1935 WILLYS
Model Designations:
Willys, Model 77, 4 Cylinder
Willys, Model 77, 4 Cylinder Body Styles
2 Door Coupe, Base Price: $475
Sedan, Base Price: $495
General Specifications
Wheelbase: 100 Inches
Engine Type: Inline 4, L-Head
Bore & Stroke: 3-1/8" X 4-3/8"
Engine Displacement: 134.2 Cu. In.
Compresssion Ratio: 5.13:1
Taxable Horsepower: 15.63
Horsepower: 48 @ 3,200 RPM
Torque: Not Available
Rear Axle Ratio: Not Available
Carburetor: Not Available .
Tire Size: 5.00 x 17 inches; Inflation Pressure, Front 30, Rear, 34
Tune Up Specifications
Spark Plug: Gap .025"
Spark Plug Type: Champion C-7, D-16, or Equivalent
Point Gap: .020"
Distributor Cam Angle: 46 degrees
Ignition Timing: "IGN" Mark on Flywheel
Firing Order: 1342
Tappet Clearance, Hot: Intake .004", Exhaust .006"
Cylinder Head Torque: 60-65 Ft Lbs
Carburetor Specifications:
Tillotson
Float Level: 1/25/32"
Valve Specifications
Tappet Clearance, Running Hot: Intake .004"; Exhaust .006"
Clearance for Timing: Intake: .010"; Exhaust: .010"
Valve Timing: Intake Opens At Top Dead Center
Exhaust Closes 5 degrees After Top Dead Center
Valve Seat Angle: Intake 45 degrees; Exhaust 45 degrees,
Valve Spring Pressure: 46 Lbs @ 2-1/4 inches (New Springs)
Valve Stem Clearance: Intake .002"-.004"
Exhaust .003"-.005"
Piston & Ring Data
Piston Removal: From Above
Piston Clearance (Minimum):
Top Land Inch .007"
Top of Skirt, Inch: .002"
Fitting Pistons with Spring Scale:
Shim Thickness: .0025 using a 3/4" wide feeler gauge
Pounds Pull on Scale: 5 to 10
Width of Ring End Gap (Minimum):
Compression Ring: .007"
Oil Ring: .007"
Clearance Between Ring & Grooves:
Compression Ring: .0005"-.001"
Oil Control Ring: .001"-.0015"
Engine Bearing Data
Camshaft End Play: Automatically controlled by spring & plunger at front
Camshaft Bearing Clearance: .002"-.0035"
Rod Journal Diameter: 1.9375"-1.9385"
Rod Bearing Clearance: .001"-.0025"
Rod End Play: .005"-.009" inches
Rod Bolt Tension: 50-55 Lbs. Ft.
Main Bearing Journal Diameter: 2.1765"-2.1770"
Main Bearing Clearance: .001" -.0025"
Crankshaft End Play: .004"-.008"
Main Bolt Tension: 60-70 Lbs. Ft.
Capacities
Cooling System: 9 Quarts
Fuel Tank: 8 Gallons;
Engine Oil Refill: 4 Quarts;
Grade of Oil: Above +32F 20;
Above +10F 20W;
Above -10F 10W
Transmission: 1 Pint
Grade of Oil: Summer 140, Winter 90
Rear Axle: 1 Pints
Grade of Oil: Summer 140, Winter 90
Auto Lite Distributor Specifications
Part #: 1GB-4078
Cam Angle: 46 Degrees
Point Opening: .020"
Condensor Capacity: .20-.25 Mfds.
Breader Arm Spring Tension: 17-20 Ounces
Centrifugal Advance Data:
Advance Starts 3 Degrees @ 650 RPM
Full Advance: 12-1/2 Degrees @ 1,700 RPM
Beginning Engine Numbers: 27056
Brake Specifications
Lining Material: Molded
Lining Dimensions/Wheel in Inches: 19-3/16"
Width: 1-3/4",
Thickness: 5/32"
Pedal Free Play: 1/2"
Wheel Alignment Specifications
Caster: +1-1/2 Degrees
Camber: +2 Degrees
Toe In; 3/32"
Kingpin Angle: 7-1/2 Degrees
Rear Axle Data
Ring Gear & Pinion Backlash: .004"-.008"
Drive Pinion Adjustment: Shims
Drive Pinion Bearing Adjustment: Shims
Axle Shaft End Play: .004"-.006"
Auto-Lite Generator Specifications:
Part # GAM-4504
Brush Spring Tension:
Main: 18-22 Ounces
Third: 18-22 Ounces
Direction of Rotation: Clockwise
Field Current @ 6 Volts: 3.89-4.31 Amperes
Low Output Test: 8 Amperes @ 1,070 RPM, 8 Volts
Maximum Output Test: 17.5 Amperes, 8 Volts
Auto-Lite Regulator Specifications:
Part # CB-4008
Voltage to Close Relay Points: 6.5-7.25 Volts
Amperage to Open Relay Points: .5-2.5 Amperes
Maximum Operating Amperage: 15 Amperes
Auto-Lite Starting Motor Specifications:
Part # MZ-4033
Brush Spring Tension: 42-53 Ounces
No Load Test: 70 Amperes, 5.5 Volts @ 4,300 RPM
Lock Test: 560 Amperes, 4.0 Volts, Torque: 11.8 Ft Lbs
Tillitson Carburetor Adjustments:
Idle Screw: 3/4 to 1-1/4 Turns Open
Main Adjustment: 2 Turns Open
Fuel Level: 1-25/32" from bottom of float to face of carburetor body.
Dash Gauge Manufacturers:
Gasoline: Motor Meter Neco
Copyright 1999, Custom Solutions & Services
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