator pedal to the floor. 1 Or, tate the thottle ever on the carbu- ‘olor and tie it back with wire. 1 OF, cut ¢ length of wood to jam between the frort seat of the car and the accelerator ‘pedal so the pedal is pushed to the floor. ‘5. Connect the remote-control ‘starter switch, i you are using one, ac: Cording to is instructions. Before using it turnthe ignition switch to ono avoiddamage to ignition-switch grounding circuit 6. Insert the compression gauge Into a sparkplug port and crank the en- {gine until the gauge records the highest com- [ression. Be sure the engine makes at least fourrevolutions. Do the same forall other cy! inders, recording each compression mark Analyzing readings Readings should be fatty uniform and ‘none should be lower than 100 pounds per Square inch (p.s.). Manufacturers have es- labished compression ‘specifeations that should be consulted if any readings are not Uniform. Generally, American Motors. and Gorera Motorsstate tht a20-p0 variation between the highest and iowestreasing oy. indersis acceptable. Chrysler calls fr per missible variation Botween the highest and lowest-eacina cvinders of ro more than 40 is. Ford cays the varation must be within 75 porcant. Thus, ithe highest reading cy! inger of a Ford engine i 150 p's, lowest‘eating should not be lower than 113 p.si Hicompression readings vary too much, o axe oo low, Gelormine which parte ere caus ing the problem as follows: 1. Squitt engine oil into the engine through the sparkplug ports. 12. Retest compression. if readings improve, piston rings are probably worn, although cylinder walls __ SCREW.IN, COMPRESSION Gal A screw-in compres: sion gauge is more ‘expensive than the pustvin type, but is rusiin, also more accurate SOMPRESSION\D\ and easier fo use. Ihe ‘RouNoED con teao !)) pISTAISUTOR Before cranking engine to test for compression, ground coll cable to metal engine part. On HEI units, discon- fect distributor harness. ‘also might be responsible for faulty compres Sion. I feadings Gon" improve, valves prob- ‘bly arant soning property ‘ote: compression i ew between adja cont cyinders, he cylinder-head gasket be tween the wo may be darraged. ‘ous may finde randings era too much compression —in excess ofthe manufactur. ‘rs maximum specticaion. Excessive com Pression shows carbon buldup leading to hard starting wren engne is warm, FM yourselfers, and professional mechanics, are making a Go-Jo clean-up the last step in any job. Whether it’s grease, grime, oil, tar, putty ...Go-Jo Pest eto eset ee tr came or without water. And Go-Jo con- tains lanolin to condition hands while it cleans, Go-Jo.. . the world’s No. | selier.. . for over thirty years. Because ecg eit es Etc at| cleaner that works. Go-Jo is available in our Post te cma ty Fine Italian Pumice for Perret nts Enjoy Fireplace Beauty PLUS Both Highest Heat Output and Efficiency! Unique design of THERMOGRATE: Free Standing Fropiace!Stove poduces more heat at hgh ef erty tran any tove (sou0u Brum. a o3e%| fefcency)s0,ou bum less wood whl eying lass door elegance! For FREE Informatn, write te. Dope set.oos 0, ox ona! St Pour mn Stee ‘NGASON TOOL CORP, DEPT. MSO ey, m8 MAY. 1980-158Oursmooth-riding Quadra radial is the quiet tire that keeps you rolling in any weather. anywhere. The tire for ordinary and extraordinary driving conditions. Dayton radial technology takes the Quadra afew extra miles in gas savings. too.* And even greater fuel economy is possible because Quadrais manufactured to p-metric specitications. P-metricsizing is a new engineering concept which allows Quadra to be inflated to 35 pounds of air pressure. This means the tire rolls easier. Less power is drained from the engine. And the less power consumed, the greater your gas mileage, % The affordable. all-weather Quacira radial with the 30.000 mile lim- ited warranty. Because economy and quality never go out of style. Check the yellow pages for the Dayton dealer nearest you. ‘Ynancompared to cr bet bay baited ire. So Texas Tes 962-7. Dla on requed The Dayton Tire & Rubber Co. incon prewure mci weigh Ga rng condces atastne Reopen ey oon re Dayton. Ohio 45401, 160 POPULAR MECHANICSZ.Testins vacuum IoLestop Connect vacuum gauge to any vac- uum soures, either on manifold or carburetor Remove filter and hous- Jing for best vacuum-gauge reading. hen used properly. a vacuum gaug vveals a great deal about the way an engine is functioning. Ian engine is runing propery, the vacu- um-gauge neadia wil hold steady at between 14 and 22 inches of mercury. You should check service itrature to determine the cor- rect vacuum-gauge reacing lor your engine, Since thera ara variations fram engine ton: gine and other factors that affect a reading, Such as altitude. For each 1000 feet elev tion above sea level at which a vacuum (gauge is used, the vacuum reading is low- ‘red by one inch of mercury. Ws important to note the vacuum-gauge reacing, but you should also be aware of the action of the vacuum-gauge needie. A nee- dle that vibrates, floats o: drops sudcenly in- {icaies the engine is malfunctioning. 1. Warm up the engine, see that the battery is charged and make sure the engine 's filed with the specified quantiy of oil 2. Connect the vacuum gauge o 2 source of intake-manifold vacuum. Ifthere is no vacuum port on the engine, connect the gauge tothe port at the base ofthe carbure- lor to which the choke vacuum break con- ects. “Anathar eno! io eannart the oauiga fe the, portat the base of the carburetor or the hose from the vacuum motor of the thermostatic air dearer. ENGINE 3. Run the engine, noting the action ot the vacuum-gauge needle. One of the read- ings on tha chart (below) will apply to your ‘stuation, ‘4. Shut off the engine and ground the ignition system as you did to make the compression test (see Testing Cylinder Compression, page 158) WHAT A VACUUM GAUGE TELLS eeding Ineraretaon Neos sexy etcorect Engin nening pret ‘ectcanors ¥ Imaneto rormat crops ec. ton Needs weriesexcesively, —Leskng head guhet Seen 31818 yo ak Needs wars owe Sin. Carel acutmen, nae eos cogs 200 a8 en- Copy exaust ye (re epee ncresen (eee oun beaten tow, 9000} ade Ircorct iion voneny. Neodie puesios evn. Bad ves wom es, cone Soonfnocs pao Feadrg beow Si. og. Engine compression (rg o'vecsam ok THROTTLE ipiestor SOLENOID, DISCONNECT SOLENOID, / Disconnect the wire lead of Idle-stop ‘solenoid before testing engine vacuum. 5. Disconnect the electric lead ‘wire to the idle-stop solenoid to close the carburetor thttle valve(s) It the carburetor doesnt have an idle-stop ssclencid, tum the idle-speed adjusiment ‘screw counterclockwise until the. throttle valve(s) is completely closed. Count the ‘number of tums so that you can retum the de-speed adustment screw to is original position later. The throttle valve(s) must be closed to avoid an inaccurate vacuum-gauge indication. 6. Remove the PCV vaive from is seat. As someone in the car cranks the en- gine, hold your thumb over the end of the positive crankease vertlaion (PCV) valve to prevent a lossof vacuum and rote the action ofthe vacuum-gauge needle, tf your reading ‘appears on the chart below, you have uncov- ‘ered a problem that should be repaired MAY 1980The two things you want from your motor oil are both in Texaco'’s Havoline Supreme. HAVOLINE Sy ust ——— Indy 500 race car driver Janet Guthrie knows that, today, drivers like you want more than a motor oil that just protects your engine. Youre also looking for a fuel economy tested oil. That's why Janet recommends that you use Havoline Supreme. Texaco’s Havoline Supreme is the 10W-40 motor oil witha special friction fighter that’s been proven in fuel economy tests. in fact, exten- sive tests showed that two leading 10W-40 motor oils advertising “extra gasoline mileage” couldn't beat Havoline Supreme. What's more, in over a million miles of rugged state trooper testing, it delivered proven engine protection, too. Up-front protection backed by. unbeaten mileage— two supreme reasons why you should change to Havoline Supreme. TEXACO Us Trust your car to the products with the Star.SPARKPLUG CABLES o1LPAN Before removing valve cover, disconnect and mark the sparkplug cables. Depending on the model, you might have to remove # chassis cross member to drop the ollpan. lost engine oil leaks come from around the oi fier, olpan or valve covers). Cilleake trom arcund the fiter are discussed in Replacing an Oil Fiter (see page 150) ‘Oit will leak from around the olipan and valve cover i retaining bolts loosen or gas- kets deteriorate. Rarely, a sharp object may puncture the pan, causing a loak ‘Lets assume that tightening bolts has not stopped a leek. Remove the oilpan or vaive cover to replace gaskets (or to replace the high point on the distributer cam. the gauge with sides parailel—don' twist it Now, close the points on the feeler gauge Lntil you feel a sight resistance as you move the gauge in and out between the points Caution: The fesler gauge must be clean, Dit transferred to the points wil cause them to ail prematurely, With the gap sét, remove the gauge and tighten the point mounting screw. Now, dou- ble check the gap seting. it has changed substantially, you should repeat the adjust- ment procedure Squirt some lighter fluid o alo- hol on a lint-toe towel and draw the towel trough the points to remove any olf or di ‘Return the distributor to ite ori nal position by aligning chalk marks on the distrbutor and engine. Tighten the hold- down bolt ‘Stops 7, 8 and 9 are net necessary for a General Motors VB car. GM points are pre- Set. However. GM distibuors, as well as all others, should be lubricated 10. Replace the lubricating ped that presses against the distributor cam. Do ‘ot lubricate the pad and keep it in use. If there is no pad, put a dropof distributer cam ‘grease, about the size of amatch head, ona high point of the cam, Only one drop on one high points needed. Overlubrcating the cam may cause grease'to splash on points, which When lubricating the cam, use just a small drop on only one of the high points. 11. Examine the center of the dis- tributor shat. I! there isa pad, lubricate with two drops of medium-weight household ol 12, Reinstall the rotor and distributor cap. Set point dwel If you find that your points need frequent adustmert, there's a good possbilty that the entire distributor must be overhauled This means you must remove the distributor and then test it on a distibulor-analyzing From pushing the limit to catchin Champions can’t be be a Seater Fro eae naan gine. You candepend on Champion =toturrin a winning-pérformance Porta tustac cere ernie oreo erties ts eats cere eect Canary Pes foe onts SparkPlus Company paar‘That’ because the Garrece Wade extra- torque screwdriver, with a 3" torque lever, adds an extraclement of power against any screw. For an extra good turn, it features a coral of II bits— four Phillips four mecric hex, three standard bits. Which saves you the trouble of keeping 10 extrascrew- drivers around. ‘The Garvete Wade extea-torque screw- driver is just 6” long when closed) and works in three modes (left oF right ratchet or fixed). It leaves in che joy and takes our the extra work cough project. genes 2 SOP Finn Ave. N,N Todo. 2 OReuiad@m ppd ea Pecan ace a at sci) Bethe Cel aencntprs 172 POPULAR MECHANICS GUIDE é IGNITION SYSTEM yO 13. Setting dwell ‘Adiwelltach meter provides the only accu- ‘rato way of setting correct dwell angle. Feeler gauge method isn't good enough. PRIMARY WIRE rol angle is the distance the distributor ‘cam rotates while distributor breaker Points are closed. Ifthe points stay open for tao shor or too long a period, current trans- mitted to sparkplugs is Gisrupted and the en- gine won't run propery. ‘Setting breaker-point gap by measuring ‘dwell angle isthe most accurate method. Us- ing only a feeler gauge is hi-or-miss. Dwell ange is measured in degrees by using a welimeter. How it works ‘The dwolimeter isa voltmeter calibrated to record voltage passing through the igntion- sysiem primary cicult as breaker points ‘open and close, points remain closed fortoo short a tme, voltage shown willbe relatively low. If points remain opened too long, voltage willbe rela- \Wvely high, Every automobile maker species the dwell for the distributor points of its models. This specification, which difers trom car to car, is normally given as ‘such as 16° {0 18°. Setting dello any figurein this range ‘is acceptabie. The Gwelimeter is normally combined with ‘tachometer in one instrument referred as ‘a tachidwel. The tachometer allows you to ‘measure engine speed in revolutions per ‘minute. The tach is a convenience feature, ‘ince point wel has to be set withthe engine NORMAL OWELL INSUFFICIENT NORMAL GAP WELL running et the epeed epocifiod by the mans facturer. You can switch from dwell function to tach function, and back again. Atach/dwoll usualy possesses a cylinder- selector switch. Depending on the engine, the switch is placedin ether the soxor e1crt poston. If your engine has four cylinders, place the switch on the eight-cylinder func: tion and double the reading Tost procedure ‘Note: There is no dwell adjustment to ‘make with electronic-gniton distibuors, which have no breaker points, 1. Connect the tach/dwell, following Insttuctions accompanying the instrument Instructions supplied with the meter will prob- ‘ably say to connect the tachdwell red wie to the side terminal of the ignition coil (the ter ‘minal to which the coilo-distributor primary wire is attached). ‘Attach the other tachidwel wire (the ‘ground), usually black, o a clean metal part ‘on the engine. 2. Switch to tach function, star the cengine and check engine idling speed. If i {does net conform to manufacturer spectica- tion, you should set the engine fo the correct ‘dling speed. 3. Switch to dwell function. To set the dwell angle on a General Motors V8 dis- tributor, leave the engine runnirg and lit the sliding window on the side of the distributor fedler gauge with the ate points open. The set- xa {ting should then beangle cap to expose the breaker-point adjustment Engage the adjustment screw with an Al- Jen wrench and slowly turn the screw as you watch the dwellmeter scale. Turn the screw clockwise to reduce dwell angle and counter- Clockwise to increase éwel angle. When the welimeterincicates the spectied dwell an- gle, remove the Allen wrench. Make sure you Close the window: leaving it ajar wil allow dit ‘and fumes to get inside the distributor ard ‘contaminate breaker points. Tur off the en- ‘ine and disconnect the tach/dwel To set dwell angle of a distributor that doesnit have a window, turn off the engine, remove the distributor cap and rotor and set WRENCH (On GM V6 distributors, set dwell angle by ‘opening window and using Allen wrench. breaker-point gap witha feeler gauge. If the dwell angle is too small, move points closer together. if the angle is too large, move paints farther apart. Reinstal the rotor and distributor cap, Start theengre and check wel ng agar Yau ‘may have to repeat thiaa couple of mos uni the specified dwell angle is locked in. When points are property adjusted, tum off the en- ‘ine and cisconnect the tachicwel. 4. After setting distributor point ‘dwell, check and adjust ignition timing. Ifyou find your breaker points are buming Up, piting or corroding prematurely, examine the electrical system tomake sure tat poinis, ‘are not receiving excessive voltage which wil ‘Serve Io cause all of the above mentioned problems. Moisture can also wear out points prema- turely. To avoid it be sure the distributor cap fits property and sparkplug cable boots are fully seated. Moisture in the distributor can also prevent your car from starting. if your dstributor isin Sound shape, yet you stil have a starting problem in damp weather, the cure isin an Aeenarl array thal dee cit iene. We anit Under several brand names, but is commonly ccaled wire dryer. os MAY 1980 173, Spray... TMP Paint Stripper on surface to be treated and apply liberally. No need forbrushes, opplicators, cleaners or thinners. TMPs amazing “bubbling action’ locsen paint (usually five minutes is. sufficient), Remove... old paint down to the bare surface in seis, Excellent for removing paint in preparation for body “: repair Beal ieee ‘Also idea! for: Biya Shipping of tumiture ‘ntique auto restoration Temoving cid gaskets and achesives emoving cecals and bumper stickers ‘Aoiloble in automotive departments, “MY ENGINE RAN WHEN ITWAS OFF T'd switch the ignition off but the engine wouldn't stop. Instead it sputtered, rocked and coughed. Then I discovered WYNN'S® SPIT-FIRE. Now my troubles are over,” writes a happy user. Yes, engine “after run" caused by heavy carbon build-up can be not only ex- asperating, but downright danger- STEP FORWARD INTO THE PAST He Facts [+ Saves up to 5% on air cond costs ality manufacturing since 1939 red SOL + 90 day $ back and 3 yr. guarantee [To order call 1-800-241-7788 ee eco eee ous mechanically. So be. kin UNIQUE ENERGY PRODUCTS ‘Add acan of your carand yoursel, P.O. Box 1009 - Dept. PMS YNN'S@SPIT-FIRE to your Stone Mourtain, Ga. 20086 gas tank today. Sold at leading drug, auto parts and discount stores.Which belt is about to ruin an engine? World leader in automotive belts and hoses. The Gates Rubber Company, Denver, Colorado Chances are, youcan’t tell. Even though the top belt has put in 35,000 miles, while the other is just starting out. The point is, most of today’s belts simply don’t show the obvious signs of wear you could once spot on fabric-wrapped belts. A belt that looks okay can suddenly fail. And an engine running without a properly functioning cooling system can turn into scrap in @ matter of minutes. Or at the very least leave you stranded. So if you can’t tell when a belt is about to go, what do you do? Prevent disaster before it happens. Get in the habit of changing belts at least every two years or 24,000 miles, no matier how they look. It's an important part of the engine tune-up. Just be sure that the new belts have our name on them. We've been producing top quality automotive rubber products for almost 70 years and every ane of them meets or exceeds new car specifica- tions. So it's no wonder Gates belts and hoses are preferred the world over, demanded by more top mechanics and sold in more places than any other brand. Tobe sure of yourbelts, be sure of the brand. And don't settle for less than Gates A = Kies14. Repairing electronic ignition lectionicigntion-system failure caused bya distributor maftunction can usually be repaired by the car owner. Mostly the fail Ure results from a malfunction with the trigger wheel (reluctor) andlor the pickup assembly (sensor. The following procedure outines how to replace these parts in American Motors and (Chrysler distributors. Ford and General Mo- lors dstribviors are discussed on page 179, AMC distributor ‘Note: Four-cyinder 1980 AMC models use the GM high energy igniton (HE!) system. All other models use the AMC unit described be- low. 4. Remove and examine the dis- tributor cap. 2. Pull the rotor off the distributor shaft and check for damiage or wear 3,, Remove the trigger wheel. It 2 washer on the center of the distributor shaft ‘and place the gear puller on the shaft so its Jaws engage the underside of the trigger wheal. Tighten the gear puller toremove the wheal If you don't have a gear puller, hold two screndnvers under the tigger wheel, one on. each side, and it the tigger wheei off the distrbutor shaft. Be sure to keep the trigger- wheel pn after removing the trigger wheel. 4. Pry the retainer and washers from the pivot pin on the distibutor base plate. Unscrew the around scraw that se- ures the sensor assembly. Lit the entire sensor assembly ou. of the distibutor. ‘5. Remove the vacuum-advance lunit if itis damaged. To do this, remove the vacuum hose and unscrew the two screws holding the unit to the distributor body. 6. Install the now vacuum-ad- vance unit. To caibrate i, insert an Allen wrench into the vacuu-hose ripple of the old vacuum unit and tum the screw clock wise, counting the turns unt the screw tight- ens. Now, tighien the adjusting screw of the new unit. Then, turn ne screw of he new unit ‘counterclockwise the same numberof turns it 400k to tighten the sorew in the old unit. 7. Install the sensor assembly, making sure the sensor pin engages the hole in the vacuum-advance-unit ink. Secure the sensor to the base plate with washers and retainer. 8. Place sensor-assembly wiring harness in slot of the distibuior housing. Install and tighten ground screw. 9. Press the trigger wheel by hand ‘onto the distibutor shaf until the groove in the whoel and the oot in tho diatibutor shaft are aligned. Tap the trigger-wheel retaining (AMC, Chrysler) 10. install rotor and distributor ‘emp, and time the ignition. Chrysler distributor Crysler uses two types of distibutors. One is a basic electronic distributor in six- ‘and eight-cyinder modes. The other is the Halleffect distroutor in most four-cylinder 2. Remove the rotor, I it doesn't ‘come off easily, place two screwdrivers un- ‘er the upper rotor housing and pry the part off, Examine the rotor. 3. Place two screwdrivers (not to ‘exceed 7 n,n width) under the eluctor and pry up. Avoid damaging the reluctor teeth 4. Remove the two screws and Jock washers that hold the pickup and plate assembly, and remove the assembly. 1B. Adjust the alr gop between the ROTOR — Senson ASSEMBLY The AMC distributor has 2 lubricating wick, which should be olled periodically. ba isd Svar RG curor suart ASSERTLY Air gap between the reluctor and the pick- ‘up Coll must be set with # plastic gauge. reluctor and pickup coil ate: the istib- tor has been reassembled. ‘Align atooth ofthe reluctor withthe tooth of the pickup coil. Ithe teeth aren't aligned, en- {ga98 the large nut inthe center of the crank- shaft puley and turn clockwise until the wo ere paralel. Loosen the pickup-coll hold-down screw and insert a 0.008-in,, nonmagnetic teeler ‘gauge between the two teeth. The gauge ‘must be nonmagnetic. Plastic is suitable. ‘Adjust tho air gap until the three ele: ments—reluctor tooth, pickup-col tooth and: feeler gauge—touch, Tighten the hold-down screw and remove the feeler gauge. No force should be needed to get the feeler gauge out. Check the mac surement by trying 1b fit a 0.0%0-in. feeler gauge between Te two teeth. Do not force the gauge. If t does rot slide into place eas ily, the adjustment is corect. Hall-effect distributor To repair the Hall-etfect distributor: 1. Remove and examine the dis- tributor cap. It's held in place by two hold- down screws. 2. Pull the rotor off the distributor. Examine the rotor. ‘3. Remove the screw and lock ‘springs and lift the Hall-otfect pickup as- sembly out of tho dieinbutor ‘4. Reverse this procedure toreas- somble the distributor. ™ MAY 1980 175f Prmans Os Gone | MURAESD, | ers oso YWONROED | Son ————————— —— by Peter Noznesky, Chairman ‘Automotive Parts & Accessories Association PEAK |=" | For the past several years, “May is Car Care Month” has been Pree hate ce | instrumental in showing automobile owners how to maintain | eerie | thetr cars. It has provided helpful hints to achieve efficient “= | operation, increase fuel mileage, and practical service tips. A | -May is Car Care Month” has been co-sponsored by the —_ | automotive Parts & Accessories Association and POPULAR | Purolator. MECHANICS for eight consecutive years. Asa result of this | program, tens of millions of car owners and drivers have learned the rewards of regular car care. In addition, hundreds of cooperating newspapers throughout the nation participate in this program by scheduling special Car Care sections during the month of May. Everyone who owns or drives a car can derive benefits from the Car Care Programs. They are designed with you in mind and have as objectives car safety, efficient performance and economy of operation. MANUFACTURERS meen Motorcraft Em | Soot Hise emcrone Sages eee urele wax] | SieEwetisos ~~ cparpion Spat (letaPa ae = | CHAMPION Erect ‘ast Paste wae Wissen. | SS Aes ekkes Chilis |" Pon... tine P= a vaPae e creative Automobile WAX . inc. | Mice | OF a ae Ogcentin| ees | kenga. |e" moToR On. a eee | Kinys |" DASE esr [Et LBFILTERS | enkiOne of these men drives himself to work, drives himself home and drives up his cost of living. He doesnt see it that way. He's been driving himself to the office every day for several years now He actually enjoys the ride. Problem is, with today's energy crisis, the man on the rights wasting both tue! and money. Gas prices alone make the trip expensive. And his auto insurance premium is higher than it has to be The man on the left has decided to conserve and save. When the gasoline shortage began he and some neighbors started carpooling to work So together they consume less gas That cuts expenses right there, What's more, because each of them drives fewer miles they save money on their auto insurance as well As a major group of property and casualty insur: ance companies, we're doing our best tohelp you keep your insurance rates affordable. That's why most auto insurers are offering discounts to those individ- als who reduce the totainumber of miles or times they drive to work, For example, people who normally drive 30 miles to and from work every day can save up to 22% on car insurance premiums just by carpooling. All they have to do is drive to work two days a week instead offive People who switch to public transportation to get to work save even more on their promiums—up 1031 % in some states. Their car becomes classified “for plea- sure use only” a less expensive category. Here's what we're doing to control costs: 1§ Offering premium discounts to those who reduce the total number of miles they drive each week to work. Discounts will vay by company, by state and by the Iype of coverage you have Cracking down on insurance fraud practces through the Insurance Crime Prevention Institute and the National Automobile Theft Bureau. Working through the Insurance Institute for Highway Salety to make cars and roads safer Investigating injuryand repair claims more thoroughly Here's what you can do: 1§ Cut down on your driving by carpooling or by using public transportation '@ Use your auto seat belt and shoulderhamess. f§ Talk fo your insurance agent or company about ways to lower the cost o! your auto insurance coverage. Lock your car. Don't invite trouble Affordable insurance is our business...and yours. This message is presented by the American Insurance Association, 85 John Steet, New York. NewYork 10038CARGO COIL. EIGHT REASONS TO SAY NO TO AIR SHOCKS No air lines to. leak. ° No trips to the air pump. No adjustments to make. No deflation on cold mornings. No inflation at. high altitude. No load placed on shock: brackets. No parts to wear. No hard ride. loaded or unloaded. Drivers all over the country are catching on fast: CarGo Coil is a much simpler way to conquer sag, drag, and sway ‘caused by heavy loads and towing —all the way up to your, full rated vehicle and tire load capacities. Patented variable-rate coil design gives tis very special spring for cars, vans, and light trucks a very special “muscle” action. As the coils progress from top to bottom, they actually take on extra designed- in strength. When you drive lightly loaded, the more-closely-spaced coils near the top give the kind of normal comfort and vehicle height you expect. Now load up heavy or hitch up your tow. As the load bears down, those wider-spaced lower coils push right back up, much like your arm tightens its muscles when needed. CarGo Coil does it all FOR LOAD CONTROL. by itself. All you do is load or unload, hitch or unhitch, get in and go. You get excellent height, ride, and control qualities all the way. This time get CarGo Coils instead of air shocks. Ask for them wherever your car is serviced or write us for information, I's eight-to-one you'll like them better. Moog Automotive, inc. FW Ae PO, Box 7224, mA St. Louis, Missouri 6317715. Repairing electronic ignition (Ford.¢ General Motors) stibutor parts thal usually wear or be- ‘come damaged are the armature, sta: tor assembly and vacuum advance. If one ‘must be replaced, be certain to folow this procedure: Ford distributor 4. Remove the distributor cap. 2. Pull rotor off the distributor shat. ‘3. Remove the adapter—the top part Of the distributor housing that possesses the ‘cap hold-down clips. Disconnect the distributor wir. ‘on each side, and it the armature of the dis- tributor shalt. Be sure to keep the armature roll pin ©. Pry the iarge wireretaining from the armature groove in the distributor ‘shaft. Unscrew the ground screw ho'ding ‘ground strap to the base plate. 7. Grab the pickup coll wiring har. ness cutside of distributor nousing and pul {up to remove it rom ts sot 8. Remove the E-cllp that holds the vacuum-advance unit ink 10 the siator as- ‘sembly. Lift the link off the post of the stator assembly and side aside. Thisreleases the stalor assembly, which can now be removed from the distributor. ‘9. Undo screws and identification 10. Replace the vacuum-advance tunit, making certain to get the correct one for your distibutor. Instucions that come withthe vacuum advance show how to cali- brate the unt. 11. Assemble all the components in reverse order of disassembly. 12. Time the Ignition system. ‘There are no other adjustments that are nec- ‘essary to make, General Motors distributor ‘The General Motors High Energy Ignition (HED systom dstnbutori¢ unique tn that all ‘electronic components ofthe ignition system ‘are housed in the distributor. To remove the integral igntion col inside the distributor cap of al GM cars with electronic ignition (except those with 140-cu.-.,L-4 engines), proceed a follows: 1. Lift the two retaining tabs of the wire-hamess connector and remove the con- ‘Rector ftom the distributor cap. 2, Remove the three coll-cover at. taching screws and if off the cover. The Reena ceil ns he ac 3. Unscrew the four collattach: IGNITION SYSTEM Ing screws and remove the integral igni- tion coll ‘4. Take out the colt arc seal. It's in the top ofthe cover. Replace this seal when ‘you replace the coil 5. To install a new coll, reverse this procedure. Control module To replace the electronic conto! module, ‘proceed as follows: ROTOR vacuut IOVANCE BSc teaos, Gz} wanness connector ROLL PIL ARWATURE SLOT el "ARMATURE STOP RING cur GROUNDSCREW KK macneric ASSENOLY GraToR vacua Connection sueeve rein vacuum ease BSc XETaNEe nds The citterence between the Ford electron- {eignition system (above) and the General Motors system (left is that the Git unit ‘houses all inition components within the ‘distributor body. The operating principle ‘of both, however isthe same. 4. Remove and examine the dis- tributor cap. 2. Unde the two screws holding ‘the rotor in the distibuior. Notice that the ‘olor has a slot that fis over @ square lug on the advance weight base. Ths assures that the rotor can only be installed one way. 3. Disconnect the two pickup leads from the module. Takenote ofthe two color coded leads. Thoy must be reinstalled: correctly. ‘4. Undo the two screws holding the module in the distributer, remove the module ard then pull of the two Wire con- actors. Removing the capacitor ‘To remove the capacitor property, do the following: 1. Remove the distributor cap and rotor. 2. Undo the screw holding the ca- pacitor. Then unglug and remove the ‘Sr install the new capacitor and reinstall the screw that holds the unit in Pace, meking sue the round wie is under a MAY 1980, 179ent 3S es 95% of all Motorists. who drive in stop-and-go traffic. who drive in hot climate. who drive with passengers or full trunk. 1 who drive on ice or snow covered roads, who drive a van or pickup. who drive a RV or pull a trailer. CD who drive up steep grades. Contrary to popular belief, owners of RVs are not the only ones who need added oll cooling protection Over 10,380,000* transmissions failed last fic hes mn cad Cercle year, Nine out of ten failures were caused by “*Courtesy of ATRA overheating. Had these motorists known about transmission oil cooling protection, they would have saved $400 to $600 on repairs. = A small investment now in a Hayden trans- C4 mission or engine oil cooler can extend the life of your car. Remember, each 20°F drop in temperature doubles oil life. Hayden packages quick do-it-yourself instal- lation instructions with every cooler. Patented Quik-Mount aad Quick Connect allows instal- lation in /2 the time of competitive coolers. __-SendSL.O0 today for Hayden Cooling Protection catalog Don’t become a statistic; stop by your local GHAYDEN auto parts store or RV Dealer today and ask INc. for Hayden oil cooling protection. 1531 Pomona Road, Corona, CA 91720CARE GUIDE Pe = Av eS ignition system 16.Timingi pistaisuToR CLAMP BOLT IGNITION SYSTEM. TIMING MARKS TIMING LIGHT LEADS ©. Aim the timing light at tho timing mark Hod the inetrmont a8 you would Diol Don't itt sgh straight down the too. ithe jgntion is imed to Specifiaton, the speciied timing mark wll appear stationary inrolabon to the pointe or ndox mark. H he timing mark wavers each tm the ming bgt emits a beam, the tring wil ave tobe ad- down belt to adjust timing. This frees the DANA CORPORATION, TOLEDO, OM 43682CATALOG. FREE Stereo Buyer’s Guide Get Yours Now! ‘4 photos, comments, your best possible prices on over 200 all- ‘ew car stereo products! ‘ dimensions charts, fitting charts, “‘how-io-instal easily” articles! 4 THE ONLY published source of true performance teats and specification comparisons! % all finest brands, including Blaupunkt, Clarion, Craig, Con- cord, Fosgate, Jensen, Linear Power, Marantz, Pioneer, Sanyo...many more! Send NOW for YOUR FREE Catalog... ‘We'll ash it to you by fle class mall, or it you can't walt, call our WATS line (re call: 800-446-1506 In Virginia Call 800-852-961 ----~ biwe: ‘Speci From @moveer Som aura ec ng ane 3 Usaeyoecheatane a 152028" two way testers I I I I I \ VES! sntmsny zzep sim I I ! I 202 POPULAR MECHANICS The PCV system al- lows blowby gases to be recirculated into the engine and keeps them from escaping into the atmosphere. the purpose of the positive crankcase ventilation (PCV) system isto dvert es- ccaping exhaust gases (blowby) from the ‘rankease into the intake marifols, where tho ‘gases can be transferred tothe cylinders for Dbuming. The PCV system was the fist auto- emissions control system installed on vehi- cles. rior to the advent of PCV in the early 1960s, blowby was ejected into the atmo- sphere through a ventilaion hose. These hhaust gases were a main cause of air polu- tion. “The typical PCV system has a PCV valve, which controls the fow of gases. The PCV valve is located in either the rocker-arm cov- er oF on the intake mantold. ‘The typical system also consists ofa hose from the PCV vaive toa portin the base ol the Carburetor, another hose trom a breather cap in the rockar arm or valve cover tothe carbu- retoraircleaner;anda fier to which fe latter hose attaches, inside the carburetor air cleaner. ‘The PCV valve is the one part of the sys- tom that is most ikaly to fal. When itfails or any other PCV component maifunctions, ‘several engine performance problems resut. These include loss of power, oil dilution, rough iding and stalin. Its, therefore, good ‘maintenance procedure to inspect the PCV system at least twice a year. Testing 4. Start the engine. Lot it warm op. 2. Pull the PCV vaivefrom its seat. Ifthe valve and attaching hose are in good Condon, you wl heer a ising sound your finger over the end of thavahe You spout Tod nese oetong suction. ‘4. Turn off the engine if there is no ‘noise or suction. Pul the PCY vaive fromthe hose and shake it. A valve in good condtion will make a clicking sound. A detective valve wont ols. If there i no elk, replace the valve. 5. Check the hose for cracks or kinks if the valve does click but there is no suction. Replace a damaged hose. Ifthe hose shows no damage, remove the hose and run a wad of cloth through ito clear a possible blockage. Reassembe the hose and valve, ‘6. Remove the air-iniet hose from the air cleaner. With the engine running, hold {an index card over the hose opening, Wait a fow minutes. Hf the card is not pulled against the hose, the hose or breather cap is blocked. Check the hose to find out if there is damage and 7. Remove the breather cap and wash itn solvers. Lat it dry. ‘8. Remove the air-cleaner cover ‘and iake the PCY fit out. This fiter may be ‘cotton wadin ahousing. Replace it. Some- times. fiter and housing are removed and re- placed as a unit. Instead, the fiter mightbe a wad of bronze ‘mesh installed in a hole in the air cleaner. Pry the fiter from the hole and replace tif t's clogged with ait ‘The PCV valve.can also beused asa diag- nostic tool. By knowing what to look for, you can spot certain signs of trouble before a problem becomes ertical. for instance, you fotice that the PCV valve frequently, be- comes heaviy fouled with oll and sludge, it's ‘ningication thattoo much blowby gasis get- tina through the rings. This could mean that ‘he rings or te intake valves are not sealing ropely and tht they shouldbe looked a ter,Mga ua ITS LIFETIME WARRANTY. Most lifetime muffler warranties guarantee thac:thé™ ‘Over Turbo-Flow’s warranted lifetime, that can add up to muffler will last. But what about performance? pinegeerirs pe eee eee re Se oe cg ee eg a Cet ee net ce ‘Turbo-Flow has extra large tubes and strong, durable Perera een eased baffles and long-lasting, zinc-cated steel construction Pree ae ree nc eas persia Ce ene een es kks turbo design can cut backpressure almost in half to Pea eens eo ae eS Tec ent rd eae ee ey E St tes TTurko-Flow can even help save gas. Its efficient performance helps you get the most outof every drop of gas, dau ae TA PUT ay tt ad M@€@RCMONT TURBO-FLOW™DON'T WAX YOUR CAR EVER AGAIN! Chemists Develop New Glaze To Save Your Paint ‘Anew dacover int choral Int, wer bang at aumly Sout the ool onary boguct'e rege, rer ‘Spaned pardon FOR A FULL REFUND! minis si (WARNINGIIT SeOUAE "tu teorncopna mrad ere, For cool control with fuel control... switch to The high coat of fuel ing Brose Fan Once you've made youll decover that Electra Fan can Soa {ot more than halp you pass up a few of those highrpriced pumps (many cars Hei 10 Bie ek fectraFan| This sificient fan can ‘io recuse your engine noise. and Foute passing up. thase pumps. ince i's thermostatically ‘con trolled—not mechanicaly criven Electra Fan knows when to Quit Beiverive dont ‘werk, overtime: roobing your Gina's: power, guzzling your gas nd wearing out your water pure bearings) So switch tothe fan with theemo- {omorrew you won't have 18 worry about keeping your cool. Or about r loss problems. Or about fosing, control when Le those high prices at he pumps Cool and fuel control you can bank on. Enratessrne ty “Actual un sang capend.on ‘naiaval mung ‘cooling tan you put under your hood isnt ‘And whan just thinking about fuel laaton makes you lose your contl=t's time to switen from Jour bet Grvon fan to amore BectraFan Is beyond your control. But the this_decish ‘mileage with ‘spower while intact, they Today. And you look at aftr wang CHEM GUE, that sorting we sty GUIDE pOMET 39 27. Servicing EGR system To test EGR valve, tap the throttle and then check for free valvestem movement. ne purpose of the exhaust-gas recicu- lating (EGR) systom is to recycle ox- haust gases into the intake manifold and, from there, to the cylinders to help reduce nitrogen oxide (NOx), a poltant. Most cars built since 1973 have an EGR system. The hear of the EGR system is a vacuum- contolied valve, called the EGR valve, that meters the small amounts of exhaust gas fed into the intake manifold. A buildup of exhaust ‘deposits on the EGR-valve mechanism can ‘cause the valve o stick. I the vale sticks in the open position, rough iing, engine hesi- tation and an increase in fuel consumption will result. If the valve sticks in the closed positon, NOx emissions will increase, Servicing the EGR valve 1. Locate the EGR valve—behind the carburetor or on the intake manifold 2, Start the engine and let it got warm, 3. Place a finger on the stom of the EGR valve. Most EGR valves have it exposed. 4. Move throttle linkage by hand ‘several tmes to increase engine speed. Ifthe EGR vale is free of deposits, the ster will ‘move up when the throttle is tapped and re- ‘um to postion when the throttle is re- leased. 5. If this does not happen, unhook the vacuum hose from the EGR valve ‘and carburetor. Make sure the hose isnt loosed or damaged. Replace a tauty 6. Remove bolts holding the EGR valve in place i the hose isin good shape. Remove the vale and examine the gasket Uunderit. the gasket isn'tdamaged, teanbe reused. 7. Clean exhaust deposits trom tho valve slam and ant with ate hrveh Chock passages for deposts. If you can't get valve stem to move after Cleaning, replace the EGR valve, | 204 POPULAR MECHANICS2" 2Buck Rebate is on! During April and May, you qualify for a $2.00 rebate with your purchase of 5 quarts of CAM2 Mileage Motor Oil. The smart oil. ‘CAM2 Mileage Motor Oil gives you mor what it's called—mileage. An average of 14 extra miles more u can add another Mileage savings. We'll send us this coupon—or a store coupon— oofs of purchase. (This offer ir CAM2 Race Proven and Buy CAM2 now. During The Great CAM2 2Buck Rebate, Yes, | want to be in on The Great CAM2 2Buck Rebate. = a men tan Soins asePURGE LINES Eisen Gas Fitter n addition to the PCV and EGR systems, ‘ther emissions control sysiems. with which you should be familar aro the evapo: ‘ave emission-contral unt, ai-injection sys- tem and catalytic converter. Knowing what these systems do, how they do it and how to ‘maintain thom ean help avoid probleme. Evaporative emission ‘The evaporative emigsion-contol system prevents gasoline vapors trom escaping into the atmosphere from the carburetor and fuel tank. The system is in operation whether or ‘ot the engine ie running. ‘Most vehices buill since 1971 have an ‘evaporative emission-control system. The hear of the system is a charcoal canister in the engine compartment thal trape vapors when the engine is not running. When the ‘engine is started, ambient air flows through a fiter into the caristor, where it picks up va- pore and feode them through tubes to the engine by way of the carburetor, where they are burned, “The one thing which upsets the functioning ‘ofthe evaporative emisaion-central aysternis lack fiter maintenance. I the airfiterin the ‘charcoal canister gets plugged, afull compie- ‘mento airis prevented trom purging the can- ‘stor of fusl vapors. In mostcases, i isnt necessary to replace the fiter (or canister) any more frequently than once every 50,000 miles. To do this job, tag them so they can be reconnected prop- ely. Loosen canister bracket fasteners and remove the canister. ‘CARBURETOR check ‘Ain IRIECTORS “ain PUMP Tum the canister upside down. ifthe can- ister has a fier, you wil ind it at the base of the unit. Remove and roplace tho fitor. tho fillor is inside the canister, itis a nenreplace- able type. In this case, the canister must be replaced Air-injection system ‘The purpose ofthe air.njecton sysiem is. toreduce the levels of hydrocarbons and car bon monoxide in the exhaust gases lor combustion. This is done by injocing air recty no he exhaust gases ateach exhaust par, which causes futher oxidation of the frinaust guess before they enter the exhaust Syster ’A.camaged airinjection system usualy does not cause poor engine performance, a {though in some iratareoe there coulé Bo a loss of engine power. Instead, th level of hydrocarbon and carboremonoxide ‘emis- sions increases and a disturbing noise may come from the engino compartment. Ths noise is caused by the air pump. Do the following it something goes wrong with your airinjecton systom: 1. Inspect the drive belt for dam- age and tension. When adjusting the be. ent pry against the ai-injection pum, which cou be severely damaged. A loose or Getectve drive bot causes the ai pump 10 operate ata reduced speed and may resultin a noisy pump. 2. Inspect airhoses and tubes.asso- ciatodwitnthe aie njecton systor for holes, ‘racks and deterioration. To test ora leak n ‘hose, spreaca soapy walrsoluton onthe par. bubbles form withthe engine runing, gatauytic Sonventer a leak erists. Replace faulty hoses and tubes. Be sure all connections are tight 3. Inspect the check valve. It is a pemway valve thrwgh which aie Rowe to Ward the engine. Hot exhaust gases should ‘not be able to flow from the engine through the exhaust vaive fo the air pump. I they do, there will be a loss of air supply and noise from the pump. To test the check valve, disconnect is hose and blow through the valve toward the ‘engine. Thon suck back through the valve The flow of air should be in one direction ‘ony—toward the engine. It there is a two- way flow, replace the valve. 4. Test the pump. To determine i tho ‘pump is operating, disconnect the air line, ‘start the engine and accelerate to about 1500 ‘pm. It air flow increases as acceleration takes place, the pump is okay. I not, chock bet tension, hoses and tubes. Then remove the pump tor service Catalytic converte: The single catalytic converter came on the scene in 1975. It converts hydrocarbons and ‘carbon monoxide into ca‘bon dioxide and water vapor ‘Begining with 1978 models, dual catalyse ‘converters were used to treat ritrogen oxide, as wel as hydrocarbon and carbon monox- ie. The second smaller converter called a "mini-ox" unit. Catalytic converters don't last forever. However, fo attain maximum lie from a con- voter, aved leaded gasoline. Unleaded gas- line is essential if converters are to last their expected service life, which is gereraly {50,000 mies. Ian emissions test determines that a cat- lytic converte is no longer doing is job, the cenire converter must be replaced inccars oth- fer than GM and some AMC models. In GM aid oune AMC models, Catalyst pees are ‘drawn out of the converter and new pellets ‘are pumped in. Special equipment is needed. ™ 208 POPULAR MECHANICSSPACE AGE PROTECTION FOR YOUR CARS FINISH. THREE LAYERS DEER 24 MONTHS LONG. Wl POLYSHELL SYSTEM FROM TURTLE WAX. Weather. Pollution. Oxidation. layers of Polymers and Silicones prime. shine They all take turns beating the shine and seal the finish. CM Mge eee args suns) Dee en omreniet Punt iese emesis oscar apply every 6 months to bring the finish up Turtle Wax. to full shine and full protection for 24 months. An offshoot of space technology and Sidon RV Cunet omc yaa] mad Aa eee meee esa) don't need buffers or special tools. All the essen- locks three layers of protection between your _ tials are included. And it works for all car finishes. car's finish and things that can kill it. Bonded xecukuntasc cere Cs Ame Bee neue Re Soe] es pees tenets Per Lance eT tay Bi oreinnead a ead poneeeni Kit CARS 1980: aneulbuyarecidel 1eoPages Overso0Photos assemoLe a onive I YOUR OWN FULL-SIZE SPORTS CAR on egretann svi etcrnesbope's onsite Sern cnaas nes mater [Spiga cggccen eects ger sare eee ee ee ee ‘Fate Oranrtoday ane receive vauale Nealeter +14 Day Money Back Guarantee + B sit honisr class ! ! 1 1 - 1 ort fimingion,DE T8888 5 $12ForignAMall re | I | we ‘Gre TOULrrEe yo See Enea 208 POPULAR MECHANICS VALVE THERMOSTAT SPRING couNTER WEIGHT stuck fast and ean he heat-rser valve, which is also called the manifold heat-control valve, is a de- vice instaled on many cars toassist engines in warming up. ‘The heat-rser valve is a thermostatically controled mechanism in the exhaust mari fold. When a cold engine is started, a ther- ‘mostat springkeeps the valve plate ciosedto ‘event hot exhaust gases from leaving the ‘engine. Instead. exhaust gases are detoured toa chamber that surrounds the intake man- fold where vaporization of the fuel mixture takes place. Hot exhaust assists inthe vapor- ization of fue. ‘Asthe engne gets warm, heat actson the thormostat opring. causing it to lose tension. This permits the heat riser to open, alowing ‘exhaust gases to pass out through the ex hhaust system. Possible Malfunctions Ht he heatriser valve svcks in the open ‘position, the folowing problems may occu: i Acoid engine may have trouble warming Lup and may stall or idle rough. Fuel economy may sutfer, since raw ful, which would otherwise be vaporized, maybe ‘drawn out through the exhaust or may run past piston rings into the crankcase. Raw ‘gasoline may also contrbute to sparkplug fouling and ol dition. IH Flat-spot acceleration (hesitation on ac- Cleration) may occurring longer warm-sp periods. Ifthe heat-iser valve sticks in the closed ‘position, the folowing problems may occur: Loss of engine power, caused by too ‘much eet acting on the fuel mixture after the ogine gets wart, IW The restricted exhaustsysiom may cause 29. Servicing heat riser” EXHAUST SYSTEM Servicing the heat-riser valve requires little more then an occasional ‘coating with high-temperature, heat-riser-valve lubricant. If vaive Is [be moved. replace the entire unit vvere cases, a stuck heat-riser valve may lead tooverheated sparkplugs, bumed valves and detonation. Testing the heat riser 1, Move the heatriser counter- weight by hand when the engine is cold You'lfind the counterweight beneath the ex- aust manifold. It should move teely, not slugoishiy. 2. Warm up the engine. Thon alow t torunat idle 3. Watch the heatriser counter- weight as someone in the car accelerates ‘and cecelerales the engine quickly. The ‘counterweight chould rotate ‘Caution: Do not touch the exhaust mani {old, which will be hot encugh to give you a severe bum. Servicing the heat riser It the neat-riser valve sticks, ry forcing by {gentle tapping with a hammer. First, tap the ‘end of the counterweight; then, tap the face Cf the counterweight Apply heat-control- valve lubricant to the heat-vave shaf. Tap the counterweight again. Then, try moving it. Repeat the procedure a couple of times be- fore gving up completely and replacing the To treat a sluggish mechanism, lubricate both ends ofthe shaft lo which the heat-risor counterweight is connected. This is done with the engine cold. Then, rotate the cou- terweight by hand. until'the mechanism moves troy. ‘The best way to keep the heat-iser valve functioning propery is to lubricate the shaft (pertociaty. W the shat ts Kepx wel luoncat- (8d, the heat-rser valve wil rarely bind and ‘backing through the carburetor, and in se- | cause rouble. ™DOUBLE YOUR MILEAGE WITH TWO EXTRA WHEELS. Percentage of gasoline used by Puch moped 20% 40% 60% «80% 100% Core ae g - a Look at the chart. extra in the bar- Te shows you the Be | cain: all the fun remarkable dif- eee | of zipping around ference a Puch moped, combined Seen on your Puch. See your Puch with your car, can make in your aver- _dealer today. He'll show you all the age mileage. extras—in quality, styling, workman- Say your car gets 16 miles on a ship and economy— that make Puch + of gas. A Puch moped will America’s best selling moped. get you over 100 miles a gallon. If you put 20% of the gas you buy into your Puch and the rest into jour car, you could double your mileage. And the more you tide your Puch, the better overall mileage you'll get. Which means a Puch moped can pay for itself in fuel savings alone. It’s true. So instead of driving a two ton car to buy a pound of hamburger, be extra practical. Ride your Puch. It’s de- signed to thrive on stop-and- go, short hauls. That way ROUND OUT YOUR you'll save wear and tear on WHEELS WITH your car for when you really APUCH MOPED need it. And while you're fe gis practical, you'll get something30. Servicing exhaust system EXHAUST EXTENSION Leak ar \ EXHAUST MANIFOLD Loose BAPFLE PLATE MUFFLER SADDLE HANGER HOLE IN |" END PLATE RUBBER — BOUGHNGT RUSTED. MUFFLER INTERNAL RUST Outlined above are the most common causes of ex- failure. To. check for intornal ret, tap. hhavet.eyetom ‘the muffler and listen for falling rust flakes. This ‘sounds like crinkling paper. BROKEN Rust me HANGER Pipe CONNECTOR PIPE exhaust sysiom usually doesn't falta ‘al once. So there is a chance you'll be abe to reuse some parts. The job of replac- ing an exhaust system, totally or in part, is Giry and takos muscle. However, # fe not complicated. and doing the job yourself will save money Inspecting the system Caution: The exhaust system must be cold {during inspection or you may receive severe buns. Inspect the system for holes. As you check the mutter, look closely at the erd piates, because itis here that deterioration frequent ly takes place, Push in gently on each end plate as you lcok for breaks around the pe- fimeter and tubes. ‘Draw your hand over ppes and muffle ust flaking off is 2 sign that the component is near failure and needs to be replaced Tap the mufler with the heel of your hand ‘and tsten for pitte-patter sounds made by flakes of rust faling inside the mutfer. there fs a ratting scund. there's a loose tube or baffle inside. Ether sound suggests the mul- fier should be replaces ‘Now, tap the muffler with a metal tool. A dul sound, rather tan a metalic ring, an- ‘other sign of internal deterioraton. The mu fier wil soon wear through, causing an ex- hhaust leak; consider replacing it now. It you're hearing ratting noises coming from the underside ofthe car, check to see ‘an exhaust system paris hitting the chassis Srbody. Alsace tolling the part may hows failed. Gertly push pipes and mutter up to soe if anything is hitting. Then, service the respective bracket, or brackets. Replacing exhaust system 4. Raise the car up and place jack ‘stands at all four corners. Do not work ‘beneath a car supported by bumper jacks. 72. Let the rear axle hang free. Ma ‘euvering the tailpipe will be easier. Judge removing the rear whesl-and-tre assembly will provide easier access. ‘2. Lubricate frozen clamps and ‘bolts with penetrating ol Loosening these ‘may be dificult, but ty io reuse as much of the ongnal hardware as possible. 4. Use deep, six-point sockets rather than open-end or Box wrenches to e- ‘move fasteners. If you are removing the ex: hhaust system from an imported car, you wil have touse metic-size tools. Caution: Wear ‘gogales to protect eyes trom rust and oil 5. Warm up the engine to free fas- teners at the exhausi-pipe/exhaust-mani- fold connection. However, be careful nat to touch the hot manifold ‘©. Use # chisel or saw to cut pipes, if you are replacing the entire ox: hhaust system and there is no catalytic con- verier. You can also cut off fastene's. I the ssysiem incerporates a catalytic converter or converters that do not need replacing, be Careful not to damage the converters and at tached pipes. Use penetraing oll to remove fasteners. 7. Grab any broken studs with locking pliers, ard, iipossible, apply neat with a propane torch to the area around the Try working the stud loose. fe doen werk, il the hud out by knocking a pilot indent inthe broken stud with a center punch. Use a cil it alittle smaller than the stud. The broken stud will usually ‘come out ofthe nole as you Dack out the dil, bt. Then, use a tiread reamer toremove any part of the stud remaining in the hole. This tool is available at auto-parts and accesso- tos stores and hardware stores. Scrow a new stud in place. '&. Restore roundness of re-use- able pipes with a pipe shaper. if you have to cut away a tallppe from a deterio- ‘ated muffle, cut at the weld line. When as- ssembling parts. coat pipe connections with exhaust system sealer and instal a U-clamp. Tighten, but not excessively Installing exhaust 1. Work from the engine toward the rear of the ear. Dont lighten fasten- ‘rs. Rather, install parts lcosely. See that they are straight 2. Check clearance between pipes and chassis by placing your hand between each component and the adjacent free, Your hand should ft easly, with ‘enough room to move an inch or two up and. down. Be sure there is ample clearance around the rear axle and fuel tank 3. Tighten components securely after checking alignment and clear- lance. Be careful not to overighten. You may crush pipes. 4, Start the engine and check for feaks by pacing your hand lightly around pipe joints. You will feel a leak if one is present. Reposiion the clamp. 5. Test-drive the carand listen for ration and equenke tram undemaath indicating that an exhaust-system compo- nent is not eufceny igh and 6 tating aganst an adjacent area 210 POPULAR MECHANICS.1. Ser ALTERNATOR To adjust alternator belt, oosen bot, pull alternator tight with a bar, tighten bolt. hen a belt snaps or loses tension, the system the belt serves stops or works at reduced effciency. Therefore, i's best service betts before they fai Inspecting belts Examine bets ontop, side and bottom sur- faces (twist belts) forthe following damage which Hf found, elle for @ replacement: 1 Cracks—acracked bel flexes excessive- ly and may spit apart 1 Peoiing—zs layers peel away, the belt ‘weakens and will eventually snap. | Spits—a spit can wok through the belt rapidly, causing the belt to separate. 1 Gilaze—a slick underside o: side surface causes a bait o sip. 1 Otsosked—ol on a belt causes the belt tosotien, Replacing a belt Make sure you get the exactsize belt ‘needed for your car- Loosen mounting bolts ofthe partcular accessory or an ider pulley. Push in so the old bet fal; then remove it. With the accessory or idler pulley all the way in, he new belt shoud Just Mt Onto the pulleys. However, you may have to pry the ‘new belt over a pulley rim with a screwdriver. ‘Anew bet should have a tigt fi. Pull back on the accessory or idlr pulley and tighten the belt 10 the recommended ‘new-belt specication (see the service man- tua). Fun the engine for at least 10 minutes: then check belt tension again to see that it ‘meets the used-belt spectication (see the service manual). There are some deviations from this procedure, as folows: I Some setups have an access hole inthe ‘adjusting brackot into whish tho pry bar 2 placed This is to assure that the pry bar positioned against a part of the accessory that can withstand pressure, and not against COOLING SYSTEM vicing drive belts somethingtragile, suchas the ar-cooling firs Sillother setups have astud-nut adjuster Of the alternator. ‘onthe power-sieering pump, elminating the 1 Other setups have a camtype aduster need to apply any tension with a pry bar (onthe idler pulley. Loosen the retaining nut Loosenthe retaining nut and use a wrench to and tum the adjuster to attain correct adjust- tur the stud-nut adjuster totighien or loosen ‘ment. Then tighten the retaining nut the drive bet. ™™ We Started With A Great Idea — Then Made It 10 Times Greater ee A | Peete | wth patent ron en rere! sro iteca ee rer ies May au6+ DRILLS WATER WELLS 50...100...200 FEET DEEP ‘Saves You Hundreds of Dollars! Did you know that vast quantities of fresh, sparkling clear water lie within 200 feet of the surface of the ground almost everywhere? In the city. In the Suburbs. Im the country. Pure, tasty water untouched by chemicals oF pollutants "Thousands of bome owners are now dling thei own well from 50 to 200 feet deep! YOU can J in saying goodbye forever to expensive, chem- feal-tasting city water’ Forget about Groughtal Ignore summertime water shortages Fee hrapetnileciy rovide gen, year round watt for Your mete meicat ty ana a Raima First Eiaes Mail eet Deeprock Mfg. Co. ons Six FREE Pon Tote (800) 821-2280 (Ask for Extension 5081 ) on uP COUFON AA Mal Toda Semritecr ae ne ‘ereame olgness ond element cal PRINT NAME DRS POPULAR MECHANICS ‘y * COOLING SYSTEM 32. Replacing UPPER RADIATOR HOSE (COOLANT TO RADIATOR) OIL-COCLER PIPE Cooling-system hoses should be checked frequently. Examine themfor cracks, softness ‘and britieness by squeezing each one firmly from one end to the other. here are four cr five cooling-system hos- 9s in acar. Two ofthem are raciator hos- 15: One delivers coolant tothe engine, while the other transfers hot coolant from the on {gine tothe radiator. The two hoses that rans- {er coolant to and from the heater are also ‘part othe coding system. In additon, there ‘may be a bypass hose from the water pump to the engine. Hoses are vital to engine operation. it a hose spits, alowing coolant to be lost, you wil be stranded, since an engine wihout Coolant wil quickly overheat and seize. For ths reason, it is wise preventive mainte- nance to examine hoses frequenlly. Some carmakers even recommend that all hoses be replaced every two years to avoid an ‘emergency situation. Incidentally, i's @ good idea to carry duct tape in the car for tempo- ray repair ita hose dooe epit. Inspecting hoses Examine hoses for cracks, sofness and braveroes by squeezing ach one frm along ts entire longth. Hoses should beresi- jont and fexble. 1 cracks appear as you squeeze a hose, ropiace War the engine waimned up and running, check hoses for bulges. A bulge signals that ‘a hose is weak and likely 1o burst. Have someone inthe car race the engine 20,you enamine the lowor racator noses Ht flaiens out, the spring inside the hose is ‘weak. Repiacethe hose, since coolant ow s beng curtailed. A colapsed lower radiator LOWER RADIATOR HOSE [COOLANT coolant hoses HEATER HOSE hose causes overheating during higher ‘speed driving. ‘Caution: When checking the lawer radiator hose, koop hands away from fan, belts and pully. Dont wear clothes that dangle. ‘As you check each hose, examine its clamps for coolant leakage. it a clamp is loose, tghten it if distorted, replace it Replacing a hose To avoid burning yourse, replace hoses withthe ongine cor 4. Drain coolant to below the level of thehose thts being replaced. coolants to be reused, drain it imto a clean container. To 200 losing ary coolant. push a length ot Geen hose over the radiator petcock and place the oer end in a container. 2. Open the hose clamps, or cut thom off # thoy aro going to be replaced. ‘3. Pull the bad hose off its connec: tore by twisting and pulling. I the hose Is ‘tuck, ft with a uty kn fst. ‘4 Clean metal connectors wih a wire bnsh of emer) cloth ‘5. Slip clamps onto the new hose and push the hose onto ts connectors. the hose ls tght and dovsnt push home, soak in Pot wate a while 6. When the hose Is seated, post- ton clamps abou! ¥« nch rom the ends of the hoes and tighten the comp 7. Pour coolant back into the radi- lator. Sia the engne andlet runes you ‘examine that system fo: leaks.33. Checking thermostat he purpose ofthe themostt i 0 tap T cscantin 2 coo engine. When the gre reaches a temperature, th tormosta pens oll coolant foto the radon. the thermostat vaive gots stuck inthe closed poston, covlrtsWeppad ie engine andthe engine wil overheat. the ‘alve gots stuck nthe open poston, ie en ‘ine warms up very slowly, ata Mou cam get an rection of whether the nemo 8 working by reraweg fe aca tor cap with the engine cai) ardinwering & thermometer ino the coolant ‘Sarthe engine and wath the thermome: tor Keep squaezing the upper racair nose. \Wnen tne ermometer reaches the temper be al which the thermostat suposed open (ve o tae 107), yousheud oo 001 Sera Sing tnengh te etea’ howe {Drain about hall the coolant tro the radar with te engine coe 2. Remove bolts holding the ther moatat housing. Remove the housing SER the thermortat from the housing. Hol the unto a bright ight. The theron valve mist te cosed You sroui Soe no ight passing around the valve. the aire coeur cose, replace tharmerte ‘. Note the temperature reading onthe hemostal. Thee the temperate a when the hemostat's designed f0 stor pening Themontats are bu to be fay pen about 20 above rated temperate Tie the thermostat to the core ter of = wood dowel. nset 055m footer gauge between the fecmosiat valve to newseg. Tie a sing 10 te. toler gauge. Place the thermostat in a pan of water, Tre terosal most be aly Imerod bu teh mat ret on the bom or apnet he sds ofthe pan. Pace a er mometer inthe pan and hes te pan 7. Pll the feeler gauge free ven tne nemometer shows that water = hated ta he temperate stamped on the thermo. Sta nosing, pus of mus Sf you can repacethe hemos The hermosa valve Sheudbe wide open when waterreaches 20 Stave te retedtomporsure, geo tke & 2. Scrape ploves ot oid gasket ror the surace of he thermostat housing and fongne, Wie surfaces wih sohent 3. Place the thermostat in the housing, spring end aang ot Note ary marang that instructs you t pant te ter ‘mostan aparicular recton 10. Place down new gasket on roweinge be woe fat ee Stee yet Ihe up with heles on thermosat housing, 11. Refit the housing and tighten the bolts. Es The thermostat is cen- tered in its housing eet ip Mite, 346 Right now! Get in on Valvolines Motor Oil’s super bestia ke tes aera Look for the colorful “Check Out Five” display wherever motor oil products are sold. Just tear off a coupon, fill it out, and send it to us, along with your receipt and proof of Pees er ener AC Cre four quarts of Valvoline Motor Oil and a pees rereer ba te pare rrerete aes from A.J. Foyt and Sater id a een Peet eee a Peer esc tars you purchased your Valvoline products. Somers esheets MAY 1980 213WASTING ENERGY FIGHTING 214 34. checking for coolant leaks The cooling-system pressure tester pressurizes ‘the cooling system, also reveals any leaks. YOUR CYLINDERS ARE © The average Detroit V8 engine starves some cylinders and overfeeds others. “Rich” cylinders use more fuel; “lean” cylinders misfire, causing bucking and surging. Not only do you have less power unequal air/fuel mixtures waste gas. Edelbrock S.P.2-P. intake manifolds help eliminate this problem. They're designed to give each cylinder equal mixtures of air and fuel, providing better fuel efficiency, whether you're accelerating or cruising. An S.P2-P.is easily puton your standard engine by youor your mechanic. Now your engine operates more efficiently, Has more power. Smoothness. Sharper response. And better mileage, provided you drive the same as you did before! ‘or more information on Edelbrock’sS.P.2-P. manifolds, visit ee nearest auto parts store or send 32.00 for our full catalog including a product line price list, decals, and re ees . rt. PN ), ircle, El Gas California 90245. OUR INTAKE MANIFOLD SAVES GAS ‘AND BUILDS MUSCLE POPULAR MECHANICS TESTER ATTACHED Fo FILLER NECK viously, itisn't necessary touse a pres- ‘Suto tester every time. Some leaks are readily apparent because of the coloring of coolants. When coolant cries, i leaves corro- sivelooking deposits at a leak ste, Look for signs of leaks at these places: taciator seams. Where upper anc lower (or side-by-side) radiator tanks are soldered to the core. ‘Around radiator hose connections ‘A petcocks. ‘Around the thermostat housing, Around engine drain plugs or freeze plugs. At transmission ail cooler connections at the radiator. 1 Around the water pump. at heater-core seams. you find no leak, but still suspect one, use the cooling-system pressure teste. How to use the tester 1. Remove the radiator pressure ‘eap (engine cold), 2. Check coolant level. Add coolant, necessary 3. Start the engine and allow it to warm up. Turn the engine off and attach a Drassure tesier to the radiator filer neck ‘4. Examine the radiator pressure ‘eapto determine the prescribed pressure for the engine. I'should be marked on the cap. it ‘not, check the service manual 'S. Pump the handle of the tester until the gauge fecords the specified pres- sure. Don't exceed this raiing. Excessive pressure may cause radiator seams to spout leaks and hoses to rupture, '6. Look for coolant leaks at the ar- ‘oasiisted above with he system pressur- ‘zed. If aleak stil is not apparent, check the pressure testor gauge. I it holds the rated ressure fora least two minutes, there is no leak Ifitdoesn't anno leak's apparent, the leak may be intemal (cracked cyinder head, water gasket or block). 7. Release pressure as cescibed in the testers instruction book Remove the tester from the radiaior. Testing the radiator cap 1. Remove and wash the cap in water. Examine its gasket. If the gasket is cracked oF bite, replace the cap. 2. Attach the cap to the cap ‘adapter of the pressure tester. Pump the pressure tester until the gauge records the fated eapacty of the cap (markod on ho ap housing). Ths pressure reading must main- tain tself at least two minutes. Ifthe needle ‘rops before this time, replace the cap. FMMOTORCRAFT DO IT YOURSELF WITH MOTORCRAFT PARTS. Allittakes is you and Motorcraft parts. and is supported by Ford Motor Company And you've got a lot to work with—tune-up ais engineers. Motorcraft parts are available parts, batteries, shock absorbers, oil fi | aang fF Most U.S.-built cars as well as many ters, air filters, and much more. Plus a | seevies guide Popular imports. handy step-by-step guide you can send for So do it yourself; send for our helpful that will help you do 15 simple repair jobs guide, and use Motorcraft parts. . .forsure. yourself. Motorcraft Of course, while you're at it, we en- | Bort Yoursett Manual | M4 ti = | courage you to use Motorcraft parts. Each P.O. Box 5386 is built to meet quality performance levels Detroit, MI. 48211 == Plesse o | ! Name | Address. - | city State Zin NOTE: CHECK OR MONEY ORDER ONLY, PLEASE. a35. Flushing the system HEATER INuer DEFLECTOR |FREE BLUEPRINTS and TRIAL LESSON —for your greater success in Building Beginners, craftsmen, even foremen and superintendents, have seat for these free blueprints and trial lesonin Pian Reading as a means of trying out Chicago Tech's home-study Builders training. See how you can lear Plan Reading, Estimating and the practical details of all types of construction in your spare time at home. Mail coupon or phone TOLL FREE today for your free ranch home biue- prints, trial lesson and catalog on CTC Builders taining, ‘* PHONE TOLL FREE (24 HRS.) 1-800-528-6050 Ext. 810 CHICAGO TECH/School for Builders 20008. Michigan Avenue, Chicago, (60618 1” guucago requecteat ioc } Sresehecree in HEATER HEATER _ OUTLET Hose Fro BUN) fore ony al Fon Til Lassen, Smpnig eee eet eS RADIATOR To backflush the system, install oe ‘ing on nearer nose, attach acapt- ‘erand connect garden hose to the ANNOUNCING Reo Say ELECTRIC VEHICLE Pew vN Ale Here, in one catalog, you can find a wide Selection of the specialized parts neededto build or convertanelectric vehicle. Batteries # Motors «Test Equipment instruments # Cables «Fuses # Connectors # Accessories # And Much More In addition, the catalog includes a number of technical articles on build- ing and converting EV’s, including diagrams and pictures. Send $2.00 to The Electric Vehicle Catalog Department EV 2 FLIGHT SYSTEMS P.O. Box 25 Mechanicsbura, Pa. 17055 VISA / MASTERCHARGE ACCEPTED FOR PARTS ORDERS POPULAR MECHANICS tes. Flush until water runs clear. Jar manufacturers recommend that you ‘drain and flush the cooling systom ev- ery two years. The job has been made easier {or the Saturday mechanic by development of a flushing kt ‘Ater the cooing system is drained and flushed, new ccolart should be added. The maximum lite ofa high-quaity ethylene gly- ‘col coolant is two years. After this time, ec ‘ives which protect the system from rust break down. Draining and flushing 4. With the engine cold, sat the heater control on est to assure that cooant in the heater core wil aso drain 2. Remove the radiator pressure cap. Z open the petcock at tne base of the racstor ‘Note: the radiator isnot equnped wih a petcock, remove the lower rackator hose 10 Gran no radiator “4. Remove the drain plug o: pugs. i possible fem the engine Black Since ths is fot possible on mast engines, t becomes necessary to backtush the engine wih @ flushing kt 0 drain coolant 8. Fit the flushing tee from the kit to the heater supply hose, Ths is the hose that runs the engine block. Ii not the one’ that connected te the. water pun. Toft the fushing tee, cut the heater supply hose, insert the tee and tighten the clamps thathols the toe. Face the toe so water which thay escape from f wont run onthe alterna. tor ‘Note: Flushing toes are available in throo sizes to match inside diameters o! heater hoses. Determine the size you need by mea suring the outside diameter of the hose and subtracting 4 in. 6. Attach a garden hose to tee us- ing the adapter in the kit. Meke sure that the heater is on, radiator cap is off and radiator petcock is open. 7. Attach the deflector to the radi ator filler neck. The detactor, which is part of the kit, throws water away from the engine. &. Turn on the water and allow It to flush the engine unti water pouring ut the deflector begins to run clear. ‘Note: # your car is equipped with airconai- Sioning, let the engine idle while flushing. ‘When flushing is complete, turn off the water (and engine fits been run- ning). Flemove the deflector rom the radiator ‘and adapter rom thetee. Allow waterto crain omplotaly kom the radiator 10. Close the radiator petcock (or reinstall the bottom hose). Now, add a 50 to 50 mixture of ethylene glycol coolant and water tothe radiator untilthe solution starts to our out of the tge. Cap the tee with the cap ‘supplied in the kit. Leave the tee in place. 11. Squeeze the upper radiator hose to expel alr. Then add more cool- tant, if necessary, to bring the solution to the fil mark on the tadiator orto just below the radiator filler neck. 12. Run the engine until the upper radiator hose feels warm. Shut off the engine. Remove the radiator cap ca and recheck the coolant levelDramatically Reduces Gasoline Consum| Major Breakthrough in ption! 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Saws to width, planes todesired thickness, and molds to any choice of patterns. Cuts any molding pattern you desire. Provides trouble-free performance. And is so simple to operate even beginners can use it! 30-Day FREE Trial! eccrine rn EXCITING FACTS NO OBLIGATION-NO SALISMAN WILL CALL 8018 Field Buiing TODAY! Kansas Gi, oa ‘BELSAW POWER TOOLS Co. 2018 Field Buiding DYES, pes send mete FREE Bons ow oes me Covet ts abot Beans Paar fora io-bay free Tal gar my om Sop (atstond there 18 No Obtgaton and hat No RUSH COUPON SESAW POWER TOOLS SS ae eneee, a! Neral als hon ath lean =I POPULAR MECHANICS 36. Servicing tires EVEN WEAR HEAVY WEAR + SCALLOP] ‘none FAULTY WHEEL ‘WHEEL HiBALANCE GVERNFLATION UNDERINFLATION ALIGANENT (CAMBER) ‘AND/OR DAMAGED WEAR WILL SHOW ON’ SUSPENSICN. EITHER SIDE COMPONENT. Tread wear can indicate: . Faulty wheel alignment will show up as 2 suspension biased tread pattern. An out-ot-balance tire will show as scallops or cupping. th proper mairtenance, meder radial tires. generally last at least 40,000 miles. Some tire comparies and automobile manufacturers advocate rotating for maxi- ‘mum tread lie. Others, inclucing some man- Uulacturers of front-end alignment equipment, claim that rotating tres is a waste of time, “The one area of agreement between the two Is f0 not rotate tres of cars with front. wheel drive. If you don't rotate, you may get ‘as much as 100,000 miles of sarvice trom reson the rear wheols, assuming the cars ‘equipped with radial tires. Maintaining tires To get maximum lle from Sres, do the fol owing 1H Chock ait pressure every 30 days with a 20d quality pressure gauge. Follow the ait Pressure recommendations ofthe car manu= factuer. They are prnted in he owner man- al and, usually, on a decal somewere in the car ‘important: Check ar pressure when tres are cold. A eo tire one that hasrit been driven more than three mies ‘or several tours lis best. hereore, to check a pros- sure in the morning before the oar is div- a & Replace a tire if ithas the following phys- ical damage: bulged areas, cuts that extend into the fabric end excessive ead weer “Tread wear that leaves tread depth ein. oF Jess across two asjacent ead nbs is conse ered excessive. Measure ead depth by placing a penny (Lincoln's head down) in the 7 a! diferent spots. Whe top of Lncohs head shows, the ted depth I too: sha tow, Check each tread 1b for embedded stones or other foreign meteral Pry them out witha scewsrver Remove valve caps and wet valve stems. water bubbies, thre a leak. Replace the valve core. Then, inflate the tre 10 specifed pressure The story tires tell ‘Tread wear pattems can tp you off to a ‘mechanical problem that is causing abror- ‘mal tre wear. If the problem is caught and tre may sil af- ‘The folowing descrbes the types of tread \woar you'e likly o encounter Im Smoon stipes actoss the 'ace ofthe te. ‘These are wear bars. They appear when the tie is nearing the end of is ite. Bars signify ‘ormal tire wear IH Tread wearing mor in the conte ofthe tire than ai the edges. The problemi chronic ‘overinfation IB Tread woering more at the edges than in the center. The problem is chronic underin- flaion 1M Troad feathering along edges. Check ‘Whee! alignment IW Tread wearing along one edge, inside oF ‘outside. Check wheel alignment (camber ad- Justmont, in particular) I Tite wearing uneveniy over one or more ‘pots. Check wheel balance. Scallops (cupping) developing evenly ‘ver an area. Check for a damaged suspen- sion system component. 1 Fut-spot developing. Analyze the way You accelerate and stop the car. A fat scot Often means that you are spinning tres when Yeu accelrao re caro you ar making serweching stops.