OG) 6 Jaaegescens REPLACED PARTS OF YOGR'CAR. This ninth annual Car Care Guide focuses on the 50 most commonly replaced parts of your car. Since these 50 parts eat up the biggest PAC Ure Ch eam Cw ee BSA Cole lo eta Relic eee UR CMa (el ete a The computers are here and we'll show you how to troubleshoot GM's new Computer Command Control, and take a look at how auto com- PCR Tat ile Bae re eel Celie CCH eer leesDo-it-yourselfers: Get filthy nasty ugly dirty.. A> a Pr ya clean. and dirt,Sparkplugs 2. Sparkplug cables 3. Distributor cap 4. Rotor 5. Points 6. Condenser 7. ignition coit Air filter 9. Fuel filter (conventional engine) 10. Fuel filter (fuel-injected engine) 14. Automatic choke 12. Glow plugs 13. Fuel injectors 14, Idle-stop solenoid 15. Fuel pump Hoses 17. Radiator cap Overflow tank Thermostat 20. Water pump 21. Drive belts 22. Oil filter 23, PCV valve 24, EGR valve 25. Charcoal canister uta Tee 26. Air-cleanermotor 27. Sensor 28. Vacuum modulator 29. Automatic transmission fluid filter 30. Battery 31. Cables 32. Bulbs 33. Fuses 34. Headlights 35. Windshield wipers 36. Tires 37. Shock absorbers 38. Brake pads 39. Brake linings 40. Brake drums 441. Brake rotors 42. Brake cylinders 43. Master cylinder 44. Starter motor 45. Starter relay 46. Engine gaskets 47. Wheel bearings 48. Ball joints 49. U-joints 50. Muffler Prepared by the editors of Popular Mechanics with technical art by Dale Gustatson, Fred Wolf, Jeff Mangiat, Ed Lipinski, Hank ken and Mike Terris. Photos by David Prult. Car Care Guide designed by Don Mannes. When Should You Change Engine Oil? How you drive determines now far and how often you should change your crankcase oil. It is nearly impossible to drive a car” properly so. that yearly changes of oll would be safe for your engine, Traffic Jams, winter_warm-ups, short runs, taking kids to school, and those short trips to the store all tend to shorten the lite of your oll On top of that, today’s engines are smaller, work harder and ru hotter. Ail of these things help foul up engine ol, create var- nish, gum and sludge as they use up the additives in the ‘A quart of RISLONE with each oll ‘change and new filter. will get rid. of power robbing its, and clean engines run longer and more econo- iy than dirty ones. Look for the big QUART red, yellow and black RISLONE can. For 40 ‘years, motorists have been telling us that RISLONE really works! amped salt tenved envelone {ot your Fite Copy 2 ens ace UG3e"Rlbs" Soon ‘wil answer some a! your usellon aSat ening Sresten THE SHALER CO. 21 East dotierson St. WAUPUN, WISCONSIN 53663 eda: Warren Packao) MAY, 1981... 136fluTO MAINTENANCE Is MORE IMPORTANT eet oy teas dreamed of 30 years ago are popping up under your hood. But fixing the cars of the '80s can be as easy as falling off a microprocessor. ROA brake drums was.a real chore. Pe end prerea reasapart?” many PM readers wanted to know. (If you refer to the 1964-66 issues of PM, you'll find that we told them.) Nor did the alternator have the farnifiar parts of a generator; that is, the armature, fied coils and brushes. ‘What in the world are rotors, stators and diodes?” letters addressed to Car | Clinic asked. Many of these Saturday mechanics worried that with the purchase of their next car they would have to hang up their tools and turnthe vehicle over to "special- ists" for repair. Well, it hasn't turned out that way. Those who wouldn't let the Sat- urday mechanic become an endangered species boned up on alternator (and oth- @) tachnology, getting much of their infor- mation in the pages of PM. The alternator is only one example of the revolution in automotive technology which has taken place since the 1950-60 era. The Ist is long, including electronic ignition, sealed fuel pumps, lubed-ior-ite ball joints, maintenance-free batteries, Now there is finally a connector designed and engineered to eliminate these frustrating, dangerous and costly problems. All-Safe’s tough, polypropylene covered connections en- sure longer battery life and performance, by iving you 45% more conductivity than sealed carburetors and computers. Our readers have been meeting this challenge. Instead of an increasing num- ber of Saturday mechanics being put out topasture, more car owners than ever are becoming Saturday mechanics. More are conventional lead terminals. doing their own work, and there's a great er amount than ever for the Saturday mechanic to do, Wyou don'tbelieve this, compare some: Cem ay Revolutionary new “Handy Clamp’ ee Ic) concept. : POAC CRIME | of ne shop manuals ofthe past mith those Reduces connection ime to mere ARR APRSSEMREOMINE | of ivy. Just tho sizeof present manvals . Henge nigel fe enough to overvholm you. For oxam NO tots required to connect te pesca ple, the manval covering te 1955 Ford ‘models is 341 pages long: the shop man- tual for the 1980 Ford Eacort (only one model) contains 625 pages. Like the coming of the alternator, pollu- tion-control devices caused chagiin be fore they were understood and “con- quered’ by the nonprofessional mechanic. What's next on the list of challenges for the Saturday mechanic? Electronics, in a word—specifically, the sophisticated computer GM has installed across the board in 1981, While the thought of working on a com- puter may seem overwhelming, almost impossible, ultimately it wont be any ‘more complex than working on pollution- control devices. Of course, you'll have to be equipped with the information that allows you 10 perform the necessary maintenance. Because of this increasing, but acces: sible, complexity of new-generation en- Qines and controls, and the increasing cost of skilled labor to maintain these eeu] Dee ee ecm es * Spring loaded brass connectors have grooved teeth to bite into battery post. + Won't vibrate loose, won't wear out. + Easily removed when necessary. Color coded Red; pos., Black; neg. Cannot be cross connected. * Completely covers post, no shorts or arcs: * Cover Is filled with anti-corrosion gel. * Heavy duty copper cable to match Joad- requirement: Special clip for safe jumper capability. Ces RT Cee und eT me ae Res ee ert Seemed Conan c air) feet Send remittance with coupon. $14.95 per set, plus $2.00 postage. tome powerplants, it becomes vitally important a ee oA meee meee Suce raus dere FNAB 5s re 1 | "Womight mourn passing ofthe rug ged, simple mecnanical systems ot the ast, but, we bet, quicker than you can ‘say siicon chip, youll be able to master Engine any new piece of hardware that shows up sem=s | under the hood. ™ CTC me ra ce P.O. Box B emcee Tea) Wake 138 POPULAR MECHANICSis CARCARE MONTH May Joseph B. Mitteiman CChaitman of the Board, AUTOMOTIVE PARTS & ‘ACCESSORIES ASSOCIATION This year represents the ninth consecutive year that POPULAR MECHANICS and APAA have co-sponsored “May is Car Care Month.” The goal of this national program is to educate car owners inthe proper ways of car mainten- ance. And, in the process, to make them aware of the auto care prod- ‘ucts that can help keeep theit care running smoothly and efficiently. Newspapers throughout the country are doing their part by publishing ‘Car Care Month sections during the month of May. ‘The cooperating Manufacturers listed on this page offer the products that can keep your carin peak condition and contribute to ‘energy savings. (On pages 142 and 143, you wil find the APA - member Retailers featuring these and other car ‘care products , plus helpful hints that enable you to “DRIVE A MANUFACTURERS Weer >ANCO | ‘onde Boy Filer ‘tole Spatoins aD Emcra SaeFan s| ‘wm Fan Cech ‘Ser 100 et 8 © Kendall. MOTOR On. Motorcraft | =< Sooer tes PEAK etresze Eeooert Pouaxer Bia ‘uaer Sate Stony Me OF Detune Nore Ot Sipe lens totrO8 rrr OrtrenmeDe GM'S COMPUTER eouusteas. — euectno. coouwr twos. IDiEsrEED MOTOR EAA Gy MEGIANICAL sean" pestiot _RGRRATION MESA SM ieN'stocn Seka ps unce BRGen EST DISTRIBUTOR AND HEI MODULE SLUM =< OXYGEN. Sensor BAROMETRIC \ Seas OO Siar ssccsanl mrurougen FUSE BLOCK: There's a computer in every 1981 GM car and we found this had its pros and cons. But you had better get used to on-board computers— they're here to stay. ~ It you buy any of General Motors’ 1981 cars, you will also be buying a.computer. The Computer Command Control (CCC) exhaust-emission sys- tem will both monitor and control many functions in all GM engines. Its no secret that keeping a car running well and still having it remein nonpolluting, along with getting good ‘mechani variables involved that must be set and main- tained in an engine. 140 POPULAR MECHANICS ‘The most important variable is that the mixture of air and tuel be Kept to the most efficient ratio for a catalytic converter to operate on. That ratio, by the way, is 14.6 parts of air for each part of fuel GM has come up with what might be thought of as an intelligent wrench The CCC computer, mounted be- neath the dashboard in the passenger ‘compartment, is connected to various SENSOR engine components. It monitors and controls carburetor, catalytic con- verter, oxygen content in the exhaust manifold, coolant sensor in the engine block, and a “check-engine” light in the instrument panel. The oxygen sensor in the sends it ‘computer is also receiving data trom ihe engine-coolant and thvollle-posl- tion sensors. The computer looks ‘over the information, then uses a sole- noid in the carburetor to make the TEMPERATURECOMMAND CONTROL | with intormatior computer's memory. (tight) is called control module (E vacuum pump and ets you service “ELECTRONIC ‘CONTROL MODULE (ECM) We snow (right) a part of one of ine Jong, Involved flow-chart diagrams in the Computer Command Control service ‘manual, Tests (like the one above, done witn 2 aigias voltmeter) are simpre, ‘but time-consuming. Most problems fill ‘few pages in the manual and can take ‘several hours of work to track down. GM's systom works by matching ‘input from sensors (circled) under dash in passenger compart- ‘ment. & $200 outlay for digital voltmeter, dwellmeter (left) 3 stored in the The computer the electronic CM) and rides various cables ‘entire system. air/luel ratio leaner or richer. The adjustment is made by turning the solenoid to a full-on or full-off posi- tion up to 10 times a second. The computer monitors not only the engine components, but also the parts of the CCC system. If any of these items should fail, the “check-engine”” light flashes on the dashboard. The car also becomes less responsive—in fact, downright cranky, and impos- sible to ignore, At this point, you have a choice: Drive it into a GM authorized- service facility or do the repair yourself. Finding out what is wrong requires about $200 worth of instruments—a digital volt- meter and vacuum pump, as well GROUND TROUBLE CODE, TEST LEAD es a few jumper wires and cables. First thing you would do is ground the test lead coming from the CCC computer. The “check-engine” light would then flash a coded sequence of blinks. ‘The “check-engine light, for exam- ple, might blink once, then pause and blink three times. It would repeat this ‘over and over (until you disconnected the ground lead) to tell you it was a Code 13 problem. If there are two or more problems, the computer would blink each code in sequence. ‘Once you have the code, the fun begins. The service manual leads you step by step in a flow-chart form until you se IF LIGHT REMAINS ON LIGHT COMES ON | uw Eni me HO NES re Ss ir wav hows suock I5iton CF” Bee ore course’, || trees SPER SensMay is CARCARE MONTH REGULAR CAR CARE IS REWARDING. . . in, dollar-savings, energy conservation, safety and in the personal satisfaction of ‘owning a well-maintained, dependable automobile "May is Car Care Month” is designed to bring to the 2283 S8RE55EB>9R 352. : FRE6 553 SXBRSR gE z 2/2 i ‘DISCOUNT Ty BOWDEN'S AUTO PARTS INC. Bowes “Seal Fast” Co. Ltd. Boyey cap! Gonsumen Quro Prepay i Cay DART@ DRUG v.08 285 3R2 5 20, MO, vA FOREST CITY =" ‘AUTO AUTO'SUPPLY ‘Avro ‘suPPLY GRAND/AUTO OKT or waSTATEWIDE AUTO SUPPLY 19.0R NATIONAL _ ay sebpe 32293 55283 ABREBREZO? 5892355 z5 229255: 33 # OWA BRE See 28 g Qusity [xMon NLNY Aa VARIETY AUTO. ‘SUPPLY Wass WESTERN AUTO) rc Coe wow excer so IL HS. O6 aa . az 223 to Help You! APAA has joined with top professionals in both the ‘automotive and entertaln- ment world to produce CAR CARE CENTRAL. @ Anew, 26-week Tolavicion Serie. © Dedicated to helping people take better care of thelr cars through better maintenance. @ Aired in prime time ‘weekend hours. @ To begin during April and May. In addition to demonstra- tions of auto maintenance procedures, CAR CARE CENTRAL will feature interviews with top celebrities and experts in the automotive field, Check your local news- paper for times in your area, Participating Retailers wil have details and also offer POPULAR MECHANICS- prepared brochures illustrating the suibjects covered in each TV show. Watch CAR CARE CENTRAL W's designed for car owners ‘who want their cars to fun better and last longer.re ———— = = ae ante! G e HE COMPUTERIZED COR Cec CR am - Ween eer Pe CUE eae ee aU Control is just the beginning. Re ge ee Ch eee ace as fam atele ele hieUlecce) PC ROR eam aes A Phu ue Ue ae ce he computers Saad) ag EC ce ue ee SUR Cue-UmLCo) Peer a a amc ae Rete Lela A BU UM CMe MCR RU gu EMM ols sepih tion dump from the Buffalo office.” BOT ee RR ed Ree eC eu ais ole aaa on a Tas ! ena Sco aa Posen ea Cena)CAR OF TOMORROW SU aucune) Roe ue eee et Gee Oe eeu ee) Creer eam) erat a ee Ce tan ny Cem a eee CC) Pee Cum cn ecs eee re te ee td Re eee eee a an his words into a microphone built into the wheel— PRC eee eee Re a eer rt Bae nen eee Mums RO eee en Ua UP Creer ie tr aie ene ome ea uC Ree nea C Le a Ges cag ogy. Let's take a look at just a few of the systems Pea id CT eg Youre never going to get lost driving this car. The eae ee ea ea Ra eed 300 largest American cities. Under the hood is a Pern cle a ee CRC MeN eae ae cue rsWHEN YOU'VE GOTTA RELY ON YOUR CAR, RELY ON HARDWORKIN’ AC-DELCO PARTS. Cae Ses okafe MSS Lae ML dna oe cold-crankin; road-handlin; dirt- the one name they look to for Fire hot. And help resist foul- fightin: hardworkin’ replacement just about everything—for just _ ing. If your car's plugs are mis- Pee erga ee eer ete om firing, a tune-up with a new eu eae pec ue CS Cae hardworkin’ people have relied Delco Freedom Il Batteries for _ improve gas mileage. Cents ot ee eRe ca Se Be eet cunt acid BS ore CO Cos OR URC ad Gert Pare ee aces cle mely eee a a ee os [ol a easeCAR OF TOMORROW (Contieved trom page 145) data directly to the car's main comput- er. ‘What you seeas you're driving is a map like a Trip-Tik. A moving spot on the map represents the position of your vehicle— accurate to about 20 feet. On the big screen Videodiscs right now can store up to 54,000 video frames on anLP-size digital platter. The first experiments have recently tak- €en place on interfacing computers to vid- eodiscs. One university lab features a large projection TV hooked up to a vid- eodisc. The disc, in turn, is controlled by @ computer. The operator sits in a chai and, using hand controis, takes a “walk’ through a videomapped city. The effect is very much like being in the real city. ‘Our cer features such a system, but hooked in right to the steering wheel. If you're heading for a strange city, you will first buy yourself a videodisc tour, plug it into your car and then “drive” through that city without leaving your garage. And, if you're heading through a scenic area at Night, just pop in the videodisc for that rea. Your passengers will be able to enjoy the show—bu keep your own eyes (on the road. ‘One thing about using an advanced ccomputer—you will have such a wealth of detail that you coulcn’t possibly view it all at once. The dashboard would be lit up like @ minor explosion. Most of the dash displays will be mzitiourpose. ‘Some controls wil be the familiar ones ‘of today—everything from courtesy-ight switches to a cigaret lighter (for the future's noncarcinogenic smokes). We showthese controls on a rotatable, mush- roomrshaped Lazy Susan. Other con- trols, grouped on the steering wheel, let you quickly call up various instrumenta- tions. One cisplay, a smal monitor, will become the focal point of your observa- tion. Shown will be a three-dimensional “ghost” image of your car, with any offending part or system flashing red. ‘The main video diaplay will be used not only for videodisc viewing but, in an emer- gency or service situation, the entire sta- us of the ca—a_sysiem-by-sysiem check—can be “dumped” to the screen. True collision avoidance may or may not ever become reality. But there's no doubl that the computer will be used to alert the driver to emergency conditions. The on-board computer willbe in con: stant communication with highway patro computers, which will keep it advised of oad conaitions, speed limits, accidents and the lke. The car of tomorrow is cioser than you + think; Computers have already opened the door. GM'S COMPUTER COMMAND CONTROL | (Coniec fom oage 141 The electronic control ‘Module (ECM), or ‘computer, slides out ‘fits carrier under the ‘dash in the passenger ‘compartment. But, for ‘most service, there is noneed toremove the computer. If anything does go wrong wit the computer, GM dealers will offer re- builts under $200. locate the actual component causing theprobiem. Some oftheflow chartsare straighiforward. But some go on for many pages and can take hours. The dealer cost of a new computer is $250. That would likely work out to around $350 retail But, even if your computer does die, you won't be socked with such a heavy expense. GM has set up 4 number of remanufacturing plants. A rebuit com- puter will est Beimeen 3100 and $200. The question is: Is the cost—both axigh nal and replacement—worth it? depends. it would seem hata COC system on a small Four simply adds an unnecessary layer of complexity. None of the Japanese cars on the market has a system anywhere near as complex to keep engines clean and efficient. Their four-bengers accomplish good mileage with conventional -electromecharical controls. For surviving VBs, the CCC is proba- bly the only way to achieve adequate mileage and emissions levels. One matter of critical importance to the Saturday mechanic is servicing the system. While troubleshooting and di- agnosis procedure is not difficult, it is certainly time-consuming. With labor rates for professional mechanics rang- ing from $18 to $36 per hour, the cost of tracing a problem might be three or four times the price of the faulty ar. Local garage operators, who as a rule don't keep up with the latest technical manuals, will probably be even less familiar with this system than a dealer's service deparment. Ultimately, the owner of a GMcar will ’be forced, by financial necessity and an information gep. into learning as much ‘ashe can about the CCC to keep his car in shape. The iniormation is certainly available and inexpensive. And, in the Jong run, the owner might be best off doing the job himset. ‘Our PM Owners Reports cn GM's 81 cars will be examining the reaction 10 this Computer Command Control Now and tomorrow Technically speaking, the computer is. a 6809 CPU running at 1 MHz, and addressing8K of RAM and 250 words of RAM memory. Putting that in English boils down to a computer somewhere around the sophistication of a good home computer, but under-utilized 'A.6809 CPU (the “brain” of this com- puter) can access a program of 48K, or six times the amount of program now there. Alli peods i the adkional mem ory—and that is very inexpensive. Pro- grams, which tell the computer what to do and when to doit, are stored in plug- in “chips.” The only diference between the computer in a Caddy and one in a Vette is the diferent program. Programs right now are set to give high fuel economy. But, as we men- tioned in PM Brectronics Monitor (page 32, March '81), thera is no reason why an aftermarkel should not develop in ‘hese program chips. i you want to lose a few miles per gallon and gain quicker acceleration, itmay someday mean just changing a program chip, ‘There are many—at least a dozen— totaly unused "ports" on the present configuration of the GM computer. ‘Those ports are ready to accept inior- mation trom anywhere you might install ‘a sensor—and they are also ready to control other devices. ‘Any good electronics technician, working with an accomplished computer programmer, should be able to think of ‘numerous add-ons to the present com- puter system, Everything from instant ‘and continuing mileage reports to coll sion avoidance might be right on the ‘automotive horizon. Our accompanying story, The Com- puterized Car of Tomorrow, details how the computer revolution in automobiles may culminate in @ Buck Rogers dream world GM deserves credit for being the first to put computers in al its cars. In one way ot another, the computer wil never leave, MAY 198147ee Ce THE 5O MOST COMMONLYsiaileshienad bate Lo] mm (ell xa i):) Per Pee ees SO.MUFFLER 29, BRAKE LININGS & yangpuete acu 43. MASTER CYLINDER (GREER onswn 20. FAweuission. FLUID FILTER Regular maintenance or replacement of these critical parts will keep your car running—and 48 ERSKETS your mind at rest—for years to come. The following 50 sections will tell you how to spot malfunctions in each of these parts, and how to fix or replace them. 38, BRAKE PADS 41. BRAKE ROTORSPeed1. SPARKPLUGS parkplugs that don't function property Jcause one or more ofthe folowing engne problems: Hard starting Stalling ough idling and roughness when driving lower speecs. Misiring at higher speeds. Lack of power upon acceleration. Excessive fuel consumption. ‘Other components of a gasoline engine can ‘cause one or more of the same conditions. To deterrrine whether sparkplugs are at fault, therefore, remove them from the engine for ‘examination Removing sparkplugs 1., Write numbers on strips of mask- Ing tape tne en in ahallng opastrphog cables. I the engine is @ four- oF six-cylinder in-tne ‘madel mounted longtudnaly, number cabes Consocutvaly from the front of the engine toward the rea. 1 the engine Is a four-cyinder transverse- ‘mounted model. number cables consecutively From left to right as you face the engine com- partment from the tron. W the engine is a six-cylinder vansverse- rmeunted model, number the gile-side cabes Ft, F-2 and F-9 as you face the engine com- pariment trom the front ("stands fr tron). Number the firewal-side cables R-1, F-2 and RS as you face the engine compartment from the front (stands for rear). i the engine is a V8, number the let bank cables Let, L-2. LS and Let from the front toward the rear as you face the front of the engine. Number the right bank cables R-1, P-2, FR and F- from the ont toward the ear as You Face the font of the engine. Caution: Proper ideniication of sparkplug cables is important to avoid incorrect reinsia- lation that would tow engne fring outa ln, possiby causing engine damage. 2. Use a sparkplug cable-removing tool (your auto parts and accessories dealer can recommend one) to grasp boots over sparkplugs. Twist and pull unt boots pop ot Sparkplug boots in some cars (K-cars, X body models and EscortLynx, for example) don't require use of a sparkplug cable puller. Boots are exira thick and large, forming han- dles that permit you to easily grasp and pull them loose by hand, ‘Caution: Don't pul on sparkplug cables themselves. You will ear apart electrical con- ductors inside the insulation, runing the cable. ul only on boots. ‘3. Clean out sparkplug ports to pre- ventirt particles trom falling into cy Inders as plugs are removed. Paricies in ‘oyinders may cause engine damage. if you have an air compressor, direct bursts ‘otcomprassed airat the pers. you don'thave ‘compressor, a product called Dust-Of,, which isavalablein photo storesand hobby shops, is ‘a00d fo use. TAPERED SEAT SQUARE SEAT Installation methods vary if plugs have gaskets or Mf thelr seats are tapered. 4. Using a ratchet wrench and cor. rectsize socket, tum plugs counter- clockwise to loosen and remove them. 4 "ein. hex socket fits most spark- plugs, but a 4+ or Yin. size may be needed ‘As you remove each plug, wrap a piece of ‘masking tape arcund it and write a number on the tape that coincides with the cylinder num- ‘ber from which the plug was taken. I plugs are tobe revsed, put each back where you Tok t installing sparkplugs Whether you reuse sparkplugs or nstallnew ‘ones, be sure they are gapped to the speci- {aon recommended in manufacturer sevice literature or on the vehicle emissions-contol label in te engine compartment. Use a wire soaring falar pagan a fatclare Fyre {hat will resut in an erroneous adjustment. Push and pull the gauge in and out between ecttodes. The gapis correct when here is a Sight drag (Viton) onthe gauge ut pugs inthe orgine as follows: 1. Install new plugs having the same designation, uriess pluns tat h been used in the engine show they were intended fora diferent heat range. 2. Examine the threaded onds of plugs te determine whether they have Square seats that use gaskets, or have, instead, tapered seats that seal ‘themselves to the cylinder head with- ‘ut the need for gaskets. Ths informe. tion will help you establish to what degree ‘lugs should be tightened. 3. Use a sparkplug thread chaser to clean sparkplug port threads beore Installing the plugs. This too is screwed into ports to dean paticies trom threads. Par tiles can lodge between a sparkplug and cy! inder head, causing compression loss anc possiynirng spartpug or oynder hea. Screw plugs into the cylinder head unl they are finger-tight pugs have tapered seas, tghten them Ye of a tum from the fngersight position. X pgs use gas- eta, ighton thom % turn from that pooton. ‘5. Reconnect sparkplug cables to their respective sparkplugs. ‘Sparkplug condition NORMAL. ‘can be used as a diag- GAS-FOULED O1L-FouLED 151 May 1981NOW, IMPORT OWNERS BUY needs —at do-it-yourself pri Why Lee Maxi-Protectio: THI 2 FILTER has a unique outer filter that traps large dirt particles, helping the filter work more effectively. Result LEE Max-Air Filters stay cleaner up to 50% longer, Igat up to 50%, loner and irap yp to 50% more Girt than ordinary singie-slage fiers THE CHEAPEST EASIEST WAY TO SAVE GAS?Q. SPARKPLUG CABLES y y - When removing sparkplug cables, always grasp the boot, twist and pull out. Don't pull on LD Feld the wire alone. To Kdentlly cables fo the proper plugs, use tape with numbers. ‘auity sparkplug cables bring about the fol- lowing engine problems: Hard starting or falure to start. Stalling | Rough idling or roughness, when criving at lower speeds. When one of these conditions occurs, wipe tne cables witn a fag and inspect hem. Bend h cable back and forth as you look for cuts and cracks. Replace cables thal are dam- ‘aged Even if cables don't show damage, they may have invisible breaks. To test for them, attach Cone end of a jumper wire, whose ends are out- ted with aligator clips, 10 the shank cf a screwdriver. Aitach the other aligator clip to @ clean ground on the engine. ‘Start the engine and disconnect one spark- plug cable at the sparkplug. See that the toot of the cable faces away from metal and pass the tip of the screwdriver slowly along the length ofthe cable. Koop the ecrowdrivar Vie to vein, trom the cable. 2 spark jumps from the cable tothe screw- diver, there isa breakin the cable, Replace it. ‘Aner a cable Nas Deen tested, reconnect it Securely to its sparkplug and test the next cable. To test the ignition coll-to-distributor-cap cable, which has to remain atlached on toth tends lor the engine to run, leave one of the other cables disconnected. Pass the scrow- river along the length of the ignition collto distributor cable. There wil be enough resi tance n the circuitto cause a sparkif there is a break in the cable, Replacing sparkplug cables Remove fauty cables from sparkplugs and the dietrbutor cap. Bo eure to Buy the sorract type of cables. Cables you buy should be as long as cables you are replacing, Note: Replace only those cables that fal to. pass inspecton. You don't have to replace cables as a sel. ‘Generally, cables for use in today's.cars are called TVRS cables. TVRS stands for Televi son-Radio Suppressor. This ype of cable pre- Vents auto ignition systems from interfering with TV and radio reception. It you need assis tance in selecting cable for your car, ask your auto parts and accessories dealer. To attach cables to sparkolugs, grasp the boots. Push and twist them onto the pugs unti they wont go any further. Toinstall acable into a distibutor-cap tower ‘or acoll, grasp the boot. As you push and twist the cabie into the tower, squeeze the boot to ‘expel air ‘Caution: Crossire is a condition that alows ‘current flowing through a cable to be induced into an adjacent cable, causing a sparkplug to fire out of tum, The result could be damage to ‘engine parts. To provent crossfire, know the positions of sparkplug cables in thei lation to each oiher. See that two cables of consecutively fring sparkplugs are nctparalle to each other, espe- Cally at heir ower lengths. To avoid cross these cables should cross. Silicone wire The best way to ensure reliable fife rom your sparkplug cablesis to use silicone wires. Most ‘der cars came equipped with organic, rub- bor jacketed cables which deteriorate rapidly Slicone-jacketed cables resist deterioration ‘caused by ozone, your cables’ No. 1 enemy, and heat. Current, the industry tests silicone cables ai 500°F. without failures. Tests have ‘aso shown that slicone withstands higher volt ‘ages and is impervious to deterioration. 'Siizane eahle gate are installed ike conven. tional rubber cables. Their longer and more ficient service lite makes the extra expense worthwhile. ™ NORMARIC Plier Uy Pere etry ia The Do-It-Yourselfer: La TEC y Ls le co CT Tl eetiie ere ae Cy AU a mt ee Ld Pics TT ato ea Car] PETG Se Ue Alarm eRe) sr ea i a tele cG Ivramrtrnfeasrar tien elim ay Inving, Texas 75082 (214) 659-1800 MAY 1981 183,pte the advent of electronic inition sys toms during the 1870s, there ae sill mi- lions of cars equipped with conventional ds- tributor gniton systems. Unike electronic ign- tion, conventional ignition has parts that are ‘subject to wear and damage. These include the distributor cap. rotor, breaker poinis and condenser. ‘A damaged distributor cap, rotor, breaker points or condenser will be responsitle for ‘Some o* all ofthe following engine problems: Failure t start or hard staring. Stating. | Rough iding or roughness when driving at lower speeds. Misfire at higher speeds. Lack of power upon acceleration. Where damage exists, it wil become a ‘ent when parts are inspected. Each par ther fore, should be removed from the distibutor ‘and examined caretully, Replacing a distributor cap Note: This information apple, 28 wel, stibuior caps of electonc sgiton systems, which shouldbe inspected. one of the ‘ondtion ated above oocurs. 1. Use numbered pleces of masking tape to identify each cable and its respective distributor-cap tower. At tach the same number b bath 88 you remore ‘each abe from the cap. abies must be retired to ther corect postions inthe cstibutor cap to avoid engine failure end possible damage that is caused by outot-timing ignition. 2. Inspect the distributor-cap tower forbbroken plastic, cracks and chips. ‘As you remove each cable, inspec! the termina for Burned metal, whichis an ecica- tion that sing hae occurred somewhere between the cable terminal and distbutor tower terminal W signs of burning ar present, replace the éstibuior cap and also the cable, which is ‘probably damaged. ‘3. Unhook the distributor cap trom the distributor after the cables are removed.A cap wil neraly be secured {o the dstibutor In Ore 0! the folowng three ways: 18 By sorng clos, one on each side of the cap. inser the bade of a. Screwdriver betwoon clips and the dstibuter body and twist the blade fo snap the clips free, Be very careful not to apply any pressure against the Plastic cap. You run the risk of cracking the este IH By L hooks, one placed on each side of the cap, Thase have slotiedheads. Insert a screw driver into the heeds and rotate the hooks Check distributor-cap towers for cracks. Examine terminals for corrosion or rust. CARBON FRacns (Check contacts for burned or eroded metal Rotor should come off with gentle force. Examine rotor tip for corrosion, arcing. counterclockwise one-half tur in order to tree the cap, HL By screws, one located on each side of the cap. Tum these screws counterclockwise until the cap is fre. ‘With the cap removed from the car, wipe it Cutside and inside with a cean cloth to remove all dir and grease. Using a flashlight, examine the cap inside and out, including the inside tow- ‘Look for visible cracks; tracks of carbon hich reveal narrow, hard-to-see cracks: pit- J, bumed or eroded contacts inside the tow: rs and on the inside (back) of the cap; and chipped plastic. Replace the cap if any damage | Giscovered, no matter Now insignticant it ‘may appear. If the cap is okay, reuse it, but fist clean the inside of each tower using a distribuiorcap ‘cleaning tool. Reinstall the old cap, tighten the hold-downs and make sure that each num- bered cabe fits into its respecively numbered ‘cep tower, if you should have to installa new cap, line up the old and new caps so that their distin- uishing marks coincide. Then, transfer the umbered masking tape from the tower ofthe (ld cap to the respective tower of the new cep. ‘Wien instaling the istrbutor cap, make sure itis oienied ‘and siting properly ‘on the distibutor. I dirtgets into the distributor, it wil cause premature failure of points and rotor. Replacing a distributor rotor Note: This information applies tothe rotors of conventional and most electronic ignition eye- toms. 1. Remove the distributor oa 2. Remove the rotor, which is mounted on top of the distributor shaft. Generally, there are two kinds of rotors: I Press-ft olor. Remove this type by grasp- ing and pulling it straight off the distnbutor shaft | Screw-on rotor. Remove this rotor by untas- {ening the screws that hold it in the distributor. ‘Then you can it the rotor off the shat. 3. Replace the rotor if the plastic body is cracked, chipped or shows carbon tracks, or if the spring contact is corroded, burned or exhibits weak tension. Important: Be sure to buy the corect oto for your engine. A press-ft rotor will ta varity of Sisubuturs, tough Be TOIOF may nox be we ‘correct part. Line up the new rotor and the old ‘one and check to soe that they are exactly the ‘seme size and shape. ™ 154 POPULAR MECHANICSDEMAND sdciarenioel of N, cece ot Fa A] NAPA ditfer coos aciatete156 ENGINE ENAMEL SPEREX cor. GIST S. MAPLE ATE, GARDENA, CA. 81248 213323-6162 POPULAR MECHANICS 5. POINTS 6. CONDENSER Ia ieng sar: pons wit mate Your car run rough miss, cminish per. formance. wasteful and, utimately when the ccomporentais, prevent your car rem running ata To avoid being let nthe lurch by failed pois, Inspect them requary. Here's how: 1. Remove the distributor cap and rotor, 2. Spread points apart for a better view. f you canno. see them Cea, remove them for Inspection. Foint euracee should not be pte hats no bug of metal on one point and no caviy, Or cavites,on he other Pies ponts mean the condenser is detec- tive, 8 toacon for replacing points and can- dorser. I points ae Bick, corroded oF wor, repace them. Note: A sight bush cast on pomt surtaces Is norma 3. Remove points from the distribu- tor. Loosen the small nut on the side of the poe sesentay ts erates Costereer peer? {anton wires and i out the point assemby Note: As you remove pars, lay them out in the order you take thom of etal them in reverse ore. I you ar doing tis ob for he frst time, rake a sketch as you proceed It vill hel to reassombie a unit correctly ‘4. Examine the point assembly to determine location of the mounting screw, or screws. Remove screws, bute iney dont cropin the ctor in some cases, the condenser is part of the point assembly. You can't Fepace one witout the othr In Shor cases, Condenser and ports are separate. To replace the condenser, rerave the serew Folding iin the distur and it out the part. %. To inatalt points in a distributor not ina General Motors car, use the following procedure: Keep pointassemby screws tnger-ight ‘tach primary ignition condenser wites Make 2 chalkmark fom the distibuor Rousing onto the engine I Looten the gisribvier housing with a ds- tnbutor wrench and rotate i untl the pont. aseombiy rubbing bockresis ona Nigh point of the disnouior cam. The block is the pont: assembly part ageinst wrich the distibuor can moves to open and close porns. © Determine fom manuiacturer service er. ature cr the vehice emissions-conro) decal the pont adjustment specication. Twist a Sscrondve" pin tne pont assembly cout sot to open the pons, 1 Open points enough to slide the correct- Size foal gauge betwen them Thon adjust ont spacing unt a sight drag is felt as ou move the gauge blade between the ports. Try toinsert the next anger ‘stween he a pons, without oreng it Hitwon't ft ports are ‘adjusted propery. Tighten the point assembly hhold-down screws. Cauton: Belore inserting a feeler gauge contact POINTS CONDENSER GROUND wire PRIMARY ‘ADJUSTING LEAD uses Stor teao’ The point gap is set by Inserting @ screw- driver into the adjusting slot and twisting it Until the size of the gap is correct. between poinis, wipe the blade clean. Dirt transferred from blade to point surfaces causes premature point failure. | Tum the distritutor so the chakmarks a lined up and tighten the distributor housing ‘mounting bolt. I Ifthe distributor cam has a lubricating pad, replace the pad. the cam does not have this pad, placea tiny drop of distributor-camgrease ‘on a high point of the cam. If apadis centered inthe distibutor shaft, apply two drops of ight oil Caution: Overtubrcating this cam wil cause Point failure i ubricant splashes onto points faces. Use a minimal amount of bncant. HE Install he roto: and distributor cap. Then, using a duelltachometer, adust point-dwell ‘angle to ongine manutacturer epecticaton Follow insiructons provided by the instrument manufacturer. 7. I you have a Genersl Motors dis- tributor, do the following to complete the Job, once distributor points and condenser have been installed: ‘Tighten disinbutor-poini assembly screws. 1 Lubricate the distributor cam (see above) {and install rotor and dstrbutor cap. HW Connect a dwelliachometer. Start the engine and open the small window on the side of the distributor cap. 1 Insert an Allen wrench in opening in the point assembly and adjust point dwell lo spec- ification by turning the wrench. I When dwell is to specication, be sure to ‘lose the distrbutor cap window tightly Le ing it openjusta crack allows dit and grease to eter the distrbutor. Turn off the engine and ™ remove the dwelltachometer.‘There's strength in the Thorobred line of radials from Dayton. Daytona S/P, Blue Ribbon and Quadra. We have a full stable of smooth riding, American-made eR Ur ee ue Bele MU RUC ‘saving money. If that's not enough, ask about Dayton ices a a Cee eeu Rate arr oy vere Sue eee Rem ke Cea Gre RR alunos ‘Akron, Ohio 44319,A EEN re a el oe aaa a _ ZIGNITION COIL PRIMARY WIRE PRIMARY WIRE TO COIL To Actylic-Tough Loree) Examine the coll for broken tower, carbon deposits, corrosion. bad ignition call, ina conventional or elec: tuonie ignition system, causes lard starting o: failure fo start Staling, I ough lng or roughness whon ring at lower speed IB Mistrng at higher speeds Lack of power on acceleration. 1 Backing. i if you experience any of these problems, lngpect the coil for cracks in the col body. Dis- Insion cable from te colt pee tered eat’ pulling the boot. Inspect the outside of the tower for broken areas, ‘cracks and chips. Look inside the tower at ‘col contact and also inside the cable boot at the cable terminal. If these areas are burned ‘arcing has taken place because ofa loose con: OLA ROM | Mesias to col anda SO ote: re rterral ier olan gion cl WHAT'S HE DOING! [oy FV ae NCE | you nces an nse cor testor you suspect that the col is causing trouble and you cant Making a Concrete mocha Testi sccad | | tel, have I tested by @ mechanic. Flower Pot! . and BRSRETEEE Eige Gabe! | fovea enigen cot } aT HOME!""| |, Disconnect imary ignition SOCAN YOU ~__________—“_| | wire from the coll negative termin: 1 i == Using masking tape, mark this wire nea. sconcismana| | _ 2 Disconnect the wire attached to Tees Ngee ee ’ ihmetea see} | the coll positive terminal. This wire goes a wepotet nsay his ie cone oe are connected tightly to correct terminals. PM SAveY SCIENTIFIC. wuSTOP The “Service Station Vacation” Insure against overheating — don't leave home without the low cost protection of a Hayden Transmission and Engine Oil Cooler. Heat — Your Car's Greatest Enemy. Today's down sized cars run hotter due to emis- sion controls, smaller engines and higher RPMs. Heat problems develop when you carry extra passengers extra baggage .. . dnve in stop-and-go traffic s drive on ice or snow © —_—— driveinhottemperatures ——] in ep es — ———— ——— Quick, Do-It-Yourself Installation. If you can change the oil in your car, you can make theinstallation yourselfin a half hourusing Hayden's patented Quik-Mount and Quick Connect. Complete illustrated installation instructions come packaged with every oil cooler Act Now, Free Offer. Purchase any . and do towing. —_—_———— “a a= Hayden Trans-Cooler™ ——— or Duo-Cool™ at your auto parts Over 11 Million Transmissions failed last year’. 9 out of 10 were caused by overheating Low Cost Protection. You wouldn't think of owning a home without insurance and yet the risk of burning up your car's transmission and engine is greater. Repairs can run as high as $600-$1500. You can buy transmission and engine insurance by installing a Hayden Oil Cooler for as little as $29.95. store and receive a Trans-Gard™ Automatic Transmission Fluid Inspec- tion System absolutely FREE ($7.95 value. Offer ends Sept. 1, 1981). 1 Limited Offer** Purchasea Trans-Gard directirom Hayden for only $5.75 prepaid 1 1 1 1 Name. 1 Address. 1a 1 ‘ For free product brochure, write: 1531 Pomona Road, Corona, CA 91720Sma UR chy THE ALL NEW Fuel Economy Buyer's Guide —Astomstve Eaton — at ote! ‘Soeien rubtahes ST rose om RRS re rst Protects Met, te ee SS eas For anything that Sticks or Squeaks. Dries ignitions in boats, RVs Protecte ele: qune ogainet nict ‘Cleans, lubricates \WD-40 COMPANY, San Diego, CA 92110 160 POPULAR MECHANICS 1 engine exhibits the following symptoms. when the carburetor air fier” gets clogged (a clogged air fiterresticts thefiow of ‘To determine whether the airfiter is respon- | site for any of these conditions, removeit from the air-cleaner housing and give ita thorough inspecton, Replacing the air filter It your engire has a cicular or oval ai-fiter housing, remove the wingnut in the center of the cover and opentthe clips, if any, around the ‘2d9@ ol the cover. Lift up the cover and remove the fier, IF your engine has a rectangular ei-fiter housing, release the clips andlor wingnuts hholiing the front pat of the al cearer, Pullhe over h icleaner 80 youcan rernove he iter. Check the fiter a8 fllows: 1. Tap the filter lightly on ahard sur- face to free loose dirt. 2. Hold a droplight in the center of the filter and look through the el ‘ment. Ifthe fiter is clogged 0 light doesn't shine through i, orf itis tor or covered with 24, repiace 3. If the filter is rectangular, hold it to @ bright light and check for the conditions described above. ‘An air filter cannot be serviced. Wit'ede- fective, you must re- lace it. Ecamine the ‘Mor with a droplight and look for any tears or holes in the Mier sloment. ‘Note: t's a waste of ime trying to clean an air fiter ty washing it or blowing on it with com- pressed air. This will only destroy the fer. 4. Wipe the air-cleaner housing be- fore you reinstall the original air fter ‘or you install a replacement air fil- tor. ‘Caution: Many fiters have the word up print- ‘24 on one side. Instal the fiter with this side facing up or, in the case of a fiter mounted transversely, facing toward the front of he car This is especially important when insialing a fiir that has been in use. Ita usedfiter's post- tion nas been reversed, the dit that nas accu- ‘mulated on the fiter may be drawn into the engine. 5. Replace the filter cover and hold- jowns. Do not overtighten wingnut end bolt- type hoid-downs. To guard against this, ighten them seuply by hand Air-pump filter Aside from the ar fiter which sits on the car- buretor, your car may also have afiter for the air pump. This pump is part of the polluion- Control system of your car; its job is to inject ambient air Gownwing of te exhaust valve 10 ‘complete the combustion process which be- {gan in the combustion chamber. ‘Most foreign care, and some domestic vebi- cles, have an air fiterthatis similar in appear- lance to the carburelor air fiter. It, 100, is equipped with a paper titer element which should be replaced. Due to the small size of these fites, it is ‘almost impossible to visually inspact them for ‘Gamage oF cioggng. Therefore, you should replace these small components at regular intervals or as often as called for in your own- e's anual ™PS GUARANTEES NEW CAR SS ee ee FOR A LIFETIME. IN WRITING! Introducing Quaker State's Lifetime Engine Lubrication Protection Program. Now Quaker State, the motor oil refined from Pennsylvania Q. What won't the guarantee cover? Grade Crude Oil, announces the most daring Protection A. It won't cover defects in manufacture, vehicles used in Program available in the oil industry. It's the Lifetime Engine ‘competition such as racing, damage caused by negligence, Lubrication Protection Program, the only program to cover collision or abuse, improper installation, or engine parts not ‘your new car's engine for as long as you own it. lubricated by motor oil. ‘This exclusive program is brand new. So tale afew minutes _@. Suppose something goes wrong and I'm covered. What do I toread the following. Once you do, youll see just how much this have to do, and how long wil it take for me to collect? program can mean to you. We're sure you'll want to take ‘A. All you have to do is notify Quaker State ofa claim, by advantage of't...and keep your new car staying on the road writing or calling collect. (Address and phone number are on with Quaker State, the warranty.) Our claim representative will contact you Q Just whatic Qualor Stato guarantocing? within 24 houre, Provide the claim roprosontativo with a A. Were not only guaranteeing the quality of our motor ol, but_ copy of your warranty, copies of your service records, and a were guaranteeing that Quaker State will protect so wel, i statement of damage and repair cost from the dealer or any your engine isever damaged because our oil fails to protect repair shop you choose. If everything is in order, the claim it, well pay for repairs or replacement of any or all of these representative will approve the claim and make the payment. parts: Pistons & rings, crankshaft & bearings, timing chain, _Q. If I dont have a brand new car, can I still gt the Protection rocker arms and pivots, rods and rod bearings, wrist pins & Program? bushings, camshafts & bearings, valve stems & guides ‘A. Lf your car has under 6,000 miles, you can switch to Quaker (grinding & adjustments excluded), oil pump, push rods, ‘State and qualify for the Protection Program at a participat- valve lifters, cylinder heads, cylinder lining or bore, distribu- _ing new car dealer's service department. But tor drive gear and timing gears or sprockets. more than 6,000 miles, it can't qualify. @. What do Thave to do to get this protection plan? @ If buy anew car now, and keep it for 100,000 miles or more, ‘A. When you buy a new car, light truck or van from a wil this Quaker State Protection Program be good for thet participating dealer, you'll get the protection plan.’Tb keep it long? in effect, all you have to do is follow these 4 steps: ‘A. Yes. Lifetime really means for as long as you own your new 1. Have all services performed by your new car dealer or ‘car—even if you keep it fore lifetime. Afterall, thousands of other auto service center. people are already driving over the 100.000 mile mark using 2. Have the oil changed according to manufacturer’ recom- Quaker State without this protection program. Now, you can mendations, orat least every 6 months or 6,000 miles, do it with Quaker State and have this extra protection for as Jong as you own your new car Q. Whyis Quaker State the only motor oil with a written Lifetime Engine Lubrication Protection whichever comes firs. 3. Have ol filter and air deaner replaced, and emission control tions. A. We've been making quality motor 4. Koop all service records. These ‘il since 1910. Inall that time, ‘must indicate that only Quaker millions of people have depended State Motor Oil was used with ‘on our ability tohelp them stay on date and mileage indicated. the road. Allthat “on-the-road test- ing’ plus our own laboratory tests. through the years, are all the proof we need. Quaker State has the con: fidence in its product to put our promise of quality in writing. STAYIN’ ON THE ROAD WITH QUAKER STATE ‘That's it. Now when the manufae- turer's warranty ends, your Quaker State limited warranty protection begins...and continues for as long as you own the vehicle! MAY 1981. 161pee as keel A eee ecm era weather instruments, car tune-up aids, Pe cee in easy-to-build, money-saving kits. RTT RCT Ey CR Cl ta eg coupon is missing, write Heath Co.,Dept. 017-772 Benton Harbor, Mi 49022 Send to: Heath Co., Dept. 017-772 Benton Harbor, MI 49022 Send my free Heathkit Catalog now. Tam not currently receiving your catalog. Name Address City ours 162 POPULAR MECHANICS The in-ine el fiters have transparent housings so thal they may be inspected visually. ‘fenown You must remove tne Integral fuel titers clogged fuel titer causes an engine to ‘exniDi one oF more ofthe following prod- lems: Failure to start. IB Rough idling and roughness when driving at lower speeds. Lack of power. HE Hestation on acceleration. “To determine whether the uelfiter of a gas- line engine is ‘aully, remove the air-cieaner ‘cover from the carburetor. Move the throttie- valve lever back and forth by hand as you peer down the carburetor throat. You should see and hear surges of gasoline being ejected into the carburetor. if you don', the fuel fiter is clogged. Replace it Replacing gasoline filters Most gasoline engines use one of three types of fiers: In-line: The fiter is nsertedin the gas line ‘between the carburetor and fuel pump. BH Internal: The fiteris inserted in the car Duretor inlet which connects withthe gas line from the fuel pump. I in-and-out: The filoris screwed into the Carburetor inlet and protrudes so the gas line an be screwed int it Before replacing a fuel iter, place a rag under the filer area to catch any leaking gas. Be sure the engine is cold and turned off. Ds- ‘onnectihe battary ground cable to avoid acc dental sparks. And no smoking! To replace an in-ine fuel fier: 1. Find the filter, which Is a canister insorted in the gas line. It's visible. Stide the clamps off the fiter onto the gas. line. ‘ignt) for. proper Inspection. 3. Twist and pull the filter from pos! tion. Remove old clamps and hoses and dis card them along with the fiter. 4. Install the new filter using new clamps and hoses. Soe that the arrow on the body ofthe fiter points toward the carbu- ‘elor. Place clamps about inch from the ends ‘of hoses to hold the fiter eecurely. 5. Start the engine and check for a leak. To replace an internal fuel fter: 1, Disconnect the gas line from the earburetor. Use wo wrenches—oneto hold the carburetor-inletnut andoneto turn the gas line rut 2. Remove the carburetor.iniet nut and take off the washer, gas filter and spring. Discard only the gas iter. 3. With the opening of the new filter facing outward toward the gas lin install the spring, then the new filter ‘and finally the washer and carburetor. inlet nut. Tighten the init nut 4. Reattach the gas line securely to the inlet nut. Start the engine and check for a leak, ‘Note: Internal fuel fiters are used primarily in OM cars. To replace an in-and-out fuel fier: 1. Find the fitter. twill be protruding rom the carburetor. The gas lina may be threaded into the gas fiter or f could be secured to the fiter by a rubber hose which is held by a clamp. 2, Detach the fuel line from the fite Either unsorew i, or side the clamo back and then twist and pull the hose ofthe filter. ‘3. Using @ wrench, unscrew the 1 ter from the carburetor inlet. 4. Reverse the procedure to install the new filter. ™ANNOUNCING The Purolator First 50000 Mile Fi Ne ProtectionPlan (PUROLATOR OIL FILTER LIMITED WARRANTY) Purolator’ got so much confidence we're offering buyers of Purolator il fiters The Purolator First 50000 Mie Engine Protection Plan at no additional cost Here's what it means to you: If your car—import cor domestic—has lessthan 20,000 miles and meets all other eligibility requirements, you may qualify for the Pian when you buy your next Purolator aifiter. I you com ply with the requirements of the Plan, Purolator will pay for certain damage caused by oil fiter failure to specified Seas ——— Purolator. Purolator Pr 970 New Buu away. New eRe, engine parts in your car up to is first 50.000 mile. Pick up your registration form with details, con- ditions and limitations of the Pian at any participating Purolator retailer. Or write Purolator at the address below. So buy Purolator and start getting Purolator's engine protection for your car. f you act now, you can ‘get a dollar back from Purolator on your next filter pur- chase. Just use the coupon below. BONUS OFFER charervas let ne memo 1 check br $1.90. nave encore ove prot Fig uerhe Pra ot PEeaorionae Basan sarge rac ral; PUROLATOR, PO BOX i Sang mn per sposeCOMPLETE YOUR DASHBOARD WITH VDO INSTRUMENTS The car you own has just “half” a dashboard! It probably lacks anything ‘more than idiot ights to warn you of engine o electrical problems. And by thetime theidio lights bink, the damage may alreadyhave been dane. That's why serious motorists install e complement of VDO instruments to monitor their car's engine and electrical eystem, There are VDO gauges toincrease your fuel mileage...0 achieve maximum power... reduce maintenance... and to quickly 270 in on malfunctions. DO gauges guide the world’s classic cars: BMW, Rolls Royce, Mercedes, Porsche. Let them safeguard your car, too. Available at sports car supply stores in three different styles. Send for new catalog showing styles and. VpO Pressure Gauge function of each gauge. VDO-ARGO, 980 Brooke Rd., Winchester, VA ‘and VDO 22601. “Temperature Gauge VO Quartz Chronometer bed VDO Outsise Temperature Gauge Most DO gauges are available in three styles: Cockpit, TopCockpit, JetCockpit a VEO actomorvenstruments ™* VDO-ARGO instruments inc | 980 Brooke Rd, Winchester VA 22601 I Send fee DO 16 ap cates town howto complet my I estboard wah VOO mstuents Fm ablker Send your motorcycle instumentcaaiog a ine » VDO— instruments for the serious motorist = sll ! I | ! 4 “Here’s My Clean-Up Kit” rere ets praia hose t off er) CO eee Piuboe ued pre a oe CORR Td the job easily — and you're the boss! KWIK All-Purpose handily does the job for all kinds of wood and BR eee erm port merken eee Us arrow tae Prien rere ara eed Ereraeeeeenes orate Role a toe eo) Roseren rial ee ent peat od td = GEILTD) Ravsaton srecianry co, cHaRLoprE:NC aga.(FUEL Fuel filters for diesel and fuel Injected engines are. critical They must be serviced and re- placed regularly in order to pre. vent damage occurring to fuel metering pump and injectors ELEMENT cuassis- MOUNTED FUEL PUMP FILTER HOUSING Januiacturers of engines that use elec- tronic fuel (gasoline) injection (EFI) or wrecked, replace it. I there are carbon deposits inside, Clean them out with a brush and solvert. 4. Remove the gasket over the VACUUM BREAK To Ghope VALVE LINK P vacuum break pulls the linkage and it closes choke valve. 1 brake is damaged or linkage Is, bent, ‘engine will stall. Hearing FOR SPARK Test eleciric choke heating element by holding wire near contact. Look for @ sper ‘choke housing. I here is carbon inside the housing, remove it and replace the gasket. $. Examine the heat tube that ‘extends from the housing to the sngine. I the tube is cracked, replace it 6. See that the piston found in the choke plaie ‘sighty when a cold engine is slariec, 50 the engine won't load up with tel and stall. the piston is binding, tte the arm hhoding tne psion and remove the pision Clean the piston and cylinder wit solvent 7. Reassemble the unit. Beiore ly cumercover soew, kale Une wave index mark on the hausirg spectied by the ‘manutacturer. Tighten screws and test choke vvaWve functioning as described eater. FM. 166 POPULAR MECHANICS.ion: Mare ‘Stag coetiien. More guivarizedistee! ia ‘Don ight ost In crea! Last year Dodge invoduced Rem Tough a line of tracks engineered beyond tough’ For 1981 Dodge Pickups havea rm wink wince more strength, durability and efficiency. ‘Redesigned roo! line, sero- Synamec side sing Reduce sre ew parking andturring lights, Relocrtedto avoid ‘ones sarking mete Rentats dents. Last year Dodge Pickups had more galvanized Stel than Ford or Chevy Tas ‘year we've more than doubled the gal Wanted sea hat provides cra ara must protecion mainiainng our ad over Ford and Chevy. We weld our pickup boxes to * cross sil brackets Ford and Chevy bat Dodge achioves the best .ge estimates’ with automatic improved seredyname sty tray duced weight andl Ue clepenedabie, ficient Sant Sixengine all contibute to ths Fam 150s supenor gas mileage thars through the box. Brackets elmanete istpprone bat Ram Tough suspensions help give Duigs Puke be agent sana payloads. Our oot box has more load area than Ford or Chevy Massive impact sie, Thats Ram Tough, 198)-styie Tougher (on the outside Tougher on the nade “Tougher on the competion. See your Dodge Ram dealer about buying or leasing 2 Ram Tough Dodge today! 8), 208%. SRAM TOUGHa a ts — 12. GLOW PLUGS Jn a sense, the glow plugs of diesel engines perform @ function similar to automatic chokes in gasoline engines. Both allow cold engines to star: quickly. Auiomatic chokes pro- Vide a richer-han-normal fuel mixture, and glow plugs heat up the precombustion cham. e's to assist in cold-engine starting. When engine temperature gets high enough to ignite ‘compressed diesel fuel, the glow-pug system 's deactivated, Glow-plug systems are tested differently from one engne to another. Some systems require a complicated testing procedure. Other systems, such as the one described here for the Vokswagen Rabbitdiesel, are fairly simple to test 1. Find the glow-plug system relay. t is a plugcin unt in the fuse box, under the left side of the dashboard. 2. Disconnect the wire from the relay to the glow-plug bus bar. The bus bar is a saries of interconnected conductors through which current flows from glow plug to glow plug. You wil find the relay-to-glow-plug bus bar wire situated at the No. 1 glow plug 3. Attach # 12-volt test light to the bus bar wire terminal and to ground. Turn the ignition key on. Do not siart the engine. Furthermore, the engine should be cold, the lamp lights, the problem of hardsstarting iin cold weather probably ies with one or more ‘glow plugs. Ifthe lamp doesn't ight you shouts hear the relay clicking. If there is no clicking, hard starting in cod weather is probably being ‘caused by a faully relay. Replace it 4. Test the glow plugs by removing the bus bar at the first, attaching a test light starter terminal and to the glow-plug ‘terminal. Wan the ignition key on (don't start the engine), the lamp should light. it doesnt, the olow olug is probably had. Test aach glow plug, using the same procedure. Note: ntime, carbon may accumulate onthe tips of glow plugs and hamper performance. You can remove this carbon with @ wire brush, ™ Be Ere gee etre) the work out of putting a healthy gleaming Bynes tes Botenternmae neta Dt REAL mere cere ttt Orbit Polisher t ney Butea uri ratiaccy Petaecaccn etl Pretty arene! reat feats Peaiegied cere pS Bete uy get a 30-foot CS Coenen) pigibaes ent SNe fine. Look for aie ated Blacks Decker. Glow plugs are tested with a test ight. To service them, remove the glow plugs and Clean them with a sift bristle brush.kate ia, ey f: rh T3. FUEL INJECTORS fual-injecton system (gas or diesel) con ‘sists primarily of an injecion (fue) pump ‘and injactors that faed fuel to each cylinder. A faulty injection pump causes: 1 Failure to start | Rough iding oF roughness when diving at lower speeds. I Lack of power on acceleration Excessive fuel consumption Excessve black, blue or white smoke from the exhaust Without equipment that costs several hun- ‘dred dollars, itisn't possible to test or repair an Injoction pump. “Troubleshooting injectors is less complica €. If you thinkan injector Is causing an engine problem. loosen the fuel pipe union at each Injector, in turn, wit he engine rurning at fast idle speed. Engine speed should change as each fuel pipe union is disconnected. Removing injectors is similar to removing sparkplugs. However, some engines, such as the Oldsmobile 5.7, require special equip- ment. Generally, you have to detach front Pines arn uracre Injectors Tovertyitan injectors faulty requires use o! pressure pump that measures flow and tests ‘spray pattern. This pump is an expensive tel Disassembling injectors for clearing and repair is not diffcult once they have been removed from the engine. Proceed as fol lows: 1. Clamp the top part of the injector en, but do not remove, the rt of the injector. Tur the injector over the lower part in vies ‘4. Unscrew the d clamp ize bord ie sateen tle piece, pentce don. ee 3 Injector nozzles are o serviced by disas- 7 sembly, replace: tment Of worn par UPPER PART NEEDLE THRUSTPIN POE TCE ite eee cra] and the starts in Stihl. Champion Spark Plug Company * Champions are original ‘equipment in productsthat stake theirreputation on performance. Like Stihl chain saws and the Porsche 924 Turbo, Champions...for improved performance in virtually every engine made. Including yours. = World's yj CHAMPION} Now 4 Seller“Would fix your car yourself? | did- with this book from Popular Mechanics/Motor!” “Imagine me fixing my own car! Me, who __ “This book's got so much! Even “quick-fix” never even changed the cil before! tips for temporary repairs. But, most of all, it “didn't think I'd have the guts to do it myself, _ shows me instead of just telling me what to do. But | sure didn't have the cash to pay a pro Every single step of the way. mechanic. So | myself the only help | knew | “Now | can't get along without it. My buddies could count on: Basic Car Care illustrated by ask me for advice. Popular Mechanics/Motor. “But | wouldn't touch a car without my bi hat book did it! 874" x 11” Popular Mechanics/Motor book” “I tuned-up the car and now Available wherever auto supplies save money on gas every mile! are sold. I've tightened-up my brakes. 8 Touched-up the body. And even - Popular _. fixed-up the electronic ignition * We build 9 § system! es MOTOR Basic Car Care or Bodywork & Painting or Tuneup & Troubleshooting guidebooks by Motor Auto Problem Solver Used Car Buyers Guide $8.85 value "aster wecnan: Mechanics Offer available at participating stores, where auto supplies are sold. © 1981 The Hearst Corporation.Tt we ee | NE ATT 14. IDLE-sTOP SOLENOID RETAINING ANTIDIESELING SOLENOID he ide-stop that helps prevent engine dieseling (where ‘an ergine continues to chug on afer the igni- tion is turned of). your car has one. its on the ccarburetor—check around the throtte linkage. Most solenoids have a threaded plunger that ‘bears agains! the throttleever arm when the ‘engine idies. Anjistal dashpots (they look ike choke vac: tuum breaks without vacuum connections) are ‘on cars with automatic transmissions. They help prevent stalling by leting the throttie cose ‘gradually when you stop after high-speed driv ing ot suéden wide-open thrattie accelerator Slaling under these conditions may indicat dashpot rouble. To see it you have @ dashpot, check the throttle lever. Like the solenoid, the dashpot has a plunger to bear against this lever. you seoachanter watva pager near tw henge ol the lever, i's a dashpot. Checking the solenoid Totest your ide-stop solenoid, have some- ‘one start the engine and accelerate slightly. ‘The plunger should contact the throtie-iever am and remain there. Tum of the engine. The plunger should retract immediately, and the throtte shouls lose. this isnt the case, foow these steps: 1. Turn on the ignition. 2, Pull the wire terminal trom tne solenold terminal. Hoid it as dose as pos: sble, without touching, to the engine or the Solenot terminal. there s no spark, ine wire may be damaged, Replace it 3. Connect @ tachometer and set engine-idling speed by turning the Idle-stop solenoid is maifunctioning | when engine runs ‘on after ignition is ‘switched off. To ad- Just an antistall dashpot (below), you tum the screw at the base. Then THROTTLE idle-stop solenoid plunger in or out. Test the unit again. Ii ‘als to function prop- ery, unbolt the idle-stop solenoid and installa | new one, Working on the dashpot Totest the dashpor, warm up the engine and lot it idle. Push the plunger into the dashpot Until it won't go any farther. There should be about a Yeh. space between the plunger ty and the throtle-leverflange. not, adustclear- ance as follows 1. Hf the dashpot plunger bears | against a capscrew on the throttle lever, Insert a ‘iwin. feeler gauge between the tip of the plunger and the ‘screw. Loosen the capscrew lockrut, if there is one, and turn screw in or cut until rests on the gauge. 2. Adjust other dashpots by moving the dashpot in or out. insert feeler gauge Detween ine plunger and throtte lever, loser | locknut holding the dashot and move dashpot toward or away from the throttle lever. 1 staiing conanues, reacjust tne asnpot using a Yar-n. feeler gauge. it there's stil a probiem after readjustment, try unbolting the ashpot romthe carburetor ardreplacng it FM ‘When you build the rugged Popular Me- chanics air compres- Sor, youll get one of themost versatile shop tools around. It's a tough workhorse that can tackle jobs you never creamed of do- ing, before — riveting, sand-blesting, pray painting, inflating and countless other pro ects. And, unke ordi nary compressors, the Mair compressor cin evacuate your car's it conditioning, system But best of all, it's fordable. With plans from the Popular Me- chanics Plans Library, you can buld the PM air compressor you~ self ard sive up to m2” Send today for your Popular Mechanics Air (Compressor plans, and add a new dimension to your workshop. Only $5.95 (add 756 for frstclass mang MAY 1981 "ESAT a el ds aul a. ie = Today, you're lucky to find one for five thousand. And replacement engines haven't gotten any cheaper, either, o it makes sense to change your oil and put in a new Fram oil filter at least as offen as your owner's manual tells you to. After all, a new Fram cil filter doesn’t cost much. A new engine does. But, the choice is yours You can pay alittle now. imi Bendix FRAM Fram and Auiolite are Bendix Companies Fram Corporation, Providence, Rhode island 02316fuel pump that has failed completly pre ‘vents engine staring and, more serous ly, can cause abreakdown on the road. To fnd ifthe fuel pumpis bad, remove the airfiter and activate the thot linkage. It no gas squirts into ‘the “carburetor, and you've already replaced th fu fier, he fuel pump is proba Dy tauty. Test and replace it if defective. ita fuel pump i faltering anis about ofl the engine may demorstrate the folowing: Rough iding or roughness. at. lower speeds Mistre at higher speeds Lack of power. 1 Backtiing Mechanical fuel pumps To determine if the malfunction is being caused by the mechanical uel pumo of a gas lire engine, proceed as follows: auton: Disconnect and ground the high- tension cable from the coll to prevent the engine trom starting 1. Disconnect the gas line at the carburetor and attach a length of hose to It. Do this with the engine of. 2. Crank the engine for 10 seconds. Gas should stream from the hose. Wit doesn't, the problem could be with the fuel pump. the {gas line on the fuel-tank side o! the fuel pump (inside the fuel tank, assurtiing the fue! fiter land gas line from the fuel pum to the carbu- retor are okay. To check whether the fue pump is faulty, proceed with testing, 3. Connect gauge as specified In manut instructions. Generally. the gauge is con- ectedto the carburetor end of the disconnect ‘A fuel pump's output is tested with a fuel- Pressure gauge teed into the fuel line. When installing 2 new fuel pump, be sure to grease the arm. it contacts the pushrod and is continually placed FUEL Une! FUELINLET TO CARBURETOR (FROM FUEL Sin 4 fuel line. insert a T-fiting between the car buretor inlet and fuel line and connect the gauge to the T-fiting ‘4. Check service data to determine the manufacturer's recommended pressure for the fuel pump. 5. Let the engine idle as you check pressure. Then shut the engine off. Replace the pump if fails to attain manutac- turer's recommended pressure, orif the gauge needle falls to zer0 when the engine is shut of Replacing a mechanical pump Tryto reach thepump from inside the engine ‘compartment. if you cant, ralse the car and tackle the job from below. pan under the fuel pump to 2. Remove the fuel lines on both sides of the fuel pump. The pump may ‘also have a hose trom the fuelevaporation ‘canister or fusl-vapor separator connected to it Remove ths, 100. 3. Take out the bolts holding the fuel pump and remove the pump from the engine. Notice whether a pushrod isprotud- ing into the pump body from the engine. Be ‘sue it stays in the engine. Using a scraping tool, clean the fuel-pump seat on the engine. Oid gas: ket material must be removed, Coat the fuel-pump seat on the ‘engine with gasket sealer. Thencoat the mounting surtace of the new fuel pump. Place a new gacket on the fu pump mounting surface. Then carefully place the fuel pump back nthe engine without ‘dsturbing the gasket. See that a fuel-pump- (TO ECCENTRIC CAM OF eaNSHAr attached rocker arm corres in contact withthe cam lobe on the engine camshaft W the pump uses a detached rocker arm (pushrod). see that tis nserted sauarely into the pump. If the pushrod refuses to stay straight, pack some heavy grease under it. 7. With the fuel pump seated in the engine, insert and tighten bolts. Attach fuel lines, reconnect the col's high-tension ‘cable, sian the engine and check for leaks. Electric fuel pumps Hf your car has an elactc fuel pump, its mounted somewhere between the fuel tark and carbureior (closer to the tank), of is actu- ally inside the tank Test eleciic-luel-pump pressure as described above. If the pump fails ‘he lest, estine electric crcut betore replacing the pump. You can co ths with relative easeit the pumps mounted externally and youhavea. rcuit diagram. Ifthe pump is inside the fuel tank, the fuel tank has to be cropped from the car, ard the sending unit, which contains the fuel pump, has to be removed from the tank. mm ELECTRIC LEAD FROM ELECTRIC SYSTEM Electric fue! pumps cannot be repaired. if they fail when tested, replace them. MAY 1981173Yes you can! With Chilton’s Easy Car Care Manual, 1981. ‘=e CORROSION AND DEPOSITS, Inspect hoses on all sides for tiny cracks and brittle surface , . texture. Check connectors for ton tretctr ss coolant leaks or hardened de- Posits incicating « twok Eerste conte oninohasat Teast four hoses: two radiator hoses and ‘wohoses from the engine to the heater. Some engines have a fith hose, which is a water- pump bypass. ‘A cooling-system hose can spring @ leak. When it dos, the engine loses coolant and ‘overnoats. ‘The engine-retun hose can give addtional trouble. ‘A problem may occur when th sttfener ‘spring inside this hose weakens. A weak spring can't stop the hose from flattening, particularly when the vehicle is driven at high speeds and Dressure against the walls of the hose is great. ‘The restricted hose cuts off coolant to the ‘engine, which then overheats. 'A wise car owner doesn't walt for a hose to {all before replacing it. Check hoses every six months and replace those that are cracked, britle, swollen, excessively sot or that have ‘other tailings. In addition to examining hoses visually and ‘squeezing them to see if they are fexibie and resilient, examine the lower radiator hose for ‘proper spring action. To do this, warm up the ‘engine andhave an assistant run the engine at high speed. Keep your eyes on the hose. it flattens, replace i Replacing ho To replace a radiator hose, do this: 1. Open the radiator drain plug and drain coolant until the level ia below the hose which has to be replaced. If coolantis clean and less than two years ol, it ‘can be reused. Attach alenath of vacuum hose {o the radiator drain plug and drect the end of the hose into a clean receptace. 2. Loosen radiator clamps and slide them onto the hose. roy 174 POPULAR NECHANICS RADIATOR SUurLeTwecx. Toremove a hose, cut it with a knife and slide clamps off connector. To replace upper hose, drain coolant to below hose level. f coolant is to be reused, remember to use clean bucket. 3. Try to pull the hose off its fittings. IW sticks, sit the hose lengthwise at several points where it attaches tothe fting. 4. Clean fittings with a wire brush or ‘emery clothbetore installing new hos- e2. If old clamps are stil in good shape, sip them onto the new hose and push the hose Cro ftings. he hoseis hard wo get onfinings, dip its ends into a pail of hot water. This makes the rubber more pablo. When the hose Is seated, position lamps‘ to ‘4 in. from Its ends. Tighten them. There are four types of hose clamps, as fol- lows: 1H Spring—The tangs of this clamp have tobe squeezed together so the clamp can be ‘moved. You can use ordinary pliers, butsprng- clamp pliers that have notches into which the tangs seat themselves make the ‘ask easier. ‘Spring clamps may, in time, lose tension. BE Worm scrow—As the screw is turned, ab engages each successive opening in the clamp. This action tightens the clamp. Vehicle vibration can cause a worr-screw clamp to loosen and coolant to leak. I hoses in your car fare held by this type of clamp, tighten the ‘lamps every other month I Tower bolt—As the bot is turned (using a wrench), a screw device pulls the clamp ‘against ihe hose. If this clamp Is loosened tO replace a bad hose, itis usually damaged inthe ‘process and cannot be reused 1 Twin-wire screw—When tumed, the clamp ‘screw squeezes 2 pair ol wires that tighten ‘round the hose. It provides the most effective clamoina, However. be careful not o overtiaht fen the clamp. The wires can cut into the hose. ‘Any type clamp, or a combination, can be used to hold hoses in any car. ™TESTER A cooling-system analyzer applies pressure to the cap as a test for possible leaks. Marke on overtiow tank Indicate proper levele for both hat and cold coolant 1 a radiator pressure cap loses its abity to ‘maintain rosaure inde he radiator. over results. Pressure helps raise the bolt ing point of coolant by approxmatly 45°F. The extra margin is needed by modarn engnes. which "run at. higher temperatures. When there's a loss of pressure because cf a weak radiator-cap spring, tere is a recucton inthe Boling point of coolart. The result, obviously, is engine boil-over. Test radiaior pressure visually and wih a radiator-cap tester. Both ways are necessary ‘A visual est reveais a worn cap and bad gas- fels. A pressure test uncovers a cap thai has lost te abt to maintan pressure. ‘With the engine cold, ty to tum the cap on the radiator filer neck. It he cap has any pay, replace i. Aiso check the tangs on the filer eck If they are damaged of worn orf ther Gamageis apparent, have thefiler neck cut out of the radiator and anew one welded in is Place. move the cap and wash itn waier. Then inspect the gasket or gaskels (there may be two-one on the valve epring and one around the inside ofthe cover). ra gasket is cracked, tom or curled, replace the cap. Important Ever cat mode uses a pressure cap that has a specific pressure ring Be sure the cap you buy has the pressure rating spec ted by the manufacturer of your ear. you get the wrong one, your engine may overnea. An ‘auto-pans and accessories dealer can help # you need assistance. Pressure-testing the cap Visually, the pressure cap may seem tobe in. nod enfin hut tha tnie leat enmae when you submit it to a pressure test, Using a radiaior-pressure tester and cap ‘adapter, perform the test as follows: 1. Connect the cap adapter to the radlator-pressure tester. Dip the cap in water to wel the gasket and attach the cap io the adapter. 2. Examine the cap to find its pres- ure rating. Nost caps are rated at 130° 15, .s.. (pounds per square inch). 3. Look at the gauge of the pressure tester while you pump the handle of the instrument to bulld up pressure. When pressure teaches the amount that's des- ignated on the cap, stop pumping. 4. Watch the gauge for at least two minutes. The needle should not drop below the designated pressure. Ifitdoes, replace the cap. Removing a pressure cap when the engine is hot ‘Athough you should ty to avoid such situa tions, there may be times when you have 10 remove a cap from a hol engine. Do this care- fully 10 avoid injury. aciator-pressure caps inmost cars have 10 be turned, so pressure is released before the cap ie removed. Place a protective cover between your hand and the hot cap—a wad- ded rag or better yet, a piece of pliable rubber thats large enough to cover the cap. “Turn the cap slowy unti it hits a siop. Don't turn it any farther. Steam and coolant will be Teleased through an overtiow hose that juts out trom the side of te tiler neck. ‘When hissing ceases, incicating that pres- sure hasbeen released, press down on the cap land remove it from the radiator. ‘Some radiators have caps equipped with a lever or pushbutton that serves as a pressure ‘allel With thane, you release pressure by lit- ing the everor pressing he button. When hiss- ing stops, remove the cap, using a protective cover between your hand and the radiator pressure cao. Overflow hoses and recovery units ‘As mentioned above, an ovediow hose ‘extends from the side ofthe radiata: filer neck. Ht your car has a coolant-recovery unit, he end Of the hose is inside a plastic tank. f your car doesn't have a coolant-recovery system, the fend of the hose points to the ground. AS ihe cooling system gets hot and builds up pres- ‘Sute, a spring-loaded outlet valve in the radia torpressure cap opensto alow excess coolant to escape through the overtiow hose into the tank oF onto the ground. the overflow hose extends into a recovery tank, coolant is drawn back into the radiator {rom the tank when coolantin the radiator cools ‘and contracts. Thus, with a coolant-recovery ‘System, Coolant Is NOx Host a long as He Ss temisnit leaking. Ifyou nd you are losing coo! ant, examine the overtiow hose and plastic tank for damage. Replace a cracked overtiow hose. Be sure iis secured at both ends. Plastic coolant-recovery tanks are prone 10 cracking. especially in cold weather. Seal a ‘crack with epoxy. I this doesn't stop the leak, ‘remove the tank trom the car and pour off cool ant. Insert a plastic bag inside the tank, extend- lng the opening of the bag over the tank open- ing, Install the tank and screw the cap on so it tightens over the opening of the plastic bag. Coolant flowing from the radiator will empty into the plastic bag. ™ ‘SPRING RUSTED, LACK OF TENSION SEALING SURFACE HOSE CAM LOCKING SURFACE When you check the cap and filler neck, lock especially for worn or bent parts. MAY 1981175.Bol Rust el Chilton’s Import Car Repair Manual. eee std gaye acted Import Automotive Repair Norte abst pcenooe eee ecg eS ed pages of step-by-step instruc- tions for repairing and nent Rac eed rupees cern reas ose eects erie gare ated to understand and follow. Bieprees Ceteer stall Positano StL PoC mentee) pier eteee gate ek new Peugeot, Rencrult and Ba pecrente to. Peed VGrtte Ree era Ferg eee rete tetag pore CHILTON Lorene paneer! peeked pte a ee en ae CNN information Eo en 176 POPULAR MECHANICS To reach the thermostat, first remove the thermostat housing. ifthe thermostat Is faulty, replace It with the correct type. Always be certain that you us gasket when you reinstall the housing. he thermostat is a vane that's normaly stoned where the radiator return hose connects tothe engine. Hot coolant tows from the engine to the radiator through this hose, which is often called the upper radiator hose. However, in some cars, he thermostat isiocat- (ed at the bottom radiator hose. When a cold engine is started, the thermo- stat is dosed. Coolant, unable to react the radiator, recculates through the engine water Jacket. Since it can't ive up its heat, as itdoes ‘when circulating through the raciater, coolant gets hot quickly ‘When engine temperature reaches a desig- nated level, the thermosiat opens. Hot coolant flows into the radiator, where Its cooled and retuned to the engin. ‘Athermostat valve can bind inthe closed or open position. iit stcks inthe closed position, the engine overheats. If tho vahe etcks in the open position, tho engine warms up slowly and may never reach normal operating temperature. Aso, the heater 4008 not receive properly heated coolant, soit cant warm the passenger compartment. To detect a faulty thermostal, remove the thermostat from the engine and tos! it Removing the thermostat To remove a thermostat rom an engine for testing oF replacement, follow these stops: 1. Drain the cooling system to be- low the thermostat housing by draw- ing off about half the coolant in the ‘engine. Drain coolant into a clean receptacte, 50H can be reused ‘2. Remove bolts holding the ther- mostat housing to the engine and remawa the hanaing. Ileal you don't ‘Need to remove the hose attached to the hous- ing. Ifthe housing sticks tothe engine, loosen it by tapping with a hammer. Don'tpry under it— you may gouge the housing or engine. evoINE CooL (THERMOSTAT CLOSED) ENGINE HOT. (THERMOSTAT OPEN] 3. Note the position of the thermo- ‘stat in the engine, so you can return ‘the old thermostat or its replacement to the same location. Remove thermostat from engine. ‘4. Check to see it the closed by holding the therm. ‘alight. If you see ight between the valve and thermostat housing, replace the thermostat 5. If the valve Is closed, check the thermostat housing and its tempera: ture rating, as shown on the housing. 6. Tie a string to the top of the ther- mostat. Extend aod over a pan ol waler and Secure the thermostat to the rod with the string. Insert thermometer in the water and put the pan on a kitchen range. Heat the water % temperature rating mostat housing, plus or minus 5°F., the valve should epen. Ii there is any question in your mind concerning the condition of the thermostat, replace tt. 8. Before installing @ new thermo- ‘stat in the ongine, use.a putty knife to remove bits of old gasket material from the engine and thermostat ho: ing surface. Work caretlly. Don't aig into the metal and don'tuse a screwdriver 0: chisel for this task. 8. Ityou aren't using» self-adhering gasket, spread a thin film of gasket Sealer around the housing surface. ‘Then place the thermostat in the housing and install the gasket. Line up the holesin the ther- ‘mostatwiththe holes inthe housing Be careful ‘otto tear or winkle the gasket as you press it down. The gasket will hold the thermostat in the howeing ae you reht Be housing to Be engine 10. Install and tighten the bolts. Rel the radiator. Start the engine and check ‘around the housing for leaks. ™Before removing a water pump, let the engine cool down and drain radiator. Then remove the fan, pulley and belts. Thoroughly scrape off old gasket mate- ‘al bofore installing new pump. BIMETALLIC COIL SPRING he water pump is the heart of the cooling system. Without it, coolant canrot be deiv- fered from the radiaior tothe engine and heater ‘and back to the radiator ‘When the water pump fails, there is a com- plete loss of coolant. This results in engine ‘Overheating. There is no question of what has happened, because coolant literally fows from the waler-pump housing, The sensible course of action is to inspect the water pump periodically. Atthe first sign of 2 leak, repiace the pump. To test a water pump. remove the water- pump drive belt and grasp its pulley in both hands. Rotate the pulley and iry moving it in ‘and out. If you fee! roughness or grinding, oF more than a slightly perceptible in-and-out ‘movernent, pump bearings may be damaged, Replace the pump. raw your hand around the water pump, just behindthe fan. Some seepage is normal. Buti there is an unusual amount of coolant, the ‘pump is leaking. Replace i ‘Gauton: A car with a transverse front-wheel- rive engine is generally equipped with ather- ‘mostatcally controlled electic fan that's placed facing he rear ol theradator. Thisis not ‘he area of the water pump. It's located at ihe front of the engine Before working under the hood of a car hav- ing an electric fan, deactivate the ‘an. This is. normaly done by disconnecting me wiring con- Nestor from the fan motor or discomeciing the battery ground cable. If left connected, the lan SILICONE FLUID CHAMBER iy balan, aus thoaigh tie seagine WAN > ‘hing. You could be injured by the fan blades, Replacing the water pump ‘Theprosedure to replace a water pump var les slighty trom engine to engine. The follow- may be used as a quide: If the engine is mounted longitu- dinally, you may have te remove the radiator and fan shroud. i; Remove the water-pump drive ‘3. Make a mark on oncof the blades toindicate the front of the fan. Take out bolts holding the fan to the water pump. Remove the fan, spacer (f there is one) and pump pulley 4, Prepare the new pump for instal- Con aoe inves ot ooatat coer: with a thin layer of gasket cement. Then place a new gasket on the surface. Make ‘sure you don't tear or wrinkle the new gasket. ross it fimly into place. tion of the old pump. Remove one bolt at a time from the old pump and insert it in the corre- sponding hole of the new pump. This procedure assures that the correct bot, which ‘may diferin size ana engin from other water- [pump mounting bolts, goes into each hole. 7. When all bolts have been taken out, remove the old water pump. ‘Scrape off bits of old gasket, making sure the engine's mounting surfaceis clean. Then apply ‘a coat of gasket coment to the surtace. 8. Push the new pump onto the ‘engine, tignterung pons py nans. Use a torque wrench to tighten bolts to the maker's specification ™ CHILTON emreeaa Y century, the Chilton Book fe AIS ses eee nate nol NALA) automotive publishin: folieeuie aks EW celulel Matera a oad emetic edueut es Peau Reon! to be, the overwhelming first choice of Americans who do all or some of Rumen ec elee lel ET cu res You can look to Chilton em colt celIEA Orr Maan) PMiciakattscaterisg RECUR lao et msacratsisaints} MAY t98t 177A comparison of projections from manufacturers’ . treadwear ratings under the new government Uniform Tire Quality Grading System indicates that on a government-specified course: Uniroyal Steeler projected to last 15,000 more miles than comparable Goodyear or Goodrich tires. ‘The U.S. Department of Transporta- tion recently gave the public a standard yardstick to compare tires by. Now, each tire company is required by law to grade its tires in three areas. Traction, ‘Temperature resistance. And treadwear. ‘And then to cmboss the resulting grades on the side of the tires. When compared, most of the similarly priced steel-belted radials in the chart fared equally well in the traction test. Same for temperature resistance. But one tire pulls ahead of the pack when it comes to the important grade that indicates the relative wear rate of your tire. ‘That tire: the Uniroyal Steeler. In fact, when you translate its 220 rat- inginto projected miles on the government- specified course, you see it was no photo finish, On that course, the mileage projection for the Uniroyal Steeler is 66,000 miles. ‘That's 15,000 miles longer than the Goodyear, Goodrich, General and most Firestone ratings in the chart would project. And 24,000 miles longer than Michelin's rating would project. ‘These mileage projections (including those in the chart) should be used for com- parison only. You will probably not achieve these results. Actual treadlife will vary substantially due to your driving habits, condition of vehicle and, in many sections of tie country, 1vad condi- tions and climate. UNIROYAL co. our Uniroyal dealer for details. aoe MANUFACTURERS’ RATINGS FOR eC o GOVERNMENT QUALITY GRADING sySTEM [,,ProrEcTion, ¥ SS MERE Manufacturer/Tire: 2--------p----4 Temperature | Treadwear Rewstince 1 SRIROTAL B/C | 220 66,000 1 SOODYEAR B/C | FIRESTONE | | B/C | 170* | 51,000 i Baal Steet it __| Be | 170 51,000 Pre eeee | ee | 10 51,000 # MICHELIN Reed a eek ee * Most I Prestone 72 res rated 200 wich pejet to 60 00 miles Source: US. D.O.T, For free booklet on gr Uniroyal, In, Tire Advertising Dej @1OH Urroyal, In ‘send your name and adress to 3t, Middlebury, Connecticut 06749. rN Sy NL211. DRIVE BELTS AIR PUMP AIRCONDITIONER A ypical engine has at least three drive belts. ome mey be double belts. Chesk that all belts are in good shape. Prater seater, atnough aimed spectticaly atthe water-pump and altema- (or dive belt (commonly called the fan belt, apalies as wall to other belts, including the Power-steering-pump belt the airinectin- pump belt anc the airconditioner-comoressor bet. Depending on the car, as ittle as one belt land as many as four may be used to operale these components. faulty fan belt 1e water purmp wil fal ‘and overheating will ‘occur. I the fan belt also dives the alternator, which is often the case, the alteratr won't ‘generate electricity. In the case of other drive belts that fail, the particular component the belt serves will no ‘work, whether its the power-sk ‘conditioner or air-injection pup. To avoid an ‘emergency, the time io uncover a bad dive bet is before it tals, With the engine off, examine belts for the folowing: WM Cracks, britieness, glaze (shiny surtace), peeling and a grease coating. Check both the {op of the belts and their pulley-sige sur- faces. 1 improper adjustment (00 loose or too tight), Place a straightedge across two of the belt's rive pulleys and press aruler down into the bok, midway betwoon the two pulloys. The belt should defect at least Min, but not more than % in Ifthe bet is too loose (which is usually the 2020, toceuoe belts otrotoh), ighton it Aloooe bet ofien squeals as & roiates. With a loose water-pump/alternator drive belt, engine over heating and a dead battery can occur. ALTERNATOR POWER: STEERING Pump GiackeD On BRITTLE’ i Inspect the underside of belts for cracking ‘and deterioration. Replace if faulty. RULER STRAIGHT Ebce, BELT DEFLECTION ‘Right belt tension will increase life of the belt, 2s well as that of the accessories. Ifthe bet is too tight, loosen it before it puts excessive strain on the accessory bearings, causing wear. Replacing or adjusting belts ‘To remove the fan belts in most cars. loosen the bots that hold the alternator. Push the alternator toward the engine to slacken the bet. To inctall (or adjust) the fan bolt of most cars, bets tight. Cauton: Leon tho pry bar againet tho solid ‘metal part of the alternator. Dorat put pressure ‘on the alternetor’s cooling fins, which may crack ™ SKILLED MECHANIC ENTHUSIASTIC BEGINNER THERE'S HELP On COMING YOUR WAY! CAR CARE CENTRAL A 26-week, 30-minute Television Series for experienced & would-be auto Doit-Yourselfers. Produced by the Automotive Parts & Accessories Association with the cooperation of leading automotive product man: ufacturers, FEATURING PRACTICAL DEMONSTRATIONS OF PROPER CAR CARE. Basic Maintenance Checks « Replace Shock Absorbers + Oll& Ol Fiter Change » Spark Plug Replace ment « Tune-Ups «ignition Tim Ing * Fusing Radiator & Chang- lng Coolant » And More « To show that car care is also fun, your host and on-scene reporters willbe visiting some interesting and well-known people and their cars. CAR CARE CENTRAL wut Be TOOLING YOUR WAY STARTING APRIL AND MAY. Check your local newspaper and auto parts retailer for details and times in your area, APAA member retailers will have POPULAR MECHANICS prepared booklets to supplement & illustrate the subjects covered on each TV show. WATCH Cap CARE CENTRAL AND PUT YOURSELF IN THE RIGHT PICTURE! AZ MAY 1981Around sharp curves. Over rough roads or countryside. At higher speeds. KYB's Gas-a-just shocks Give you superb control that's just ot possible with ordinary shocks. How? Their patented large diam. eter design uses pressurized nitro- gen gas and all-weather fluid to Greate an automatically adjusting, double action shock that won't fade or suffer lag control. So you won't suffer unnecessary bounce, sway 0r poor cornering. KYB's Gas-a-just shocks. For car ‘owners wno not only appreciate performance, but demand it. Find them where you buy parts, available to fit most cars, light trucks and vans They'll keep you glued to the road. Write for free brochure: KYW KYB Corporation of America 207 Eisenhower Lane South Lombard, lilinois 60148 ‘ut under eense of Dr. dearben syst. 180 POPULAR MECHANICS aypass CHANNELS FILTER ELEMENT, FULLELOW on” GALLERY CROSS ORILLED| CRANKSHAFT ‘olLpuMP PICKUP. G2" osoiting an oi erin tal here is ‘No way of teling when one is clogged. Fillers possess bypasses that permit oil to keep flowing even Ff fiter passages are blocked. This temporarily prevents major ‘engine damage. However, 1a car owner insists on using @ {iter clogged with dity ol, engine fe is bound to be affected Replace an oll itor as often as the car man, utacturer recommends in the maintenance ‘schedule of your owner's marual. Generally, this is every second oil change. the exception being the first time oil is changed in a new However, many Seturday mechanics re- place olfitrs every time they change ol. They ‘contend that there's no sense mixing fresh oll with the one quar of dirty oll trapped in the fter. There is merit to this argument. Anottier technique is toremove the itr, drain the city ‘ll from it and replace it Installing an oil filter To install a new oil filter, do this: 1, Warm up the engine. Hot olisthirner and flows more readily than cold ol, which is thick. However, use caution when working around the engine. Parts may be hot enough to 2. Place alarge pan under the ollpan rainplug. Loosen the plug and then remove ity hand. Let the oll drain Caution: If the drain plug and washer fallinto the drain receptacle, let the oil cool belore retrieving them. ‘3. Place apan under the oll filter. Use an cilfiter wrench to loosen the fter. Then remove it by hand, ‘Note: There aro several types of ol-titer wrenches, each designedio meet he needs of ‘particular engine design. Check with an auto- parts and accessories

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