Repair Procedure

This repair involves the installation of new governor weights (mechanical advance), a new dual chamber vacuum advance canister, 3-port thermo valve, and related vacuum harnesses. The new vacuum advance system will lock manifold vacuum to the distributor during cold engine operation for improved cold driveability.

NOTE: THIS PACKAGE WILL INCREASE SPARK KNOCK DURING ENGINE WARM UP. THIS WILL NOT DAMAGE THE ENGINE AS INDICATED IN THE OWNERS MANUAL.

1. Remove the distributor cap and rotor.

2. Loosen the governor retaining cap screw. This cap screw is usually quite tight, so loosen this screw prior to removing the distributor.

3. Remove the electrical connections at the coil, the vacuum hoses at the distributor, and remove the distributor. It is important to note the position of the distributor shaft so when the distributor is reinstalled, it will be properly indexed with respect to the crankshaft.

FIGURE 1:

4. Unscrew the governor cap screw. Remove the governor assembly (Figure 1).

5. Remove the screws securing the igniter and remove the igniter assembly.

FIGURE 2:

FIGURE 3:

6. Remove the two screws holding the vacuum advance unit to the distributor and then remove and discard the vacuum advance canister (Figures 2 and 3).

7. Replace the vacuum advance canister with the new dual diaphragm advance canister, PN MD611472, supplied in the kit (Figure 3).
8. Reinstall the igniter assembly into the distributor. Make sure the attaching screws are secure.

9. Install the new governor assembly, PN MD607474, provided in the kit. Torque the retaining cap screw to 39 inch pounds.

10. Remove the fuel return hose that runs from the fuel pump to the fuel return chassis line. Install hose and sleeve assembly, PN 4418103, in this location. Secure this hose and sleeve assembly to the existing bracket located on the right front corner of the camshaft cover.

FIGURE 4:

IMPORTANT: THIS CONVOLUTE TUBING MUST BE INSTALLED TO PREVENT THE NEW DUAL DIAPHRAGM ADVANCE MECHANISM FROM ABRAIDING THE HOSE (FIGURE 4).

NOTE: THE FUEL RETURN HOSE DOES NOT GET REPLACED ON VEHICLES THAT HAVE FUEL FOAMING AND/OR VAPOR LOCK KITS ALREADY INSTALLED (TECHNICAL SERVICE BULLETINS 18-05-86 AND 18-0-6-86).
11. If the vehicle is already equipped with a 3-port thermo valve, the new 3- port valve, PN MD081274, does not have to be installed. If the vehicle has the 3-port valve, proceed to Step 16. If the vehicle is not equipped with a 3-port thermo valve, proceed with Step 12.

12. Drain and save engine coolant.

13. To gain access to the thermo valve, remove both the coolant temperature sensor (2-wire) and the temperature gauge sending unit (1-wire). If the vehicle is equipped with a fuel reservoir, it will need to be set aside by removing the thermostat housing bolt that secures the reservoir.

FIGURE 5:

14. Remove both vacuum lines from the thermo valve. Remove and discard the vacuum line at the thermo valve side of the EGR valve. Cut a piece of this discarded hose and connect the secondary vacuum diaphragm to the carburetor base (Figure 5).
15. Remove the thermo valve and replace it with the 3-port thermo valve, PN MD081274, provided in the kit (it may be necessary to loosen the alternator mounting bolts and push the alternator out of the way). Use sealer on the threads to prevent coolant leakage.

FIGURE 6:

16. Replace the EGR valve with the new EGR valve, PN MD097314, which is included in the kit. Install the vacuum switching valve bracket, PN MD100733, in conjunction with the EGR valve. This bracket is mounted using the two EGR bolts (Figure 6).
17. Making sure it is properly positioned, install the distributor, distributor cap, and all wires to spark plugs and coil.

FIGURE 7:

FIGURE 8:

FIGURE A - HOSE ROUTING DIAGRAM:

18. Install the new vacuum overlay, PN MD107136 (Figures 7, 8, and 9), for proper routing and connections with existing and new parts.
19. "Snap" the vacuum switching valve into the newly installed bracket, PN MD100733. This is accomplished by pushing the valve into the brackets two "spring arms."

20. If the vehicle is equipped with air conditioning:

a. 1984 Model Year

Install vacuum tee, PN 3671410, provided in the kit into the throttle kicker vacuum line located on the manifold tree. Gather the vacuum hoses together near the manifold and secure with snap clip, PN MD470362.

b. 1985 Model Year

Locate the vacuum line going to the VCOTV (Vacuum Controlled Orifice Tank Valve) at the manifold vacuum tree. Insert the supplied tee, PN 3671410, into this vacuum line.
21. Reinstall coolant temperature sensor, temperature sending unit, and engine coolant. Reinstall the fuel reservoir if so equipped. Apply Loctite/Mopar Sealant, PN 4318034, to the bolt threads before reinstalling. Torque to 15 foot pounds.

22. Start engine and allow to warm up.

23. Remove vacuum hoses from distributor vacuum advance unit and adjust ignition timing to 7~ BTDC.

24. Reinstall vacuum advance hoses, using caution that each hose is installed on the correct port.

25. 1984 Federal Vehicles Only

Remove the right front kick panel and note the part number on the electronic control unit. If any part number other than MD080152 is present, the ECU must be replaced with PN MD080152.

FIGURE 10:

26. Type Authorized Modification Label, PN 4275086 (Figure 10), and affix near original VECI label.

27. California Vehicles Only

Clean existing vacuum hose routing label surface and apply new vacuum hose routing label, PN 4306845, over old label.


POLICY: Reimbursable within the provisions of the warranty


TIME ALLOWANCE:
Labor Operation No. 1984 1985

25-01-45-99 1.3 Hrs. 1.1 Hrs.


FAILURE CODE: AM - Authorized Modification