Chrysler 160 Instruction manual

ENGLISH
9/70
WORKSHOP MANUAL
CHRYSLER 160
CHRYSLER 160-G .T.
CHRYSLER 180
21381' M
. 0970

CLASSIFI.CATION SYSTEM
COMMON TO ALL AFTER-SALES MANUALS
A- ENGmE
AO -Engine assembly
A1 - Cylinder-block
A2 -Moving pa!'ts
A3 - Cylinder head
A4 -Timing gear
B - LUBRICATICN
BO - General
B1 - Oil sump
B2 - Oil pump
B3 - Oil filter
C - FUEL SYSTEM
CO - General
C1 - Petrol tank
C2 - Petrol pump and pipes
C3 - Air filter and warm air intake
~ - Carburettor
C5 - Exhaust
D - COOLlNG
DO - General
D1 - Radiator
D2 -Fan
D3 -Hoses
D4 -Water pump
E - ENGINE ELECTRICAL SYSTEM
EO - General
E1 - Starting
E2 - Charging
E3 - Ignition
F - TRANSMISSION
FO - General
F1 - Clutch
F3 -Gear box
F4 -
Automatic gear box
F5 -
Drive shaft
E~ - Differential and wheel shafts
G - SUSPENSION
GO - General
G1 - Front suspension
G2 - Rear suspension
G3 -Wheels
G4 - Tyres
H - STEERING
HO - General
H1 - Steering
H3 - Adjustment of vehicle trim
Adjustment of front wheel
set geometry
J - BRAKES
JO - General
J 2 - ]Tont brakes ( discs)
J3 - Rear b rakes (drums)
J4 - Rear brakes (di scs)
J5 -Brake control system -
servo-brakes
K - BODY ELI!."'CTRICAL SYSTEM
K1 -Wiring diagram
K2 -In ner electrical instruments
K3 - Ind i cator lights
K4 -Windscree n-wipers
K5 - H orns an d control system
K6 - Air cond itioning
L - BODY llJ \VHITA .AND TRDI
LO - General
L1 - F ront end
L2 - Centra 1 section
L3 - Rear end
M - PAmT - APPLICATION PROOEDl.IRES
N - ACCESSORIES
N1 -Car radio
N4 - Trailer attachment
Reprint or translation, even partial, is strictly prohibited without written permission from CHRYSLER FRANCE CHRYSLER
160 • 160 CiT· 180

PRESENTATION OF MA NU AL;:
This 1anual is part of the series of publications designed with a coaaon classification syste~ for easter
aatntenance of our vehicles:
•
Spare Part Catalogue
• Workshop Manual
• Tfu Schedule
• list of Specific Tooling
The classification system coaaon to these aanuals will be found on page 1.
This aanual Is divided Into chapters corresponding to the aa in units of the vehicle.
Chapters are identified by a letter.
Within the framework of a chapter, the classifications of sections, I.e. of fnforutton concerning the
units of which a given assembly Is coaprlsed, Is identified by the letter corresponding to th e relevant
chapter
followed by a nuaber used to identify the Individual unit.
For easter 1nforaat1on finding, the section reference is followed by a roaan nuaber, which specifies the
nature of the inforaatton given on the unft In the section concerned:
I. Description - General - Genera l spec ifications.
II.
Tightening torque values.
Ill. Specific tooltng.
IV. Unit aaintenance and adjustaent procedures,
V. Unit reaoval and re-fitting procedures.
VI. Removed unit dismantling and re-asseably procedures, Inclusive of Inspection after
re-asse~bl y.
VII. Recondt ti on! ng procedure - Acceptance crt terla for recoverable coaponents.
The lnforaatlon classification reference, or section syabol, appears In the box printed on the top outer
comer of each page.
Page numbers are shown lamedlately below the classification reference or section nuaber, and page
nuaberlng starts fro• 1 for each individua l section.
The structure of our classification system, therefore, Is as follow s:
1 -
Chapters : identified by a letter. They correspond to the main vehicle assa~bltes.
2- Sections :Identified by the chapter identification letter followed by a nuaber·
Identifying the unit concerned, and a roman nuural In dicating the nature of the
infor~~ation.
3- Page numbers : progressive numbering of pages for each section.
Reprint or translation, even partial, is strictly prohibi t ed without written permission from CHRYSLER FRANCE CHRYSLER
160- 160" -180

KEEPING MANUAL UP-TO-DArE
Up-dating is a continuous process. It is achieved by the publication of additional pages to the baste text.
which have to be Inserted before the corresponding 1odlfled pages.
Additional pages are coloured for easter tdenttftcatlon.
The classtftcatfon reference- section nu1ber- of each 'additive• corresponds to the reference nu1ber of the
basic page It 1odtftes.
Two add Itl ona 1 boxes are provided under the sect! on nUiber:
- the first box wtll contain the word ADDITIVE followed by a nu•ber Indicating the order of classification,
In cases where several ADDITIVES correspond to the sa1e original page;
- the second box will contain the page number, and an indication of the number of pages of the ADDITIVE
concemed.
Exaaple:
._ . _,._ _ _ Section number
1
-~ ,-- Original page number
ADDITIVE
-~---- - Order of classification for ADDITIVE
Page
-~--- -- Page No./Nu11ber of pages
z 1369
Note: Approxf•ately every 3 years, a.new manual pooling all previously issued additives is
published.
CHRYSLER
160- 160" -180
Reprint or translation, even partial, Is strictly prohibited without written permission from CHRYSLER FRANCE
(

GENERAL
• Veh i cle identification
• Dimensions and weights
• Jacking the vehicle
• Operations to be carried out before delivery
• Operations to be carried out for free overhaul
• Certified and recommended ma i ntenance oper a tions
Reprint or translation, even partial, is strictly prohibited witho ut w ri tten permission from CHRYSLER FRANCE
CHRYSLER
160- 160 GT- 180

<'

Fig. 1 - A : Type Serial No.
B: Original body paint
I
dent! fl cation."
Fig. 2 - Engine No.
VEHICLE IDENTIFICATION
G.001
Fig. 3 - Gear-box No.
G. 002
Fig. 4 - Dtfferentfal No.
Reprint or translation, even partial, is strictly prohibited without written permission from CHRYSLER FRANCE
I
GENERAl
1
G. 003
G.004
CHRYSLER
160 • 160 GT • 180

GENERAL
2
DIMENSIONS AND WEIGHTS
JACKING THE VEHICLE
DIMENSIONS
Overall length
Overa 11 wt dth
Front overhang
Rear overhang
Wheel-base
Front wheel track
Rear wheel track
Ground clearance
Unloaded ntght
Loaded weight
WEIGHTS
160 160GT-180
4 457 ••
4 527 ••
1 728 ••
780 ••
1 010 ••
815 ••
1 045 ••
2 667 ••
1 400 II
1 397 II
120 II
160
Manual Trans. Auto. Trans.
Unloaded wefght In running order
1 065 kg 1 080 kg
I. e. at front
572 kg
585 kg
at rear 493 kg
495 kg
Total authorized loaded weight
1 490 kg
t. e. at front I
at rear
Total authorized loaded weight
2 190 kg
rl th tral ler
RECOMMENDA TI ONS FOR VE HIC LE JA CKI NG
- To Jack up vehicle, support ft on following pofnts only:
• locations for Jacking In lower door sfll area behind
front wheels and ahead of rear wheels.
CHRYSLER
160GT-180
lan. Trans. Auto.
Trans.
1 095 kg
1 110 kg
585 kg 595 kg
510 kg
515 kg
1 520 kg
I
2 670 kg
I
160. 160 GJ. 180 , Reprint or translation, even partial, Is strictly prohib i ted without written permission from CHRYSLER FRANCE
(

0
OPERATIONS TO BE CARRIE D OUT BEFORE DELIVERY
OPERA liONS TO BE CARRIED OUT FOR FREE OVERHAUL
GENERAl
3
01)~TIONS TO BE CARH. I W O U'l' B El' 'Ollli DE LI VBRY
B.r:FOJ . {~ 'l't~STIKG
AFTr~ TESTING
- Remove protective coating an d wash car. -Correct
all possible faults.
- C
heck wheels are properly tf gh tened.
-Inflate tyres to correct pressure. -
Check th at hea d li ghts are se~ properly.
- C
heck levels of all fluids. -
Adjust idle setti ng.
- Ch ec k sealing for all systems.
-
Check that battery is correctly ch arged,
H.OAD T ~S T
F Th iSHI NG
- Check operation of: - C
lean Inside and outside,
,
all mec han ical units - Ch
eck overal l appearance •
•
all electrical un its and accessories
• a
ll bo dy components and eq uip me nt
OP&UI. TIONS 'l'U BS CA.RH.I .IID OlJI' l~' OR l' ID ;~ O V ~ UL
1 - V~ICLE RESTING ON GROUND
- Check operation of bonnet catch release control.
Operations in engine compartment
- Remove air filter assembly with cool a!r Intake
sleeve, oil
fume suction tube, carburettor air
intake connect! on, and cylinder-head cover.
- Remove 4 spark-p1 ugs.
-Re-tighten cylinder-head setscrews to a 9
11 da N torque in the prescr! bed order; th! s
operation
is to be carried out when engine is
cold.
-Set valve clearance to:
•• 25 mm for Inlet valves
•• 35 mm for exhaust valves.
S"h.'TTING PROCEDURE
Put vehicle into gear (4th), release hand-brake,
and move a wheel to rotate engine In order to set
valves of a given cylinder In a balanced position,
so that play between valve stem and bearing bush
of opposite cylinder can be adjusted.
Example: to adjust rocking levers for cylinder
No. 1, set cylinder No. 4 In balanced position;
rocking-levers for cylinder
No. 2: cylinder
No. 3 valves; rocking-levers for cylinder
No. 3: cylinder No. 2 valves; rocking-levers
for cyl! nder
No. 4: cylfnder No. 1 valves.
-Re-fit cyltnder-head cover
after checking
condition of gasket.
Check, clean, and adjust spark plugs
electrode
gap .6 ••·
- Re-f! t spark p1 ugs.
- Chec k and clean carburettor.
-
Check accelerator corltrol stroke, otl linkage.
-
Check operation and clearance of choke control,
on 160 model only.
-
Check cleanliness of fuel pump ff lter.
- Check engine o!l and brake fluid levels.
-
Check that the following are correctly
tightened:
•
radt ator
•
inlet .anifold
• water outlet
cover and elbow
• earburettor
, water pu11p
• t!1!ng gear cover
• water draining
plug on cylinder block
, 4 upper nuts on exhaust aan!fold
• 2 upper nuts fastening exhaust flange to
aan!fold
• front
shock-ab&orber upper attachunts
• servo-brake and clutch and brake uster-
cylInder&.
Reprint or translation, even partial, Is strictly prohibited without written permission from CHRYSLER FRANCE
CHRYSLER
160-160 GT • 180

GENERAl
OPERATIONS TO BE CARRIED OUT. FOR FREE OVERHAUl
4
- Check connection of electric fan and its thermo-
switch on 160 GT and 180 models.
- Check sealing of cooling system and condition of
all hoses, together with radiator level.
-
Check sealtng of fuel supply systM.
Re-fit
air filter assembly.
• Adjust belt tension.
Operations in luggage compartment
- Check proper operation of luggage trunk opening
control.
-
Check proper operation of lock.
-
Check that retainer Is tightened correctly,
adjust tt
if necessary.
-
Check that rear shock-absorber fastening nuts are
tightened properly.
Operations inside car
- On front doors, check proper operation of:
•
door opening controls
•
door locking systems
• wl ndot-11 fters
• 1 ocks
• courtesy light switch on lower front pillar
- On rear doors, check proper operatl on of:
•
door opening controls
•
door locking systeas
•
wf ndow 11 fters
- If necessary, adjust front and rear door strikers.
- On front seats, check:
• correct s11dfng of seats
•
corr~t locking In various positions
• proper Inclination
and locking of seat backs
In position.
- Check proper operation of:
• side ventilators
• roof
light
• 1 nlgh t and day• rear vi n •I rror
• electric clock
on 160 and 180 1odels
'
• cfgar lighter on 180 1odel
• trip recorder resetting device on 180 1odel
- Check that glove box fs c1 osl ng properly and that
lock operates correctly.
-
Check proper operation of:
• clutch and brake pedal stops
• side lights
• nu•ber plate light
•
lnstruunt cluster lighting
• d
ipped headlights ·
• headlights
(if . need be, adjust headlights)
• headlight Indicator light on Instrument
cluster
• Ignition
and starting switch, anti-joy-ride
device
• oil
warning li~ht
• •ater temperature Indicator
• fuel
gauge
charging Indicator light
• front
and rear R.~. and L.H. trafffcators
•
trafflcator Indicator light
• steering-wheel trafffcator control return
system
• h om
• windscreen-wiperw (on both positions)
•
win dscreen-washer (adjust nozzles If
necessary)
• air-conditioner
fan
• air distributor and defroster.
2 - VEHICLE ON LIFrlNG RAMP
(operations on underside of car)
- Check that the following are properly
tl gh tened:
•
R.H. and L.H. engine mountings
• oil filter to cylinder block
• 4 exhaust ~anlfold lower nuts
• 2
lower nuts fastening exhaust flange to
unlfold
• gear box fastening relnforc8111ent to
cylfnder block
• rack to front cross-umber
• starting 1otor
to clutch housing and
cylfnder block
• clutch receiver cylfnder
• gear
box and clutch housing
• gear box rear cover
• engine central aountlng to gear box and
cross-• •ber to body
• drag links to kfng pin an;
• stab! 11 zer rod to body
• drag ll nk 1ock-nuts
•
tachometer tapping to gear box.
CHRYSLER
160 • 160 GT • 180
Reprint or translation, even partial, is strictly prohibited without written permission from CHRYSLER FRANCE

OPERATIONS TO BE CARRIED OUT FOR FREE OVERHAUL
CERTIFIED AND RECOMMENDED MAINTENANCE OPERATIONS
GENERAL
5
- Check condition and proper operation of rack
sealing bel lo ws.
- Check sealing of crankcase and of gear box
and differential housings.
-
Check that the following are properly
tightened:
•
king pin
• screws fastening king pin lower knuckle
• wheel play tie-rods
• alternator
to cylinder block
• transmission coupling )oint
transmitter relay
to body
• differential cover
• rear suspension 1
ower arms to body
differential to suspension ann
• upper suspensIon arms to di ff eren tia1 and
body
• anti -roll bar to body and differential
• petro1
tank
• exhaust straps
• exhaust collars
•
brake equalizer to body
• rear shock absorber 1 ower attachments.
-
Check hydraulfc brake system sealing.
-
Check gear box 1 eve 1
-
Check differential level
-
Check fue 1 gauge connection and its
attachment
to tank.
Operations on outside of car
- Inflate tyres to required pressure (inclusive of
spare
wheel tyre); required pressure : Saloon
Front : 1. 7 bar- Rear : 1.9 bar.
-
Ver ify a nd check that bolts are correctly
tightened
on a ll ' wheels.
- Check and, If necessary, adjust hand-brake
setting•
-
Lift front and ba .lance front wheels (if ne~essary) •
Star t engine
- Check proper operation of choke •
-
Check al temator output.
- C
he ck that oil warning light is off•
-
Check and, if necessary, adjust closing angle of
distributor
co ntacts.
-
Check and, if necessary, adjust In! tfal settl ng
of distri butor, using stroboscopic lamp.
- Adjust idle setting•
-
Check gear shifting and selection•
ROAD TESTING
- During this test, check proper operation of:
• releasable
fan
• air-conditioner
• revolution Indicator
•
speedo11eter
CERTIFIED AND RECOMMENDED MAINT~CE OPERATIONS
Please, kindly consult guarantee booklet for
year under consideration.
Reprint or translation, eve n partial , is strictly prohibited without written permission from CHRYSlER FRANCE
CHRYSLER
160- 160 GT • 180

(

AO
AO/I
AO/I
- ENGINE ASSEMBLY
- Gen e ral specification s
-
Engine/dr iv e uni t moun tin gs
AO/II - Tightening torque val ues
AO/II I - Sp ecific tooling
AO/V - R emova l and re-f i t ti ng of engin e
AO/V - Replac em en t of an engine side mo untin g
AO/VI - Dismantl ing and re-asse m bly of e ngin e
Reprint or translation , even partial, is strictly pro hibite d witho ut wr i tten perm ission fr om C HRY S LER FRANCE
CHRYSLER
1 60 - 160 CiT- 180

CHRYSLER
160 • 160 GT • 180
W.1317
Reprint or translation, even partial, Is stridly prohibited without written perminion from CHRYSLER FRANCE

/)
AOII
GENERAL SPECIFICATIONS
1
0
Type: Internal co11bustlon engine, 4 stroke, 4 cylinders In lfne with 15 transverse Inclination,
overhead ca.shaft.
Location on car: at front, long1tudlnally.
Firing order: 1 - 3- 4- 2
Direction of rotation: Clockwise when observer Is facing front of engine.
Overall dimensions of engine-drive unit:
length (wt th flywheel and fan) 685 ••
width (without atr filter) 560 11
height (without air filter) 700 11
Weight of eng i ne only with accessories: 155 kg approx.
Weight of engine-drive unit: 200 kg approx.
361 Engine
341 Engine
Trade naae
CHRYSLER 160 CHRYSLER 180
Bore 83.40 II 87.70 Ill
Stroke
75 II 75 II
Cubic capacity
1639 c.c. 1812 c.c.
Stroke/Bore ratio 0.899
0.855
Coapresslon ratio 9.2 ! 0.1
9.2! 0.1
Reco•unded fuel
Super
Super
IG!nt1um II octane lnd~tx
98 98
For countries with low octane Index
Co1pressl on rath
8.2 8.2
Reco11ended petrol ordinary ordinary
Mtnl1u1 ~ octane Index
90-91
90-91
Fiscal power (French standards) 9
cv 10 cv
Effec ttve DIN power
80 CV at 5600 r.p.1.
97 CV at 5600 r.p.1.
DIN uxl1u11 torque 12.5
1daN
14.7 •daN
at 3000 r.p.1.
at 3000 r.p.1.
Specific power
51.9 CV/H tre
53.5 CV/lf tre
-
Reprint or translation, even partial, Is strictly prohibited without written permissi on from CHRYSLER FRANCE
CHRYSLER
160-16061-180

AOII
ENGINE-DRIVE UNIT MOUNTINGS
2
r
Fig. 1
The engine drive unit Is fastened In three
points:
- a
side point on either side of the cyl i nder
block, by 1eans of brackets and rubber
blocks (Fig. 1) bearing against R.H. and L.H.
slde-••bers;
- a central rear
point : a cross-~ember fl tted
between side-umbers carries a 1sllentbloc•
vulcanized on a tab; this tab, rhich
Fig.2
G.005
protrudes from the s!lentbloc, directly supports
the gear box extension (Fig. 2).
Note: The side 1ountlngs attached to the
cylinder block h ave different fastening distances
between centres.
G.006
CHRYSLER
160-160"- 180
Reprint or translation, even partial, Is strictly prohibited without written permission from CHRYSLER FRANCE

0
AOtll
TIGHTENING TORQUE VALUES
Distributor to front cover •••••••••••••••
Alternator
to cylinder block •••••••••••••
Rocking lever, ad}ustlent screw and nut ••
Draining plug to cylinder block ••••••••••
Valve cap ••••••••••••••••••••••••••••••••
011 draining plug ••••••••••••••••••••••••
Inspection plug for chain tensfoner ••••••
Spark-plug to cylinder head ••••••••••••••
Starting 1otor teralnal ••••••••••••••••••
Side tf .. piece to cylinder head ••••••••••
Earthing cable to tel"'lfnal
Post tl ve cable to term! nat
•••............
Carburettor to Inlet 1anlfold ••••••••••••
011 suap to cylinder block •••••••••••••••
Filter cartridge
to support bracket ••••••
1 daN
5
1.5
2
3
4
4
3
1.5
1.5
0.5
1
2
Front cover to cylinder head •• •• •••• .•••• 1.25
Timing gear cover to cylinder block •••••• 1.25
Connecting rod cap ••••••••••••••••••••••• 7.5
Searing cap to cylinder block ••••••• ••••• 11
Inlet manifold to cylinder head •••••••••• 1.5
Exhaust 1an!fold to cylinder head •••••••• 2
Spark-plug harness duct to cylinder head.. 1.5
Oil pump body to cylinder block •••••••••• . 1.25
Cover to oil pu1p body................... 1.5
Side cover to cylinder head.............. 1.25
Cover on water outlet •.••••••••••••••• ~.. 1.25
Cylinder head cover...................... 0.75
Cylinder head to cylinder block •••••••••• 9
Starting 1otor
to cylinder block ••••••••• 5
Diaphrag• to crankshaft.................. 8
Pressure swftch ·························• 3.5
1
• daM
Anti-vibration pad to cylinder block ••••••• 1.5
Guiding pad to cylinder block •••••••••••••• 1.5
011 pu1p to cylinder block ••••••••••••••••• 1.25
later pu1p to tt1!ng gear cover............ 1.25
Petrol pump to front cover................. 2
Crankshaft pulley ·············•············ 9
Teaperature tapping........................ 1.5
Gear wheel to ca1shaft ••••••••••••••••••••• 1.5
Water outlet to cylinder head ••••••• .... ... 1.25
Filter cartridge support bracket to cylinder
block •••••••••••••······················· 1.25
Engine 1ountlng to engine.................. 2.5
Alternator supporting bracket to tiling
gear cover.................. ..... . ....... 1.5
Bearing seal supporting bracket............ 1
Strainer to cover.......................... 1.25
Bracket assembled to support •••••••••.••••• 2.5
Bracket assembled to cross-181ber .......... 2.5
Rear bracket to rear cross-1ember •••••••••• 2.5
Rear bracket to gear box extension......... 2.5
Ch ain adjuster to cylinder block •••••••••••
Adjuster to alternator •••••••••• ,.......... 2
Alternator adjuster
to timing gear cover... 2
Pressure swftch •••••••••••••••••••••••••••• 1.5
Rear cross-ma.ber to body.................. 2.5
Fan and pulley to 341 engine............... 0.5
Fan and pulley to 361 engine............... 1.25
Engine flywheel to crankshaft.............. 8
Reprint or translation, even partial, Is strictly prohibited without written permission from CHRYSLER FRANCE CHRYSLER
160-160 GT- 180

• I