Fiat - X19 - Service Manual - 1979 - 1982

X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 xv' PRODUCED BY FIAT MOTORS OF NORTH AMERICA. INC. PUBLICATIONS AND TECHNICAL TRAINING DEPT. COPYRIGHT © 1982 by FIAT MOTORS OF NORTH AMERICA, INC. All rights reserved — This book may not be reproduced in whole or in part without the ex- press permission of Fiat Motors of North America, Inc. The descriptions and illustrations appearing in this book are not binding. Fiat reserves the right to make at any time any changes or modi- fications to the characteristics of the automobile without necessarily bringingvthis book up- to-date. Print No. 3399 (2/82) PRINTED IN U.S.A. FOREWORD This manual has been written to provide basic information for the proper servicing of the X1 /9 models. The information is grouped in sections. Each section is identified by two—digit numbers. Each section covers the service procedures for the individual groups and sub-groups. They are identified by a number. The root of the number is taken from the general sub-group code now being used for the Parts Catalogue and the Service Time Schedule. This number identifies the service time schedule operation, parts catalogue sheet for the part covered by the service procedure, and the service procedure. HOW TO USE THE MANUAL The information identification number consists of five digits, as follows: a) The first two digits identify the section. b) The third designates the group within the section and is used in conjunction with the first two. Cl The last two digits indicate an assembly or task consisting of several parts. This number identifies the sub-group. It refers to the sub-group in both the Parts Catalog and the Service Time Schedule. Find the information required as follows: 1) Find the tab index page for the information on the first page of the manual. 2) Find the group and subgroup for the information on the table of contents. UPDATING TH E MANUAL — Revision sheets are supplied together with a revised ”Composition of the Manual" sheet. — Revision sheets can be of two types: 1) Replacement sheets: In this case the new sheet will carry the same page number as the old one. A notation in the bind margin will read Supersedes page . . .dated . . ." 2) Complementary sheets on topics already dealt with: in this case the additional sheet will carry the same sub-group number as the sheet on which the topic has been first dealt with. The page number will be followed by a letter suffix. Example: If additional information is needed for information on page 2, the new sheet will be 2A. BREE X1/9 CONTENTS Section GENERAL INFORMATION MAINTENANCE ................................. oo ENGINE ......... _................................ 10 CLUTCH ......................................... 18 TRANSMISSION DIFFERENTIAL AXLE ........................................ 21 /27 BRAKES ............... . ........................ 33 STEERING SYSTEM ............................. 41 SUSPENSION AND WHEELS ................... 44 ACCESSORIES .................................. so ELECTRICAL .................................... 55 BODY ........................................... 7o SERVICE MANUAL 1.|..||1.|1.|1||| \I'l. X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION MAINTENANCE TUNE UP 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 GENERAL INFORMATION MAINTENANCE - 00 Page Identification Data ................................... Tune-Up Specifications ............................... 00-3 00-4 Engine and Drive Train Specifications .................. 00-6 Chassis Specifications ................................ Electrical Specifications .............................. Weights and Dimensions ............................. 00-7 Capacities ........................................... 00-8 00-9 00-10 General Information 00 Page 00-1/2 00 General Information IDENTIFICATION DATA Chassis Type and Identification Number - Punched on cowl on right side of from luggage compartment (above battery box). Page 00-3 F.M.V. Safety Standard 115 Tag Type of vehicle and chassis number. Located on left panel top between instrument cluster and windshield. .1'1' l/uAbD lIHl’S'” Chassis Plate - Located on right side of front luggage compartment. . Jill... =_|llI“ -_, F.M.V. E.P.A. Regulations Conformity Tag - Air pollution control Specifica— tions for correct engine tune-up and adjustments. Located in engine compartment on left side. Engine Type and Identification Number - Punched on crankcase, flywheel side. Safety Standard Con- formity Tag - Month and year of manufacture. gross vehicle weight rating, gross axle weight rating, chassis number and vehicle type. Located on left door jamb. fllmllulu [Elfin—fl . narr- bl .‘ Vehicle Emission Control Information Label - Located on left door jambc “CATALYST F.M.V. Safety Standard 110 Tag Tire data and vehicle capacity. Located on right door jamb. ‘ 1:1,.I. ulfihl l‘Jl-r'li .anluh ' ll I'm? er In mnmrlmvtl lllr pinnrl In my mag-am ‘- Page 00-4 TUNE-UP SPECIFICATIONS (VEHICLES WITH CARBURETOR) Valve clearance (engine cold): — Intake ......................................... — Exhaust ....................................... 0.011 to 0.014 in. (0.28 to 0.35 mm) 0.015 to 0.018 in. (0.38 to 0.46 mm) Fuel pump pressure at 4000 rpm ............... 3.5 to 4.3 psi Spark plugs: — Type ......................... AC Bosch .............................. Champion ..............................Marelli ——Gap ............... Normal 42XLS W175T30 N9Y CW7LP 0.023t00.027in. (0.6 to 0.7 mm) Resistor R42XLS W175TR30 FINQY CW7LPR 0.027t00.031in. (0.7 to 0.8 mm) Ignition timing .................................... 5° BTDC at 800 to 850 rpm Distributor advance: — Centrifugal ................................... — Total (ignition timing and centrifugal) ......... 23° to 27° at 5500 rpm 28° to 32° at 5500 rpm with air pump ............................. without air pump .......................... 16° to 18° at 12 in. Hg 26° to 30° at 12 in. Hg —~ Vacuum Idle Speed( 1) ...................................... 800 to 900 rpm C0 leveHat idle)(‘) ................................ 1.0 to 2.0% [‘l Idle speed and CO must be checked and adjusted with hose to reed valve or check valve pinched off. General Information 00 Page 00-5 TUNE-UP SPECIFICATIONS (VEHICLES WITH FUEL INJECTION) Valve clearance (engine cold): — Intake ......................................... — Exhaust ....................................... 0.011 to 0.014 in. (0.28 to 0.35 mm) 0.015 to 0.018 in. (0.38 to 0.46 mm) Fuel pump pressure .............................. 39 to 45 psi (2.7 to 3.2 bar) Spark plugs: — Type .......................................... — Gap ........................................... Champion RN9Y 0.027 to 0.031 in. (0.7 to 0.8 mm) Ignition timing .................................... 10° BTDC at 800 to 850 rpm Distributor advance: — Centrifugal ................................... — Total (ignition timing and centrifugal). . . . . — Vacuum ...................................... 16° to 20° at 3500 rpm 26° to 30° at 3500 rpm 12° to 16° at 11 in. Hg Idle speed ........................................ 800 to 900 rpm CO level (at idle) .................................. 0.5 to 0.9% Page 00-6 SPECIFICATIONS ENGINE Type: — Vehicles with carburetor with air pump ............................. without air pump .......................... — Vehicles with fuel injection ................... Arrangement ..................................... Number of cylinders .............................. Bore .............................................. Stroke ............................................ Displacement .................................... Valve arrangement ............................... Compression ratio ................................ Horsepower rating, SAE net: 1 38AS .031 138AS.040 13888040 Mid transverse Four 3.40 in. (86.4 mm) 2.52 in. (63.9 mm) 91.44 cu. in. (1498 cc) Overhead valves. Single overhead camshaft driven by toothed timing belt. 8.5 to 1 — Vehicles with carburetor with air pump ............................. without air pump .......................... 66 at 5250 rpm 67 at 5250 rpm — Vehicles with fuel injection ................... Torque rating. SAE net: — Vehicles with carburetor with air pump ............................. without air pump .......................... — Vehicles with fuel injection ................... 75 at 5500 rpm 76 ft. lbs. at 2500 rpm 77 ft. lbs. at 2500 rpm 80 ft. lbs. at 3000 rpm CLUTCH Type .............................................. Dry single plate, diaphragm spring, hydraulically controlled, with no pedal free travel. TRANSMISSION Gears ............................................ Gear ratios to 1: — First .......................................... —- Second ....................................... 5 forward, 1 reverse 1979-80 1981 ~82 2.235 2.235 3.583 — Third .......................................... 1.454 — Fifth .......................................... ‘ 0.863 — Fourth ........................................ — Reverse ....................................... 1.042 3.714 3.583 1.461 1.033 0.863 3.714 DRIVING AXLE Type .............................................. Final drive ratio ................................... Power drive to rear wheels. . . . . .'.. ............... Combined with transmission. Helical-toothed cylindrical gears. 13/53 (4.077 to 1) By axle shafts connected to final drive and to wheels through constant-velocity ball joints. 00 General Information Page 00-7 BRAKES Type .............................................. Disc brakes on all four wheels. — Diameter ..................................... — Originalthickness ............................ —- Minimum thickness after refacing ............ 8.937 in. (227 mm) 0.421 to 0.429 in. (10.7 to 10.9 mm) 0.368 in. (9.35 mm} Hand brake for parking ............................ Mechanical, acting on rear wheels. Brake discs: — Minimum thickness from wear ............... 0.354 in. (9 mm) STEERING Type .............................................. Steering wheel turns, lock to lock ................. Corresponding rack travel ........................ Turning circle diameter ........................... Front wheel toe-in, unladen ...................... Rack and pinion, breakaway column with two universal joints, twin equal length tie rods. 3 4.6 in. (117 mm) 32.5 ft. (9.9 ml +3/32 to +5/64 in. (+2.5 to +6.0 mm) FRONT SUSPENSION Type .............................................. Caster, unladen .................................. Camber, unladen ................................. Independent, control arm, strut bar, knuckle pillar and strut assembly with integral shock absorber and coil spring. +6°10’ 0° to «1" REAR SUSPENSION Type .............................................. Camber, unladen ................................. Toe-in, unladen ................................... Independent, control arm, knuckle pillar and strut assembly with integral shock absorber and coil spring. -O°45' to ~1°45' +13/64 to +11/32 in. (+5.0 to +8.5 mm} WHEELS AND TIRES Wheel rim type ................................... Tires: — Type .......................................... — Inflation pressure: Front ...................... Rear ....................... 5J x 13 in. 165/70 SR 13 in. 29 psi (2.0 kg/cmi) 32 psi (2.2 kg/cm2) Page 00-8 ELECTRICAL SYSTEM Battery: — Voltage ....................................... — Capacity at 20 hr. discharge rate .............. Alternator: —— Continuous current rating Bosch ..................................... Marelli .................................... Voltage regulator: — Regulating voltage at 77°F (25°C) ............. Sta rte r: — Type .......................................... Power rating Bosch ............... . ..................... Marelli .................................... Ignition system: Type .......................................... Spark advance ................................ Pickup coil resistance ......................... ignition coil resistance at 68°F (20°C) primary ................................... secondary . ................................ Ballast resistor resistance .................... 12 60 Ah 65 amps 55 amps 13.8 to 14.2 Direct drive. Direct engagement by solenoid and freewheeling pinon. 0.8 kW 0.9 kW Bosch breakerless electronic Centrifugal and vacuum 890 to 1285 ohms 1.1 to 1.7 ohms 6,000 to 10,000 ohms 0.85 to 0.95 ohms 00 General Information Page 00-9 WEIGHTS Curb weight: — Vehicles with carburetor with air pump ............................. without air pump .......................... 2130 lbs. 2120 lbs. For air conditioning, add .......................... 80 lbs. — Vehicles with fuel injection ................... 2130 lbs. Seating capacity .................................. 2 persons Carrying capacity ............................ ..... 430 lbs. DIMENSIONS 46.5” (1180 mm) ~—— 867" (2202 mm) ———n 156.3" (3969 mm) «— 53.6" (1362 mm) —r 53.3" (1355 mm) —- *— 61.8" (1570 mm)—' Page 00-10 CAPACITIES UNIT It QUANTITY REFILL kg U.S. Units 47 — 12.2 gals. 11.6 — 12.2 qts. Engine sump and filter t‘) 4.1 3.7 4.3 qts. Transmission and Axle 3 2.7 3.2 qts. SAE 90 oil (not EP) containing anti-wear additives 0.127 5.3 025. SAE 90 EP oil or lithium-base Fuel tank Radiator, cylinder jackets and heating system Steering box 0.140 Unleaded gasoline with octane rating of at least 91 (Research Method) Use 50-50 antifreeze and water mixture Low-ash content detergent oils-AP! Service SE to to MIL-b46152 I grease with molybdenum disulphide Constant-velocity joints and boots (each) — 0.100 3.2 028. Brake hydraulic system 0.440 0.440 1 pt. Clutch hydraulic system 0180 0.180 6.4 025. Lithium-base grease with molybdenum disulphide DOT 3 Motor Vehicle Brake Fluid to F.M.V.S.S. No. 116 Same as brake system ('1 Total capacity including sump, filter and lines is 5 qts. (4.7 It). Amount indicated in table is requirement for periodic oil changes. X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 ENGINE - 10 PARTS CATALOG. SERVICE MANUAL 8: SERVICE TIME SCHEDULE CODE Page 10 10 100.00 101.01 101.03 101.05 101.06 101.07 101.15 102.01 102.02 102.04 102.21 102.26 102.58 103.01 104.01 104.02 10A Specifications ............................... Torque Specifications ......................... Engine Removal and Installation ..................... Disassembly ............................... Assembly ................................. Crankcase and Cylinder Head ................... Crankshaft and Flywheel ...................... Connecting Rods and Pistons ................... Camshaft Drive .............................. ValveMechanism ....... Auxiliary Drives ............................. Fuel Tank and Lines .......................... Fuel Pump and Lines ......................... Carburetor and Air Cleaner ..................... Accelerator Linkage .......................... Fuel Injection System ......................... Exhaust and Emission Control System ............ Lubrication ................................. Radiator and Fan ............................ Water Pump and Ducts ........................ Service Tools ................................ 1 0-1 1 0-9 10-1 1 10-21 10-30 10-43 10—57 10-63 10-69 10-71 10-75 10-77 10—81 10-83 10-89 10-91 10-105 10—1 15 10-121 10-123 10-127 1O Engine:Specifications Page 10-1 CYLINDER BLOCK-CON-RODS IN. MM Cylinder bore diameter ............................ Cylinder bores are graded into classes with 0.004" (0.01 mm) progression. 3.4015 to 3.4035 86.400 to 86.450 Auxiliary shaft bushing seats, diameters: v—drive end ..................................... —inside end ..................................... 1.5236 to 1.5248 1.3794 to 1.3805 38.700 to 38.730 35.036 to 35.066 Crankshaft main bearing seat diameter ................ 2.1459 to 2.1465 54.507 to 54.520 thrust ring seats ............................... 0.8716 to 0.8740 22.140 to 22.200 Big-end bearing housing diameter .................... 1.9146 to 1.9152 48.630 to 48.646 Thickness of standard big-end bearing ................. 0.0603 to 0.0606 1.531 to 1.538 Range of undersize big-end bearings for service .......... 0.010. 0.020, 0.030, 0.040 0.254, 0.508. 0.762, 0.016 -— fit clearance ................................... 0.0014 to 0.0034 0.036 to 0.086 Smallvend bore diameter ........................... 0.9425 to 0.9438 23.939 to 23.972 Small-end bushing O.D. ........................... 0.9455 to 0.9465 24.016 to 20.041 Small-end bushing fit, interference ................... 0.0017 to 0.0040 0.044 to 0.102 Grade 1 ..................................... Grade 2 ..................................... 0.8663 to 0.8664 0.8664 to 0.8665 22.004 to 22.007 22.007 to 22.010 Piston pin-smalI-end bushing fit: —clearance of new parts ........................... 0.0004 to 0.0006 0.010 to 0.016 :0.0039 10.10 DESCRIPTION Length of rear main bearing seat between Big-end bearings: Small~end bushing ream bore, fitted Maximum misalignment between c/ls of connecting rod small-end and big-end: measured at 4.92" (125mm) from the shank .......... Page 10-2 PISTON —- PINS — RINGS DESCRIPTION IN. MM at right angles to C/L of piston pin: ~at 1.08" (27.5mm) from piston skirt edge Class A ..................................... Class C...................................... Class E ...................................... 3.3999 to 3.4003 3.4007 to 3.4011 3.4015 to 3.4019 86.360 to 86.370 86.380 to 86.390 86.400 to 86.410 Maximum difference in weight between pistons ......... 10.0802 £2.59 Oversize piston range.............................. 0.0079, 0.0157, 0.0236 0.2, 0.4, 0.6 Grade 1 ..................................... Grade 2 ..................................... 0.8660 to 0.8661 0.8661 to 0.8662 21.996 to 21.999 21.999 to 22.002 Piston ring groove width Top groove .................................. Center groove ................................ Bottom groove ............................... 0.0604 to 0.0612 0.0799 to 0.0807 0.1562 to 0.1570 1.535 to 1.555 2.030 to 2.050 3.967 to 3.987 Standard piston pin diameter Grade 1 ..................................... Grade 2 ..................................... Oversize piston pin range for service .................. 0.8658 to 0.8659 0.8659 to 0.8660 0.0079 21.991 to 21.994 21.994 to 21.997 0.2 Piston ring thickness —first: compression ring ........................... -second: oil ring ................................. 4third: oil ring with oilways and expander ............. 0.0582 to 0.0587 0.0779 to 0.0783 0.1545 to 0.1553 1.478 to 1.490 1.978 to 1.990 3.925 to 3.947 —clearance of new parts ........................... 0.0011 to 0.0019 0.030 to 0.050 Piston pin in boss: clearance of new parts .............. 0.0001 to 0.0003 0.002 to 0.008 Piston ring fit (side clearance) —first: compression ring, clearance of new parts ......... wsecond: oil ring, clearance of new parts .............. —third: scraper ring, clearance of new parts ............ 0.0018 to 0.0030 0.0016 to 0.0028 0.0011 to 0.0024 0.045 to 0.077 0.040 to 0.072 0.030 to 0.062 0.0118 to 0.0177 0.30 to 0.45 Diameter of standard service pistons, measured Piston boss bore diameter Piston fit in here, measured at right angle to pin, 1.08” {27.5mm) from piston skirt edge Ring end gap in bore: —first: compression ring ........................... —second: oil ring ................................. 0.0118 to 0.0177 0.30 to 0.45 —third: scraper ring ............................... 0.0098 to 0.0157 0.25 to 0.40 Oversize piston ring range, for service ................. 0.0079, 0.0157, 0.0236 0.2, 0.4, 0.6 10 Engine: Specifications Page 10-3 CRANKSHAFT — MAIN BEARINGS IN. MM Main bearing journal standard diameter................ 1.9990 to 1.9997 50.775 to 50.795 Standard main bearing insert thickness ................ 0.0722 to 0.0730 1.834 to 1.840 Main bearing inserts, for service...................... 0.01, 0.02, 0.254, 0.508, 0.03, 0.04 0.762, 1.061 Crankpin standard diameter ........................ 1.7913 to 1.7920 45.498 to 45.518 Main bearing-to-journal fit: -—clearance of new parts ........................... 0.0019 to 0.0037 0.050 to 0.095 Length of rear main bearing journal, shoulder-to-shoulder ........................... 1.0620 to 1.0640 26.975 to 27.025 Rear main bearing seat thrust ring thickness ............ 0.0909 to 0.0929 2.310 to 2.360 Thickness of oversize thrust rings .................... 0.0959 to 0.0979 2.437 to 2.487 —c|earance of new parts ........................... 0.0021 to 0.0104 0.055 to 0.265 Max. misalignment of main bearing journals ............ 0.0012* 003* Max. misalignment of crankpins to main bearings journals ..................................... $0.014 $0.35 Max. out—of—rou nd of crankshaft jou rnals and crankpins, after grinding ..................... 0.0002 0.005 Max. taper of crankpins and journals, after grinding ...... 0.0002 0.005 Squareness of flywheel resting face to crankshaft centerline: — Max. allowable tolerance with dial indicator set laterally at a distance of about 1 11/32" (34mm) from crankshaft rotation axis............................ 0.0010 0.025 0.0039 0.10 0.0039 0.10 DESCRIPTION Crankshaft end play, thrust ring installed: Flywheel: —para|lel relationship of driven plate face to crank- shaft mounting face: max. allowable tolerance .......... ”squareness of above faces to rotation axis: max. allowable tolerance ........................... *Total indicator reading Page 10-4 CYLINDER HEAD DESCRIPTION IN. MM Valve position ................................... Overhead, inclined 18° Operation ...................................... Single ohc Drive .......................................... Toothed belt Valve guide bore ................................. 0.5492 to 0.5499 13.950 to 13.970 Outside diameter of valve guide...................... 0.5527 to 0.5534 14.040 to 14.058 Valve guide oversize on 0.0., for service ............... 0.0079 0.2 Inside diameter of valve guides, fitted in cylinder head. . . . 0.3158 to 0.3165 8.022 to 8.040 Valve guide fit in head: — interference ................ 0.0025 to 0.0043 0.063 to 0.108 Valve stem diameter .............................. 0.3139 to 0.3146 7.974 to 7.992 Valve stem fit in valve guide: nclearance of new parts . . . . 0.0012 to 0.0026 0.030 to 0.066 Valve seat angle in cylinder head ..................... 45° t5’ Valve face angle.................................. 45° 30’ 15' Valve head diameter intake ...................................... exhaust ..................................... 1.4173 1.3031 36 33.1 Width of valve seats in cylinder head (contact su rface): —intake and exhaust, about......................... 0.0787 2 intake ...................................... exhaust ..................................... 1.1811 1.0531 30 26.75 Lift on CIL of valve (without play) intake ...................................... exhaust ..................................... 0.3622 0.3641 9.2 9.25 Diameter of tappet bores in head .................... 1.4567 to 1.4577 37.000 to 37.025 Outside diameter of tappets ........................ 1.4557 to 1.4565 36.975 to 36.995 Fit clearance between tappets and bores in head ......... 0.0002 to 0.0020 0.005 to 0.050 Thickness of cap plates ............................ 0.1456 to 0.1850 (in 0.0019 progressions) 3.70 to 4.70 (in 0.05 progressions) Inside diameter of valve seats in cylinder head 10 Engine: Specifications Page 10-5 VALVE SPRINGS Valve spring installed height (A) under a load of . 85.7 lbs (38.9 kg) .................. 32.8 lbs (14.9 kg) ................... Valve spring installed height under 131 lbs (59.5 kg) .................... a load of 62 lbs (28.1 kg) ..................... Minimum permissible load, referred to height (A) ........ INNER SPRING OUTER SPRING 2 1.220 in (31 mm) 1.417 in (36 mm) — — .846 in (21.5 mm) 29.5 lbs (13.5 kg) 1.043 in (26.5 mm) — 79 lbs (36 kg) VALVE MECHANISM —- CAMSHAFT IN. MM Diameter of bearing bores in head: —drive end...................................... 1.1807 to 1.1816 29.989 to 30.014 middle ....................................... —intermediate, flywheel side ........................ —flywheel end ................................... DESCRIPTION - —intermediate, drive side........................... Diameter of camshaft jou rnals: 1.8890 to 1.8900 47.980 to 48.005 1.8968 to 1.8976 1.9047 to 1.9057 1.9126 to 1.9136 48.180 to 48.205 48.380 to 48.405 48.580 to 48.605 1.1795 1.8878 1.8957 1.9035 1.9114 29.944 to 29.960 47.935 to 47.950 48.135 to 48.150 48.335 to 48.350 48.535 to 48.550 —drive end...................................... —intermediate, drive side........................... —middle ....................................... — intermediate, flywheel side ........................ —flywheel end ................................... 1.1787 to 1.8872 to 1.8951 to 1.9030 to 1.9108 to Fit between bores in head and camshaft journals: —fit clearance ................................... 0.0012 to 0.0028 Cam lift: —+ l nlet ................................. 0.362 — Exhaust .............................. Valve clearance: . .. Inlet opens ................................... . — Inlet closes ................................... ... ..... ..... ..... ..... ..... — Exhaust opens ..... — Exhaust closes ................................. 0.030 to 0.070 9.2 9.25 0.364 12° 52° 52° 12° B.T.D.C. A.B.D.C. B.B.D.C. A.T.D.C. Page 10-6 VALVE MECHANISM — TAPPETS Standard tappet bore diameter ...................... 1.417 to 1.418 37.000 to 37.025 Standard tappet O.D. ............................. 1.456 to 1.457 36.975 to 36.995 Tappet fit clearance............................... 0.0001 to 0.0019 0.005 to 0.050 Shim thickness .................................. 0.146 to 0.185 in 0.002 steps 3.70 to 4.70 in 0.05 steps .024 .027 .011 to .014 .015 to .018 0.60 0.65 0.28 to 0.35 0.38 to 0.46 IN. MM Diameter of bushing bores in crankcase: ~drive end ...................................... «- Inside end ..................................... 1.5236 to 1.5248 1.3794 to 1.3805 38.700 to 38.730 35.036 to 35.066 Inside diameter of bushings finished in bores: —drive end ...................................... — inside and ..................................... 1.4041 to 1.4049 1.2598 to 1.2606 35.664 to 35.684 32.000 to 32.020 Diameter of shaft journals: —drive end ...................................... -— Inside end ..................................... 1.4013 to 1.4023 1.2575 to 1.2583 35.593 to 35.618 31.940 to 31.960 Valve clearance —for checking valve timing —for general operation adjusted cold Inlet ...................... Exhaust .................... Inlet ...................... Exhaust .................... AUXILIARY SHAFT DESCRIPTION Fit between bushings and bores in crankcase............ Fit between bushings and shaft journals: — fit clearance interference fit at all times 0.0017 to 0.0036 0.0016 to 0.0031 0.044 to 0.091 0.040 to 0.080 "‘* 10 Engine Page 10-7 FUEL SYSTEM (VEHICLES WITH CARBURETOR) Carburetor Type ....................................................... 2-barrel downdraft with vacuum controlled secondary, mechanical and vacuum accelerator pumps. and an automatic choke Float level .................................................. 0.266 to 0.285 in. (6.75 to 7.25 mm) Fuel Pump Type ....................................................... Mechanical Capacity equal to or greater than ........................... 19.8 gal./hr. (75 L/hr.) Control lever stroke ........................................ 10.098 in. (2.5 mm) Fuel pressure at 4000 RPM ................................ 3.5 to 4.3 'psi FUEL SYSTEM (VEHICLES WITH FUEL INJECTION) Fuel Injection System Type ....................................................... Bosch L—Jetronic with Lambda sensor System test pressure ...................................... 33 to 39 psi (2.3 to 2.7 bar} Fuel Pump Type ....................................................... Electric Fuel pressure .............................................. 39 to 45 psi (2.7 to 3.2 bar) .21. Page 10-8 .- LUBRICATION ' / Oil Pump Type ......................................... gear Pump Drive .................................... by auxiliary shaft Oil pressure relief valve ........................... built into oil pump Clearance between gears upper side and cover mating face ......................... 0.0008 to 0.0041 in. (0.020 to 0.105 mm) Clearance between gears and pump housing inside wall. . . 0.004 to 0.007 in. (0.11 to 0.18 mm) Play between drive and driven gears ................. 0.0059 in. (0.15mm) Full flow oil filter with by-pass ..................... disposable cartridge type Low oil pressure indicator sending unit ............... electric Oil pressure at 212°F (100° C) ...................... 49.7 to 71 psi (3.5 to 5 kg/cmzl ! ‘ COOLING SYSTEM -- Water Pump Type .......................................... ' Pump Drive ..................................... centrifugal, vane type ' Vee belt Fit between impeller vanes and pump housing .......... 0.031 to 0.051 in. (0.8 to 1.3mmi Radiator cooling fan drive. . . . , ..................... electric motor Cooling fan control ............................... cut-in temperature............................. cutout ...................................... radiator mounted temperature switch 92 i 2° C (198° F) 87 : 2°C (189° F) Thermostat —begins opening at ............................... «maximum opening at ............................ —travel of valve .................................. 172.4° to 1832" F (78° to 84° C) ' 194° to 201° F (90° to 94°C) 0.295 in (7.5mm) Water temperature indicator ........................ electric (gauge) Radiator cap valve opening pressure .................. 11 psi (0.8 kg/cml) Radiator overflow recovery ......................... plastic expansion tank | . ( 10 Engine Page 1 0-9 TORQUE SPECIFICATIONS TORQUE FIGURE Kgm F1. Lb. DESCRIPTION THREAD N-rn Bolt, main bearingcap............ ................. M 10 x 1.25 80 8.2 59 24.4 2.5 18 ENGINE Bolt, engine breather ...... ,_ .......... ." Bolt, cylinder head to crankcase ”5:55 .' ........... .-. M 8 '“1. _-)-‘ See torque procedure on pg. 10-48 See torque procedure on pg. 10-51 — 19 mm hex ................. ‘. L'; . q. . . . . .\ ..... — 17 mm hex ................ .' . . . _.'............ M 12 x125 M 10 x 1.25 ”Nut, cylinder head to crankcase stud ............... M 12 x 1.25 93 9.5 Bolt, cylinder head extension‘to cylinder head ...... M8 20 2 Nut. intake and exhaust manifold to cylinder head M 8 27 2.8 20 Nut. connecting rod bolt ............................ M 9.x 1 51 5.2 38 Bolt, self-locking, flywheel to crankshaft. . . .. ...... M 10 x 1.25 83 8.5 61 Bolt, camshaft sprocket ............................ M 1-0 x 1.25 83 8.5 61 Nut. bearing to belt tensioner support .............. M 10 x 1.25 44 4.5 ., 33 Bolt. oil pump shaft drive gear ...................... I M 10 x125 83 8.5 61 Nut, drive pulley on crankshaft ..................... T; M 20 x 1.5 137 14 101 Bolt, alternator lower support to crankcase ......... M 10 x 1.25 49 5 36 . Nut, alternator to lower support .................... M 10 x 1 .25 49 5 35 Nut self- locking nylon lined alternator to upper support ................................. M 10 x 1.25 49 5 36 Bolt. air pump to support ........................... M 9 29 3 22 Bolt. air pump support to cylinder head extension .. M 8 29 3 22 Bolt, water pump to crankcase ..................... M 8 29 3 22 69 . "4 14 1 2 t i J. ' l Page 10—10 DESCRIPTION Bolt, A/C compressor support to crankcase THREAD N-m TORQUE FIGURE Kgm Ft. Lb. ........ M 10 x 1 .25 49 5 36 fiQlt-oht bracket to A/ C compressor .............. M 10 x 1 .25 49 5 36 x —‘,8olt, rear bracket to A/C compressor ............... M 10 x 1.25 49 5 Spark plugs ........................................ M 14 x 1.25 37 3.8 27 Bolt, crosspiece to body .................... ........ M 10 x 1.25 59 6 43 Bolt, rubber mount to engine ............... ........ M 8 14.5 1.5 11 . Bolt. rubber mount to transmission .......... ...... M8 24.4 2.5 18 N ut. rubber mount to transmission ............... .. M8 24.4 2.5 18 Bolt. rubber mount to crosspiece .......... ......... M 8 24.4 2.5 18 Bolt, engine reaction rod ................... . ....... M 8 24.4 2.5 18 ENGINE MOUNTS ,....i. "“"‘"--.... u | 36 Engine Assembly REMOVAL AND INSTALLATION (Vehicles with Carburetor) NOTE: Engine and transmission are removed as an assembly through bottom of engine compartment. Loosen fuel cap. Remove cap from expansion tank. Drain cooling system. Loosen clamp holding fresh air duct (3) to fan. Disconnect hoses from side of air cleaner (1). Remove three nuts (2) and washers holding cover on air cleaner. Remove four nuts holding air cleaner on carburetor. Lift air cleaner. disconnect hose from bottom and remove air cleaner with fresh air duct. 1. Air cleaner 2. Nuts 3. Fresh air duct NOTE: Mark lines, hoses and wires prior to removal to identify for installation. Disconnect battery ground cable. Disconnect fuel return hose (6) and charcoal canister hose (5) from carburetor. On vehicles with air conditioning, disconnect hose from last idle valve (2) and unplug compressor clutch wire connector. Disconnect wires (1) from idle shutoff solenoid and carburetor fan thermoswitch. Disconnect gulp valve and charcoal canister hoses (3 and 4) from intake manifold. 1. Wires 2. Fast idle valve 3. Hose 4. Hose 5. Hose 6. Fuel hose Remove clamp (1) holding fuel hoses to firewall and separate from firewall. Disconnect fuel inlet hose (2) from fuel pump. Remove distributor cap [3) and rotor. Disconnect distributor wire connector at distributor. Disconnect wires from gulp valve thermoswitch (6), coolant temperature sending unit (4), and oil pressure sending unit (5). Discona throttle cable by removing Spring clip (7) at end of cable and "E" ring at base of bracket (8). 1. Clamp 2. Fuel inlet hose 3. Distributor cap 4. Coolant temperature sending unit 5. Oil pressme sending unit 5. Gulp valve tharrnoswitch 7. Spring clip 8. Bracket 100.00 Page 1041 Loosen clamps and remove coolant hoses (8 and 10) from housing (11). Disconnect coolant hose (1) at union. Disconnect two expansion tank hoses (6 and 7) at housing. Remove bolt (5) and two nuts holding expansion tank (4) and remove tank. Unplug reverse light switch wire (9) at connector. Disconnect vacuum hose (2) from electrovalve (3). On air conditioned vehicles, disconnect fast idle electmvalve vacuum hose from vacuum tree. 1. Coolant hose 5. Bolt 6. Hose 2. Vacuum hose 7. Hose 3. Electrovalve 8. Coolant hose 4. Expansion tank 9. Wire 10. Coolant hose 11. Housing Hold spring (2) compressed and remove cotter pin, spring. and remaining washer from end of operating cylinder rod (3). Remove two bolts (5) holding cylinder (4) to support plate. Move cylinder out of way. Disconnect speedometer drive (1) from transmission. Disconnect wires from starter. 1.5peedometerdrive 2. Spring 3. Cylinderrod 4.0peratingcylmder 5. Bolts Remove rear access panel from inside trunk. Remove two nuts (1) and clamp (5) attaching exhaust pipe (6) to manifold (7). Remove shield (4) from end of alternator (3). Remove nut and cable (2) from alternator and unplug charge indicator wire connector. 1.Nuts 2.Cable 7. Manifold 3.Alternator 4.Shield 5.Clarnp 6.Exhaustpipe Engine Assembly 100.00 Page 10-13 0n vehicles with air conditioning, discharge system by slowly bleeding freon to prevent excessive loss of system oil. WARNING: Wear safety glasses. Do not discharge freon near open flame. a toxic gas may result. Disconnect high and low pressure lines (2 and 3) from compressor (1). Cap open hoses and fittings. 1. Compressor 2. Line 3. Line Raise and support rear of vehicle. Remove rear wheels. Remove six screws and four bolts retaining rear grille assembly and remove rear grille assembly. Disconnect six springs (1 and 3) supporting muffler (2) and lower complete exhaust system from vehicle. 1. Springs 2. Muffler 3. Springs Disconnect ground strap (1) from chassis. Remove six Allen head bolts (3) from transmission end of left side half-shaft (4]. Repeat above procedure to disconnect right side half-shaft from transmission. NOTE: Discard Allen bolts and replace with new ones for installation. Torque to 31 ft. lbs. (4.3 kgm). 1. Ground strap 2. Inner CV joint 3. Allen bolts 4. Half-shaft Page 10-14 Remove three protective shields (6 and 15). Remove two bolts (9) holding transmission link (7) to selector rod (10). Loosen bolt (5) at transmission end of transmission link. Swing link out of way. Remove two brake cable support brackets (14) from iron! control arm brackets (12). Remove four control arm nuts (1, 2 and 13) and bolts (8), noting number and position of shims between control arms (3 and 16) and mounting brackets. Swing control arms downward and out of their brackets. NOTE: SuSpension assemblies may be removed completely by removing brake calipers and nuts securing strut assemblies at top. Attach a lift sling A.60592 to engine/transmission lifting eyes and lift slightly. Remove four bolts (11) holding crosspiece (4). 1,Nut 2_Nut 15. Shield 3.Controlarm 16. Control arm 4.Crosspiece 5.Bolt 6.8hield 7.Link 830" 9. Bolts 10.Rod ll.Bolt 12.Bracket 13.Nut 14.Brackot Engine Assembly Remove through bolt (2) holding reaction rod (1) to bracket (3) on engine. 1. Reaction rod 2. Bolt 3. Bracket Remove coolant hose (1) from water pump. Remove through bolt (3) holding front engine mount (2). Raise vehicle slightly and rock engine/transmission assembly to clear front engine mount. Carefully raise vehicle while supporting engine/transmission assembly. Slide assembly out from under vehicle. Install engine in reverse order of removal. Tighten all nuts and bolts to specifications. Refill cooling system to proper level and check all lines and hoses for tightness. 1. Coolant hose 2. Engine mount 3. Bolt 100.00 Page 10-15 Page 10-16 REMOVAL AND INSTALLATION [Vehicles With Fuel Injection) NOTE: Engine and transmission are removed as an assembly through bottom of engine compartment. Disconnect battery ground cable. Loosen fuel cap. Remove cap from expansion tank. Drain cooling system. Loosen clamps (1 and 3) and remove air supply hose (2) after disconnecting attached vacuum hoses. Plug Openings to prevent dirt from entering. CAUTION: Relieve fuel system pressure before discon— necting fuel lines. To do this, remove vacuum hose (5) from fuel pressure regulator (4). Connect vacuum pump to regulator and pump vacuum up to 20 inches. 1. Clamp 2. Air supply hose 5. Vacuum hose 3. Clamp 4. Fuel pressure regulator NOTE: Mark lines. hoses and wires prior to removal to identify for installation. Disconnect the following electrical connectors: cold start valve (10), ground points (14), throttle switch (7), fuel injectors (8), voltmeter (4), fuel injector fan thermoswitch (6) and, on vehicles with air conditioning, compressor clutch (5). [5}. Also inlet and, (13) disconnect charcoal canister vacuum hose (11), fuel hose (9). alternator cooling duct (1), fuel return hose (2) on vehicles with air conditioning, fast idle electrovalve vacuum hose (12) and vacuum source hose (3). 1. Cooling duct 2. Fuel hose 3. Vacuum hose 4, Voltmeter connector 5. Compressor clutch connector 6. Thermoswitch 7. Throttle switch 8. Fuel injector 9. Fuel inlet hose 12. Vacuum hose 10. Cold start valve 11. Vacuum hose 13. Fast idle electrovalve 14. Ground points Disconnect throttle cable by removing Spring clip (1) at end of cable and “E" ring at base of bracket (2). Disconnect connectors from oil pressure sending unit (3), coolant temperature sending unit (7) and thermotime switch (6). Flemove distributor cap (5) and rotor. Disconnect distributor wire {4i at distributor. Disconnect wires from starter. 1. Clip 2. Bracket 3. Oil pressure sending unit 4. Distributor wire 5. Distributor cap 5. Thermotime switch 7. Coolant temperature sending unit .v .mmo n .L "‘4 Engine Assembly Disconnect two expansion tank hoses (1 and 3) at housing (8). Remove bolt (2) and two nuts holding expansion tank (9) and remove tank. Loosen air cleaner hose clamp (6) at air flow sensor (7). Remove two nuts holding air cleaner to body and remove air cleaner (4) with hose (5). 1. Hose 2. Bolt 7. Air flow sensor 3. Hose 4. Air cleaner 8. Housing 6. Clamp 5. Hose 9. Expansion tank Unplug reverse light switch wire connector (6). Disconnect coolant temperature sensor connector (8) and auxiliary air regulator connector (9). Hold spring (1) compressed and remove cotter pin, spring, and remaining washer from end of operating cylinder rod (3). Remove two bolts (7) holding cylinder (5) to support plate (4). Move cylinder out of way. Disconnect speedometer drive (2) from transmission. 1. Spring 2. Speedometer drive 3. Cylinder rod 5. Cylinder 6. Connector 7. Bolts 4. Support plate 3. Coolant temperature sensor connector 9. Auxiliary air regulator connector From inside trunk. remove floor mat. Remove three screws retaining insulation panel and remove insulation panel. Remove feur screws holding floor panel (2). Remove floor panel. Remove 10 screws holding access panel (1). Loosen clamp (4) on cooling duct (3). and remove access panel complete with duct 1. Access panel 2. Floor panel 3. Cooling duct 4. Clamp 100.00 Page 10-18 Unplug Lambda sensor connector (6) and remove Lambda sensor (4) from exhaust pipe. Remove three nuts (5) attaching exhaust pipe to manifold (7). Remove shield (1) from end of alternator. Remove nut and cable from alternator. On vehicles with air conditioning, discharge system by slowly bleeding freon to prevent excessive loss of system oil. WARNING: Wear safety glasses. Do not discharge freon near open flame. a toxic gas may result. Disconnect high and low pressure lines (3) from compressor (2). Cap open lines and fittings. 1. Shield 2. Compressor 3. Line B. Connector 7. Manilold 4. Lambda sensor 5. Nuts Raise and support rear of vehicle. Remove rear wheels. Remove six screws and four bolts retaining rear grille assembly and remove grille assembly. Remove two bolts (2) holding exhaust system support (3) to transmission bracket. Disconnect six springs (1 and 4) supporting muffler (5) and lower complete exhaust system from vehicle. 1. Springs 2. Bolts 3. Support 4. Springs 5. Muffler Disconnect ground strap (1) from chassis. Remove six Allen head bolts (3) from transmission end of left side half-shaft (4). Repeat above procedure to disconnect right side half-shaft from transmission. NOTE: Discard Allen bolts and replace with new ones for installation. Torque to 31 ft. lbs. (4.3 kgm). 1. Ground strap 2. Inner CV joint 3. Allen bolts 4. Hallvshaft 100.00 Engine Assembly Page 10-19 Remove two bolts holding protective shield under fuel pump and remove shield. Remove three remaining protective shields (7). Remove two bolts (8] holding transmission link to selector rod (9). Loosen bolt (5) at transmission end oi transmission link. Swing link out of way. Remove two brake cable support brackets (13) from from control arm brackets (11). Remove four control arm nuts (1. 2 and 12) and boltsi6). noting number and position of shims between control arms (3 and 14} and mounting brackets. Swing control arms downward out of their brackets. NOTE: Suspension assemblies may be removed completely by removing brake calipers and nuts seCuring strut assemblies at top. Support engine/transmission assembly. Remove four bolts (1 O} holding crosspiece (4). 1. Nut 2. Nut 13. Bracket 3. Control arm 14. Control arm 4. Crosspiece 5. Bolt 6, Bolt 7. Shield 8. Bolts 9. Selector rod 10. Bolts 11. Bracket 12. Nut Page 10-20 Remove through bolts ll and 3) retaining reaction rod to brackets and remove reaction rod (2). 1. Bolt 2. Reaction rod 3. Bolt Remove coolant hose (2) from water pump. Remove through bolt {3) holding front engine mount (1). Raise vehicle slightly and rock engine/transmission assembly to clear front engine mount. Carefully raise vehicle while supporting engine/transmission Slide assembly out from under vehicle. Install engine in reverse order of removal. Tighten all nuts and bolts to specifications. Refill cooling system to proper level and check all lines and hoses for tightness. 1. Mount 2. Hose 3. Bolt Engine Assembly 100.00 Page 1 0-21 DISASSEMBLY Place engine in a suitable engine stand. Remove oil dipstick. Drain oil and remove oil filter. Disconnect vacuum line from distributor. Remove not (7). lockwasher (6), and clamp (2) holding dis— tributor to engine. and remove distributor (1 ). Remove bolt (5) and washer from cyclonic trap (3). Remove cyclonic trap and gasket (4) with hose attached. 1. Distributor 6. Lockwasher 2. Clamp 3, Cyclonic trap 4, Gasket 5. Bolt 7. Nut Remove three bolts (3), lockwashers (2). and washers (1) holding starter to transmission. Remove starter (4) from transmission. 1. Washers 2. Lockwashors 3. Bolts 4. Starter On vehicles with fuel injection, use a 5 mm hex wrench to remove two bolts (3) holding auxiliary air regulator (7) to cylinder block. Remove regulator with hoses (‘l and 6) attached. 1. Hose 2. Clamp 3. Allen bolt 7. Auxiliary air regulator 4. Clip 5. Clamp 6. Hose Remove two bolts (5) and remove shield (6) from transmission. Remove the following: bolt (10), three bolts (3), lockwashers (2). washers (1). nut (8), and washer (7) and separate transmission and shield (9) from engine. Slowly (a few turns each bolt) remove six bolts to remove clutch assembly from flywheel. 1. Washer 2. Lockwesher 3. Bolt 4. Transmission 5. Bolt 6. Shield 7. Lockwasher 8. Nut 9. Shield 10. Bolt On air conditioned vehicles, remove two nuts (8), washers (7), bolts (2). and washers (3). Remove belt (12) and compressor (1) complete with brackets (11). Remove bolts (4 and 10) and lockwashers (5 and 9) to remove mount (6). 1. Compressor 6. Mount 12. Belt 2. Bolt 3. Washer 4. Bolt 5. Lockwasher ?. Washer 8. Nut 9. Lockwasher 10. Bolt 1 1. Brackets On vehicles with integral voltage regulator, remove bolt (7), nuts, washers, lockwashers. and bolt (6) holding alternator to engine. Remove alternator (3). 0n vehicles with separate voltage regulator, remove bolts. washers. lockwashers holding alternator to engine. Remove alternator (8). Remove drive belt. Remove bolts (5 and 17) to remove mounting brackets (4, 11, and 14). 1. Bolt 2. Bracket 3. Alternator (with integral voltage regulator) 4. Bracket 5. Bolt 6. Bob 7. Bolt 8. Alternator (with separate voltage regulator) 9. Spacer 10. Spacer 11. Bracket 12. Bolt 13. Bolt 14. Bracket 15. Bolt 16. Bolt 17. Bolt Engine Assembly lf equipped with air pump. loosen clamp (12) to disconnect hose (1) from check valve (16). Remove bolt (6), washer (5), and bolt (13) to remove air pump (2) with hoses (1 and 14) attached. Remove drive belt. Remove bolts (3 and 8) and washers (4 and 9)-to remove mounting bracket (10). If not equipped with air pump. disconnect hose (1 1 ) from reed valve (17). Remove locknut (15) holding check valve (16) or reed valve (17). Unscrew and remove valve. 1. Hose 2. Air pump 7. Bracket 12. Clamp 13. Bolt (with air pump) 3. Bolt 9. Washer 8. Bolt 14. Hose 4. Washer 6. Bolt 5. Washer 11. Hose 10. Mounting bracket 15. Locknut 16.‘Check valve 17. Reed valve (without air pump) If equipped with EGR, remove three nuts (1), bolt (7), and washers (2 and 8) to remove tube (3). spacer (27) and gasket (26). Remove two nuts (5), washers (6), and shieldM). Unscrew fining (25) to remove tube (9). Remove gasket (10) and seal (24). Disconnect vacuum line (23) from EGR valve (13). Remove bolts ( 11 and 20) and washers (12 and 19) to remove EGR valve (13) and gasket (18). Loosen clamp (21) to disconnect water hose (22) from water manifold. Remove two bolts (14) and washers (15) to remove mounting base (16) and gasket (17). 1. Nut 2. Washer 3. Tube 4. Shield 5. Nut 6. Washer 7. Bolt 8. Washer 9. Tube 10. Gasket 11. Bolt 12. Washer 13. EGR valve 14. Bolt 15. Washer 16. Mounting base 17. Gasket 18. Gasket 19. Washer 23. Vacuum line 20. Bolt 24. Seal 21. Clamp 25. Fitting 22. Hose 26. Gasket 27. Spacer Loosen clamp and remove hose (2). Remove two bolts and remove water manifold (3) and gasketl4). Remove four bolts and washers holding water pump (5) to engine. Remove water pump and gasket (6). Remove four bolts and washers holding thermostat assembly (1) to engine. Remove thermostat assembly and gasket. 1. Thermostat assembly 2. Hose 5. Water pump 6. Gasket 3. Water manifold 4. Gasket 100.00 Page 10-23 Page 1c24 Remove four bolts (17), iockwashers (16) and washers (15) to remove timing belt covers (12 and 13) (14 and 18 for air pump equipped vehicles). Remove attaching hardware (1 to 3, 5 to 7, and 9 to 11) to remove shields (4 and 8). 1. Nut 2. Lockwasher 3. Washer 4. Shield 5. Bolt 6. Washer 7. Bolt 8. Shield 9.Washer 10. Lockwasher 11. Nut 12 and 13. Timing belt covers 14 and 18. Timing belt covers (with air pump) 15. Washer 16. Lockwesher 17. Bolt Stop engine rotation by installing tool A.60640 on flywheel. Remove two bolts (9) holding timing indicator (10) and remove indicator. Remove camshaft sprocket bolt (11) and auxiliary shaft sprocket bolt (12). Remove drive pulley nut (13) using wrench A.50121. Remove out (1), washers and spacer (2). Press bracket (3) against tensioner in right engine mount (4) then remove pulley (5) and timing belt (8). Remove tensioner support bracket (3) from stud (7), and remove stud. Remove three bolts (8) holding engine mount (4) and remove mount. Remove camshaft sprocket (14), auxiliary shaft sprocket (15), drive pulley (16) and belt drive sprocket (19). Remove nuts and bolts holding belt shields (17 8t 18) and remove shields. l4 1. 2. 3. 4. 5. Nut Spacer Tensioner support bracket Right engine mount Tansioner pulley 6. 7. 8. 9. 10. Timing belt Stud Bolt Bolt Timing indicator 11. 12. 13. 14. 15. Bolt Bolt Nut Camshaft sprocket Auxiliary shaft sprocket 16. 17. 18. 19. Drive pulley Belt shield Belt shield Belt drive sprocket 100.00 Engine Assembly Page 10-25 On vehicles with carburetor, remove clamp (2) and fuel pump line (3) at carburetor (1). Leave filter (4) and fuel lines attached to pump (5). Remove two nuts (12) and washers (11) from studs (10) holding pump to engine. Carefully remove pump from engine, being certain that actuating rod (7) is removed. When reassembling, make sure that gaskets (6 and 8) and insulator (9) are installed in order shown. NOTE: Gasket (8) comes in three different sizes which are used to adjust pump stroke (pressure). 1. Carburetor 6. Gasket 11. Washer 2. Clamp 3. Fuel hose 7. Actuating rod 8. Gasket 4. Fuel filter 9. Insulator 5, Fuel pump 10. Stud 12. Nut Disconnect water line (1) from thermovalve housing (2) to carburetor (3) at carburetor by loosening clamp (4). Disconnect main vacuum line (5) by pulling free at vacuum manifold (6). Disconnect vacuum lines (7) to carburetor by pulling free at carburetor. NOTE: In order to minimize confusion during reinstallation of lines. do not remove thermovalves (8) or vacuum lines from thermovalve housing (2) unless they are to be replaced. Remove two nuts (9), lockwashers (10) and washers (11). Remove thermovalve housing (2) with attached lines and vacuum manifold (6). 1.Waterline 2. Thermovalve housing 10. Lockwasher 11.Washer 9. Nut 3. Carburetor 4. Clamp 5. Main vacuum line 6. Vacuum manifold 7. Vacuum lines B.Thermovalves On vehicles with carburetor. remove (our nuts (1) and lock washers (2) holding carburetor (3) and spacer (4) to intake manifold. Remove carburetor (3) and spacer (4). 1. Nut 2. Lockwasher 3. Carburetor 4. Spacer Remove three nuts [Hand washers (2) holding shield (3) to exhaust manifold (4). Remove shield. Remove seven nuts (6) and vvashers (71 holding intake (5) and exhaust (4) manifolds to engine. Remove manifolds and gaskets (B and 9). «levees-sum,— N U! _ Washer Shield Exha usl ma nifold Intake manifold N U! . Washer Gasket . Gasket Using cylinder head tool A.50131, remove five nuts on carburetor side and five bolts on spark plug side. Carefully remove cylinder head assembly. Lay on wooden blocks to protect Open intake and exhaust valves from being bent. Remove and discard cylinder head gasket. To disassemble cylinder head, refer to 101.01. Engine Assembly 0n vehicles with fuel injection, disconnect accelerator cable from linkage. Remove two nuts (8) and washers holding cooling air duct (6) to studs (4) on manifold (5). Disconnect cooling air hose from duct. Remove duct. Remove four nuts (2) and washers holding air intake to manifold. Carefully lift air intake (1) off studs (4) in manifold. Tilt air intake backwards. 1. Air intake 2. Nut 3. Gasket 4. Stud 6. Cooling air duct 7. Nut 8. Nut 5. Manifold Remove four nuts (4) and washers (3) holding air intake manifolds (1 ) to engine. Remove intake manifolds. 1. Air intake manifolds 2. Stud 3. Washer 4. Nut Remove three nuts (1) and washers holding shield (3) to ex— haust manifold (4). Remove nuts (5) and washers holding exhaust manifold to engine. Remove exhaust manifold. Using tool A501 31 for 1 9 mm hex bolts and nuts or tool A.501 72 for 17 mm hex bolts. remove five nuts or bolts on intake side and five bolts on spark plug side. Carefully remove cylinder head assembly. Lay on wooden blocks to protect open intake and exhaust valves from being bent Remove and discard cylinder head gasket. To disassemble cylinder head, refer to section 101.01. 1. Nut 2. Washer 6. Washer 3. Shield 4. Exhaust manifold 5. Nut 100.00 Page 10-27 Page 10-28 Remove three bolts (4) and lockwashers holding auxiliary shaft lock plate (lland seal (2). Remove plate/seal and then remove shaft (3). 1. Auxiliary shaft lock plate 2. Seal 3. Auxiliary shaft 4. Bolt Remove six bolts (3) and washer plate (4) holding flywheel (2) to crankshaft, remove flywheel. 1. Tool A.60640 2. Flywheel 3. Bolt 4. Washer plate Turn engine upsidefclown and remove twenty bolts (1) and lockwashers l2) holding oil pan (3). Remove pan and gasket (4). 1. Bolt 2. Lockwasher 3. Oil pan 4. Gasket - ' _ _. "‘ Engine Assembly w 100.00 Page 10-29 Remove six bolts and lockwashers holding flywheel end cover plate (3). Remove plate and gasket. Remove five bolts and lockwashers holding timing gear end cover plate (51. Remove plate and gasket. Remove three bolts (2) and lockwashers holding oil pump assembly (4). Remove pump and gasket. Remove bolt (6) holding oil return pipe (1) and remove pipe. 1. Oil return pipe 2. Bolt 3. Flywheel end cover plate assembly 6. Timing gear and cover plate 6. Bolt 4. Oil pump Remove nuts (1) holding connecting rod end caps (2). Remove caps complete with hearing inserts. Remove four rod-piston assemblies from the top of cylinder block. NOTE: Turning crankshaft will make this operation easier. Remove bolts (3) holding main bearing caps (4). Remove caps along with lower bearing inserts. 1. Nut 2. Connecting rod end caps 3. Bolt 4. Main bearing caps Remove crankshaft and take out upper bearing inserts. Remove two thrust ring halves (1) from saddle bore at flyv wheel end. 1. Th rust ring halves Page 10-30 ASSEMBLY install cylinder block on workstand. After thorough lubrication with clean engine oil, out main bearing inserts into position and install crankshaft (2). NOTE: Before and during installation of crankshaft refer to Crankshaft and Flywheel for procedures and inspections. The two thrust ring halves (1) are positioned at the flywheel and saddle bore. Thrust rings may be installed before or after mounting crankshaft. ‘l. Thrust ring half 2. Crankshaft Install main bearing caps l1) and lubricated inserts. Make sure caps are installed at proper location. Cap without notch is at timing gear end of crankcase, then cap with one notch. etc. Torque cap bolts to 59 ft. lbs. (8.2 kgml. 1. Main bearing caps Install new seal and gasket on flywheel and cover plate (1). Install carer/seal to crankcase with six bolts (2) and lockwashers. NOTE: Arrows in illustration indicate that with cover installed, the distance between cover seal and crankshaft should be equal all around. 1. Flywheel end cover plate 2. Bolt 100.00 Engine Assembly wmseweppr Bolt and Iockwasher Water iacket cover plate Gasket Gasket Bolt and Iockwesher Cover plate Gasket . Bolt and lockwasher . Water jacket cover plate 1D. 11. 12. 13. 14. 15. 16. 17. Gasket Flywheel end cover plate Oil seal Bolt and Iockwasher Bolt and Iockwasher Oil drain plug Oil sump Gasket GASKETS AND SEALS Page 10-31 18. 19. . 21 . 22. 23. 24. . Gasket Auxiliary shaft Iockplate Bolt and Iockwesher Oil seal Gasket Timing gear end saver plate Oil seal Bolt and lockwasher Page 10-32 Secure flywheel to crankshaft with washer plate (1) and six bolts {2}. Lock crankshaft against turning with tool A.60640 (3). Torque bolts to 61 ft. lbs. (8.5 kgm). 1. Washer plate 2. Bolt 3. Tool A.60640 After lubricating pistons (11 and cylinder bores with clean engine oil, install connecting rod-piston assemblies in cylinder bores using appropriate piston ring compressor (2). NOTE: Before and during installation of connecting rod-piston assemblies, refer to CONNECTING RODS AND PISTONS for procedures and inspections. install assemblies in the proper cylinder, according to number stamped on connecting rods and caps. When installation is complete these numbers should face away from auxiliary shaft. 1. Piston 2. Piston ring compressor Lubricate bearings and crankpins with clean engine oil. Attach connecting rods/bearings to crankpins. Install end caps/bearings (1) and torque nuts (2) to 38 ft. lbs. {5.2 kgml. 1. Connecting rod end caps 2. Nut Engine Assembly 100.00 Page 10-33 Install new seal and gasket on timing gear and cover plate (1). Install coverr'seal to crankcase with five bolts (2) and lockwashers. NOTE: Arrows in illustration point to references for controlling centering with respect to crankshaft. 1. Timing gear and cover plate 2. Bolt Lubricate bushings for auxiliary shaft (3) with clean oil, install shaft. Secure shaft in place with three bolts (4), lockwashers, Iockplate (1), new seal (2) and gasket. install auxiliary shaft sprocket with bolt and washer. do not torque fully at this time. 1. Lockplate 2. Seal 3. Auxiliary shaft 4. Bolt Install oil pump (1) and gasket. Before final tightening of bolts I5), install oil pump and distributor drive gear, coupling it to gear on auxiliary shaft. Temporarily fit distributor (3) into crankcase. While using sprocket (2) to rotate auxiliary shaft, secure oil pump by tightening the three bolts alternately. NOTE: If auxiliary shaft binds or crawls during rotation, loosen pump and repeat operation. Install oil return pipe (4) with one bolt (6) and lockwasher. Install timing belt drive sprocket (7) and generator drive pulley (8). Install pulley nut (9), and with flywheel blocked, torque nut to 101 ft. lbs. (14 kgml. 1. Oil pump 2. Auxiliary shaft sprocket 3. Ignition distributor 4. Oil return pipe 5. Bolt 6. Bolt 7. Timing belt drive sprocket 8. Generator drive pulley 9. Pulley nut Page 10-34 Install oil sump and gasket with twenty bolts and lockwashers. Install cylinder head gasket, making sure that word “ALTO" is facing up. Install head assembly complete with valves, springs, and camshaft bearing assembly. NOTE: Before and during cylinder head installation refer to CHANKCASE AND CYLINDER HEAD Section for precedures and inspections. On vehicles with 19 mm hex nuts and bolts, install five bolts {1), and nuts (2), and flat washers. Gradually tighten in sequence shown and in at least two stages. Final torque will be 69 ft. lbs. [9.5 kgm). Special wrench A.50131 I3) is required for intake side nuts. 1. Bolt 2. Nut 3. Wrench A.50131 0n vehicles with 17 mm hex bolts, torque the bolts as follows: a Lubricate all head bolts and washers with SAE 30 engine oil. Let excess oil drop from bolts and washers for 30 minutes. NOTE: In the next steps tighten and torque cylinder head bolts in sequence as shown. - Using wrenches A.50172, torque all cylinder head bolts to 14.5 ft. lbs. l2 kgm). - Retorque all cylinder head bolts to 29 ft. lbs. (5 kgrn). ' 0 Apply paint marks to one corner of all the head bolts and a corresponding mark to the cylinder head. C Using wrenches A.50172, tighten all head bolts to a 90° angle {1). a Retighten all head bolts to a second 90° angle (2). PAINT MARKS CYLINDER HEAD NOTE: All cylinder head bolts must have been tightened a CYLINDER HEAD BOLT -\ total of 180° in two separate stages. . 900 2 90 O 100.00 Engine Assembly Page 10-35 Install belt guards (17 and 18). Install camshaft sprocket (14) with bolt (11) and washer. Do not torque fully at this time. install right engine mount (4) with three bolts (8) and Iockwashers. install spring tensioner in its seat in mount. Install tensioner pulley support stud (7) and bracket (3) to crankcase. . Install tensioner pulley (5) to bracket and lock it temporarily with nut (1), washers and spacer (2). Install timing indicator (10) with two bolts (9) and lockwashers. 1. Nut 2. Spacer 3. Tensioner support bracket 4. Right engine mount 5. Tensioner pulley 6. Timing belt 7. Stud 8. Bolt 9. Bolt 10. Timing indicator 11. Bolt 12. Bolt 13. Nut 14. Camshaft sprocket 15. Auxiliary shaft sprocket 16. Drive pulley 17. Belt shield 18, Belt shield 19. BE": drive sprocket Page 10-36 Crank engine with tool A.50459 until crankshaft pulley mark (3) is aligned with TDC timing mark (7). Position camshaft sprocket so that marks (1) and (2) are aligned. NOTE: Auxiliary shaft sprocket (8) does not have to be aligned. Move idler pulley in direction of arrow as far as possible and secure in place with not. Install timing belt (9) with slack on tensioner side. CAUTION: Always install a new timing belt. Timing belts cannot be reused. Under no circumstances must belt tension be adjusted following its initial installation. Ensure that timing belt teeth are perfectly coupled with sprockets. Loosen idler pulley not (4) and tensioner will tighten belt. Torque idler pulley nut in this position to 33 ft. lbs. (4.5 kgm). Check that timing marks are still correctly aligned. With flywheel blocked, torque auxiliary shaft sprocket bolt (5) and camshaft sprocket bolt (6) to 61' ft. lbs. (8.5 kgrn). .ommummt-a . Camshaft sprocket mark . Reference mark on timing belt guard . Crankshaft pulleyr mark . idler pulley nut . Auxiliary shaft sprocket bolt .Camshaft sprocket bolt .TDC timing mark . Auxiliary shaft sprocket . Timing belt . Pulley drive belt Engine Assembly On vehicles with carburetor, install intake manifold (1), exhaust manifold (2). and gaskets with seven nuts and washers. Torque to 20 ft. lbs. (2.8 kgm). Install shield (3) with three nuts and washers. 1. Intake manifold 2. Exhaust manifold 3. Shield 0n vehicles with carburetor. install carburetor (1) and spacer (2) with four nuts (3) and washers. 1. Carburetor 2. Spacer 3. Nut Install water pump (1) and gasket with four bolts (2) and lock— washers. Torque to 22 ft. lbs. (3 kgm). Install water manifold (3) and gasket with two bolts (4) and lockwashers. 1. Water pump 2. Bolt 3. Water manifold 4. Bolt 100.00 Page 10-37 0n vehicles with carburetor. install EGR mounting base (1), gasket and tube {5i with two bolts (2) and lockwashers. Install tube {6) and shield (11} to exhaust manifold fitting and to EGR mounting base with two nuts (9) and lockwashers. Install EGR valve (3) and gasket with two bolts (4) and lock— washers. 1, E68 mounting base 6.1'ubs 2. Bolt 3. EGR valve 7. Nut B.Tube 9. Nut 10. Spacer 4. Bolt 5. Tube 11. Shield Attach thermostat housing (1) and gasket to cylinder block with four bolts (21 and lockwashers. Attach water manifold hose (3) to thermostat housing. 1. Thermostat housing 2. Bolt 3. Water manifold hoes - On vehicles with carburetor, install fuel pump (5) with gaskets ! l6 and 8}, insulator l9), and actuating rod (7). _ Retain pump to studs (10) with two nuts (1 2) and washers (1 1 l. I NOTE: Gasket [8) comes in three difierem sizes which are used to adjust pump stroke (pressure). Secure fuel lines (3] and filter (4) to carburetor with clamps (2). . 1. Carburetor : 6. Gasket ' 11. Washer 2. Clamp 3. Fuel hose 4. Filter 5. Fuel pump 7. Actuating rod 3. Gasket 9. Insulator 10. Stud 12. Nut “my 100.00 Englne Assembly Page 10—39 0n vehicles with carburetor, install thermovalve housing assembly (1) with two nuts (2) and lockwashers. Attach vacuum and water lines as shOWn. 1. Thermovalve housing assembly 2. Nut To AUTOMATIC CHOKE FROM AUTOMATIC CHOKE T0 INTAKE MANIFOLD TO CARBUHETOR VACUUM SOURCE TO CARBURETOR ACCELERATOR PUMP TO ELECTRO VALVE T0 CARBUHETOR POWER VALVE T0 T0 WATER MANIFOLD ' 1: I EGR VALVE _ _ 33 "2 1" l -' .."_.—.c3:; TO INTAKE MANIFOLD VACUUM Install cyclonic trap (1) in engine with hose attached. Install \ ______rr_.. bolt (3) and lockwasher (2). __£______.fl / kgm) (2.3 Torque to 17 ft. lbs. L V ——-_-_--/ r 1.Cyclonictrep 2. Lockwesher 3. Bolt _ ____ _ / / \ \ I '____—-—-—---"'—'—_' / 0n vehicles with fuel injection. install intake manifolds (4) to cylinder head. Install air intake (1) and gaskets (3) to intake manifolds with nuts [2] and washers. Install cooling air duct (5). Attach auxiliary air regulator to engine with two Alien bolts and washers. Install regulator with hoses attached. Make sure that clip is installed under both clamps. 1. Air intake 2. Nut 5. Cooling air duct 3. Gasket 4. Intake manifolds Install distributor. make sure that cylinder No. 1 is on com— pression stroke {both valves closed). Turn crankshaft until notch on pulley it) is lined up with TDC indicator plate (2). 1. Pulley 2. TDC indicator plate Remove distributor cap and rotate shaft until rotor faces terminal on can corresponding to cylinder No)? #- Without moving the rotor from its original position. insert distributor {1) in crankcase. Secure distributor with not (3) and clamp (2). Final adjustment of timing will be accomplished with a timing light. Refer to 551.01. 1. Distributor 2. Clamp 3. Nut Engine Assembly 100.00 Page '10-41 /42 Install alternator support (1) to engine with 4 bolts (2) and torque to 36 ft. lbs. (5 kgm). 1. Alternator support 2. Bolt Install alternator bracket (4) to water pump housing with two bolts. Place alternator (6) on bracket and secure in place with two bolts (5). If equipped with air pump, inatall pump support (2) to cam housing with four bolts and torque bolts to 22 ft. lbs. (3 kgm). Attach air pump (1) to bracket (4) and support (2) and secure in place with two bolts (3 and 7). To adjust belts. refer to 101.15. 1.Air pump 2. Support 3. Bolt 4. Bracket 5. Bolt 6. Alternator 7. Bolt If equipped with air conditioning, attach compressor (1) and brackets (2) to support and alternator (4) with bolts, washers. and nuts (3). To adiust belt, referto 101.15. 1. Air conditioning compressor 2. Bracket 3. Nut 4. Alternator "'./ Crankcase and Cylinder Head 101.01 Page 10-43 CRANKCASE CHECKING CYLINDER BOHES Carefully examine cylinder bore surfaces. if only slight scoring or scratches are found, dress bores. Use extra fine emery cloth wrapped around a hone. Make sure piston clearance in bore does not exceed .006 in. (0.15 mm). NOTE: For a new assembly, the piston clearance in bore, measured at right angle to pin and 1.08 in. (27.5 mm) from piston skirt edge is .0011 to .0019 in. (.030 to .050 mm). Zero dial indicator (1) using gage A.96148 (2). Check cylinder bores at three points, both lengthwise and crosswise. if wear or out of round is such as to require reconditioning, the following should be adhered to. if metal to be removed is less than .006 in. (0.15 mm), honing will do. If it exceeds .006 in. (0.15 mm) the cylinder block should be rebored. Cylinders should not be rebored beyond .0236 in. (0.6 mm). 1. Dial indicator gauge 2. Standard bore gage A.96148 1a measurement 23 measurement ii 3a measurement Page 10—44 Bores should be reconditioned in relation to diameter of oversize pistons aVailable (.0079, .0157, .0236 in. — 0.2, 0.4, 0.6 mm) and to specified clearance of .0011 to .0019 in. [0.030 to 0.050 mm) between pistons and bores. As shown, letters are stamped on bottom face of cylinder block, opposite each bore, to indicate their diameter. This is done since the actual bore may vary from 3.4015 to 3.4035 in. {86.400 to 86.450 mm) and bores are selected in .0004 in. (0.01 mm} classes. Standard pistons are also selected in classes and must be matched with cylinder bores belonging in the same class (Refer to CONNECTING RODS AND PISTONS). Cylinder Block Gasket Surface The cylinder block gasket surface may become warped or distorted. Using a surface plate coated with lampblack, check for spots where metal must be removed to make surface perfectly level. The check may also be accomplished with a straightedge (1) and feeler gage (2). The straightedge should be placed in line with the diagonals of cylinder block surface, and lengthwise in the middle. When refacing cylinder block, care should be taken to remove as little metal as possible. 1. Straightedge 2. Feeler gage Auxiliary Shaft Bares and Bushings Check that bushings press fitted in crankcase bores are not out-of-round or loose and that oil holes are in exact alignment with crankcase oilways. Inner surface of bushings should be smooth and free from scuffing. Replace if damaged. Should it become necessary to replace bushings, remove old ones from bores using driver A.60372/1/‘2 (1) for drive end bushing l3) and A.60372/1 for inside bushing. 1. Driver A.II372I1 2. Tool A.6037212 3. Bushing, drive and Crankcase and Cylinder Head 101.01 Page 10-45 Bushings are press fitted to their own bores in crankcase. First // drive and bushing using driver A.60372/1/2. ,. install inside bushing (2) using driver A.60372/1 (1) and then When installing bushings, make sure to position them so that bushing oil hole is perfectly aligned with oil passage from crankcase. 1. Driver A.60372!1 2. Inside bushing Bushings should be finished reamed using tool A.90365 (1) to specified inside diameter after they have been press fitted in place. to ensure a correct fit and alignment of auxiliary shaft journals (refer to specifications on previous page). 1. Reamer A.90365 pin 2. Cutter 3. Bushing, drive end 4. Centering Distributor and Oil Pump Drive Gear Bushing Check that bushing {1) has not ovalized or become loose in bore. Inner surface should be smooth and show no traces of wear. Replace if necessary (refer to LUBRICATION). 1. Buahing ,II- Page 10-46 CYLINDER HEAD REMOVAL AND INSTALLATION (Vehicles With Carburetor) Disconnect battery ground cable. Drain cooling system. Disconnect hoses from side of air cleaner (1). Remove three nuts (2) and washers holding cover on air cleaner. Remove four nuts holding air cleaner on carburetor. Lift air cleaner. disconnect hose from bottom and remove air cleaner with fresh air duct (3). 1. Air cleaner 2. Nuts 3. Fresh air duct NOTE: Mark lines. hoses and wires prior to removal to identify for installation. From carburetor, disconnect fuel inlet and return hoses (4), charcoal canister hose (2) and all remaining vacuum and coolant hoses. Disconnect three electrical connectors (1) from carburetor. Disconnect throttle linkage (5) at carb'uretor. Remove four nuts (3) holding carburetor. Remove carburetor and spacer. ‘l. Connectors 2. Hose 3. Nut 4. Fuel hose 5. Throttle linkage Remove two nuts (1) and washers holding reaction rod bracket (6) to cylinder head. Remove through bolt holding reaction rod (2) to body bracket. Set reaction rod and bracket assembly to one side with vacuum tree and hoses attached. Remove two bolts (3) holding thermovalve housing assembly (5) and remove it without disconnecting lines from housing. Remove three bolts and disconnect thermostat housing (4) from head. Coolant hoses can remain attached to housing, 1. Nuts 2. Reaction rod 3. Bolt 4. Thermostat housrng 5. Thermovalve housing 6. Bracket Crankcase and Cylinder Head 101.01 Page 1 047 Disconnect spark plug wires {2). Disconnect wires from gulp valve thermoswitch (1) and coolant temperature sending unit (4). Disconnect throttle cable by removing spring clip (6) at end of cable and two bolts (7) holding bracket (8) to head. On vehicles with air pump, disconnect hose (5) from check valve (3). 1. Gulp valve thermoswitch 2. Spark plug wire 3. Check valve 4. Coolant temperature sending unit 5. Hose 6. Clip 7. Bolt 8. Bracket Removing timing belt cover (one-piece cover) or upper and lower timing belt cover halves (two-piece cover). Disconnect coolant hose (3) from water pump. 0n vehicles with air pump (1). remove two bolts (4) holding air pump and remove pump. Remove four bolts attaching air pump support (2) to cam hous— ing and remove support. On vehicles with air conditioning, remove bolts and nuts holding alternator and remove alternator. Alternator may be placed to one side without disconnecting electrical leads. If alternator bracket is a one-piece assembly attached to both head and block. remove attaching bolts and bracket. 1. Air pump 2. Support 3. Hose 4. Bolt Loosen tensioner pulley nut (1) and remove timing belt (2) from cam sprocket. Remove bolts (3) and nuts holding belt guard (4) and remove guard. 1. Tensioner pulley nut 2. Timing belt 3. Bolt 4. Belt guard Page 1 0-48 ' r Remove rear access panel from inside trunk. Remove two nuts (1) and clamp (3) attaching exhaust pipe (4) to manifold 12). Disconnect charcoal canister hose (7) from exhaust manifold. ~_. , Disconnect EGR valve lines (Bl at EGR valve (5). then dis~ connect lines at manifolds. Disconnect remaining hoses from intake manifold. 1. Nuts 6. Line 2. Manifold 7. Hose 3. Clamp 4. Exhaust pipe 5. EGR valve Remove cylinder head hold down bolts and nuts. Nuts on carburetor side will require special wrench A.50131. Remove head. Installation is reverse of removal. Refer to CAMSHAFT DRlVE (101.06) for timing of valve assembly. install all new gaskets. Head gasket is installed with word “ALTO" facing up. Tighten hold down bolts and nuts in order shown. Torque in at least two stages. Final torque is 69ft. lbs. (9.5 kgm). NOTE: If cylinder head has 17 mm hex hold down bolts, refer to torquing procedure on page 10-51. 1. Bolt 2. Nut 3. Wrench A.5013'l ---- Crankcase and Cylinder Head 101.01 Page 1 0-49 REMOVAL AND INSTALLATION (Vehicles with Fuel Injection) Disconnect battery ground cable. Drain cooling system. Loosen clamps (1 and 3) and remove air supply hose (2) after disconnecting attached vacuum hoses. Plug openings to prevent dirt from entering. CAUTION: Relieve fuel system before disconnecting fuel lines. To do this, remove vacuum hose (5) from fuel pressure regulator (4). Connect vacuum pump to regulator and pump vacuum up to 20 inches. 1. Clamp 2. Hose 3. Clamp 4. Fuel pressure regulator 5. Vacuum hose NOTE: Mark lines. hoses and wires prior to removal to identify for installation. Disconnect the following electrical connectors: cold start valve (3). ground points (6), throttle switch (7), fuel injectors (13), and fuel injector fan thermoswitch (12). Also start lator (10). with disconnect charcoal canister vacuum hose (1), cold valve fuel hose (4), fuel inlet hose (2), auxiliary air regu. hose (5). distributor vacuum hose (8). fuel return hose fuel pressure regulator vacuum hose (9) and, on vehicles air conditioning. vacuum source hose (11). 1. Vacuum hose 2. Fuel hose 3. Cold start valve 4. Fuel hose 5. Vacuum hose 6. Ground points 7. Throttle swrtch 8. Vacuum hose 9. Vacuum hose 10. Fuel return hose 11. Vacuum hose 12. Injector fan thermoSwitch 13. Fuel injectors Disconnect throttle linkage by removing spring clip from linkage cable and at bellcrank (6). Remove bolt (1) and washers holding fuel pressure regulator bracket (2) to air intake (3). Remove two nuts (4) and washers holding fuel injector cooling air duct (5) to manifold studs. Disconnect air hose from duct and remove duct. Remove four nuts and eight washers holding air intake to manifold. Carefully tilt air intake backwards off studs and remove from vehicle. 1. Bolt 2. Bracket 6. Bellorank 3. Air intake 4. Nuts 5. Cooling air duct Page 10-50 Remove two Allen bolts (2) and pull auxiliary air regulator [31 away from head. Hoses and electrical lead can remain attached to regulator. Disconnect throttle cable by removing Spring clip (1) at end of cable and two bolts (8) holding bracket (5) to head. Disconnect spark plug wires (4). Disconnect connectors from coolant temperature sending unit {6) and thermotime switch (7). 'r l 1. Spring clip 2. Allen bolt 3. Auxiliary air regulator 4. Spark plug wire 5. Bracket 6. Coolant temperature sending unit 7. Thermotime switch 8. Bolts .5'— ' Remove two nuts (4) and washers holding reaction rod bracket [5} to cylinder head. Remove through bolt (1) holding reaction rod (6] to body brac- ket. Remove reaction rod and bracket assembly. Remove three bolts (2} and disconnect thermostat housing [3} from head. Coolant hoses and electrical lead can remain attached. 1. Bolt 2. Bolt 6. Reaction rod 3. Thermostat housing 4. Nuts 5. Bracket From inside trunk, remove floor mat, insulation panel, floor panel and access panel. Remove three nuts (3] attaching exhaust pipe (2) to manifold(4). On vehicles with air conditioning, remove bolts and nuts holding afirnator (1) and remove alternator. Alternator may be placed to one side without disconnecting electrical leads. if alternator bracket is a one-piece assembly attached to both head and block, remove attaching bolts and bracket. 1.Alternator 2. Exhaust pipe 3. Nuts 4. Manifold 101.01 Crankcase and Cylinder Head Page 10~51 Remove upper and lower timing belt cover halves. Loosen tensioner pulley nut (1) and remove timing belt (2) from cam sprocket. Remove bolts (3) and nuts holding belt guard (4) and remove guard. 1. Tensioner pulley nut 2. Timing belt 3. Bolt 4. Belt guard 4‘). 1 & Remove cylinder head hold down bolts and nuts. Nuts on intake side will require special wrench A.50‘l31. Remove head. NOTE: Engines built after number 4028877 (without air conditioning) or 4037356 (with air conditioning) are equipped with 17 mm hex bolts. Use special wrench A.50172. Installation is reverse of removal. Refer to CAMSHAFT DRIVE (101.06) for timing of valve assembly. Install all new gaskets. Head gasket is installed with word “A LTO” facing up. 0n vehicles" kgrn). 0n ve __ 3‘“ ’- ' .‘ mm bolts and riots; tighten bolts in order shown. Torque in at least two stages. Final torque is 69 ft..|bs. (9.5 . 2.4;- '3. ‘ . '- " s with 17 mm bolts, lubricate all bolts and washers with SAE 30 engine oil. Let excess oil drip from bolts and washers for 30 minutes. "\ NOTE: In the next steps, tighten and torque cylinder head bolts in sequence shown. ‘1, ‘ Using wrenches A.50172 torque all cylinder head bolts to 14.5 ft. lbs. (2 kgm). Retorque all bolts to 29 ft. lbs. (4 kgm). Apply paint marks to one corner of all head bolts and a corresponding mark to the cylinder head. Using wrenches A.50172, tighten all head bolts to a 90° angle (1). Retighten all head bolts to a second 90° angle (2). NOTE: All cylinder head bolts must have been tightened a total of 180° in two stages. PAINT MARKS 90° CYLINDER HEAD CYLINDER HEAD BOLT Page 10-52 DISASSEMBLY AND REASSEMB LY Remove camshaft housing cover (1) by removing six nuts (2). Remove intake and exhaust manifolds. Remove camshaft housing (5) from cylinder head by removing six bolts (3) and six nuts (4). 1. Camshaft housing cover housing 2. Nut 3. Bolt 4. Nut 5. Camshaft Position valve spring compressor (1) A.603l1 as shown and compress spring {2) to release spring locks (4) (if spring locks are stuck in grooves carefully tap spring cup (3), taking care not to damage valve stem}. Remove springs and cups. Remove spark plugs. Remove oil seals and take out valves from bottom side of head. 1. Valve spring compressor A.60311 4. Spring locks 2. Valve spring 3. Spring cup To reassemble head reverse above procedure. Before installing valve springs, install valve seals (2) on valve guides (4) with pilot A.60313 (1). Place oil seal on pilot, and mount pilot on valve stem. Press seal down onto upper end of valve guide with installer A.603‘l3/2. 1. Pilot A.6031 311 2. Oil seal 3. Valve stem 4. Valve guide Crankcase and Cylinder Head Cleaning Cylinder Head Clean carbon from combustion chambers using wire brush driven by a portable electric drill. Flemove carbon deposits from exhaust ducts and descale water jackets. Inspect and clean intake ducts and oilways to camshaft lobes and tappets. Inspecting and Refacing Gasket Surface Apply a thin coating of Iarnpblack on a surface plate and run cylinder head mating face over it. The resulting contact pattern should be evenly spread over the whole cylinder head gasket surface. If it is not. there is distortion and the head will have to be refaced on a surface grinder as shown. Be sure to remove only enough stock to Correct the faulty condition. After refacing, combustion chamber depth must be checked with gage A.96238 (1) to make certain it has not been reduced beyond allowable limits. With gage resting at center of combustion chamber, the gap between gage and gasket surface should not exceed .010 in. (0.25 mm). If gap exceeds .010 in. (0.25 mm), replace head. 1. Depth gage A.96238 2. Feeler gage 101.01 Page 10-54 Inspecting and Refacing Valve Seats Valve seats must show no evidence of pitting on contact face. If pitted, they must be refaced. Using appropriate valve guide pilot that provides the tightest fit in guide, fix taper stone assembly (1) to guide. Make sure taper stone has angle of 45° i 5' and is new or recently dressed. Start grinder before stone contacts seat, otherwise seat may be damaged. Ul- 1. Taper stone assembly VALVE AND VALVE SEAT ANGLES Once valve seats have been refaced, seat width should be narrowed. Install reamer assembly (1) on valve guide pilot and carefully ream seat. Use a 20° reamer (2} and a 75° reamer (3) alternately until the width of intake and exhaust seats is dimension L = .083 to .087 in. {2.1 to 2.2 mm). 1. Reamer assembly 2. 20° reamer 3. 75° reamer 101.01 Crankcase and Cylinder Head Page 10-55 VALVES INSPECTING AND REFACING VALVES Clean carbon from valves with power wire brush. Inspect valve stem for distortion and signs of cracking, replace valve if necessary. of valve head margin Serviceable valve may be refaced at angle of 45° 30' i 5'. At completion of refacing, check that thickness (3) is at least .020 in. (0.5 mm). stem height after refacing, Should it become necessary to grind valve stem tip to eliminate dishing due to wear or to reduce remove only what is necessary. edge. If there is any With each valve reinstalled in its seat, use gage A.96219 (1) to check that stem (2) tip just grazes the gage tip. grinding by height stern reduce gage, and stem between interference 1. Gage A.96219 2. Valve stem 3. Valve head margin .020 IN. (0.5 MM) MINIMUM VALVE GUIDES INSPECTING AND REPLACING VALVE GUIDES Valve guides are press fitted in their bores with an interference fit of .0025 to .0043 in. (0.063 to 0.108 mm). They should be replaced when scored or worn or when there is excessive clearance between them and the valve stem, which cannot be corrected by replacing valve. Valve stem fit clearance in guide is .0012 to .0026 in. (0.030 to 0.066 mm) for both intake and exhaust valves, and maxi mum wear limit is .006 in. (0.15 mm). 1.4173 in mm L36 __ __;_..\ INTAKE / ' '55:) 30, :5, ,3” x? _ é 1.3031 in 33,1 mm /- —.._...___— EXHAUST Page 10-56 When replacing valve guides, use driver A.60395 (1) for disassembly and driver A.60462 for reassembly. NOTE: Replacement valve guides are prefinished and unless minor damage occurs during assembly no reaming is required. Should damage occur use reamer A.903‘ID to refinish bore. 1. Driver A. 60395 VALVE SPRINGS Inspect valve springs for cracks or weakening. Test spring tension using appropriate spring tester; then compare tension and deflection data on tester with specifications shown. 1.545 m.,41.s mr— 1.220 114.31“ .846 m, 21.5 ma T _ LBS 33 21 No 14910 ms 54.. 2 5 I Kg 211 1 :1. 2 SPECIFICATIONS FOR TESTING VALVE INNER SPRING LBS as 23.3 in, 33.9 21.5 '_. 2.122 "L, 53.9 Mill—r 1.417 "I, 35 “H 1.043 |N., 26.5MM I LBS m 15.5 IIq 59.5 22.5 SPECIFICATIONS FOR TESTING VALVE OUTER SPRING 101.03 Crankshaft and Flywheel Page 10-57 MAIN BEARING JOURNALS AND CRANKPINS INSPECTION Carefully inspect crankshaft for cracks on main bearing journals and crankpins as well as on crank arms. If any are detected, crankshaft should be replaced to prevent failure. Should journals show light traces of scuffing, these can be dressed off by using an extra- fine carborundum stone. If deep scoring is discovered, or if micrometer measurements of journals shew an out-of-round condition in excess of .0002 in. 2.1459 "1., 54.5071“! 2.1485 ”1., 54,520 MM (.005 mm), journals will have to be reground to next undersize. .0718 |Il., 1,825 MM .UTZ1IN., 1,831MIII 1.9990 111., 50,775 Mill 1.9998 01., 50,795 MM When regrinding journals, be sure to pay special attention to specified fit clearances in relationship to undersize bearing range available for service. Depending on amount of wear, main bearing journals and crankpins should be reground to undersize diameter shown in tables. The same journal radius that existed originally should be maintained. MAIN BEARING THICKNESSES Standard l Undersiza bearings .01 in bearings .03 in .02 in l (0.254 mm) 1 (0.508 mm) .0818 in .0768 in .0118 in .04 in (03162 mm) (1.016 mm} .0868 in .0913 in (1.925 mm) (1.952 mm) (2.079 mm) (2.203 mm) (2.339 mm) to 1D to to .0871 in .0821 in .07'1'1 in .0721 in (2.212 mm) (2.339 mm) (2.085 mm) (1.831 mm) (1.968 mm) to .0921 in MAIN BEARING JOURNAL DIAMETERS ._ 5““‘md l Undersize .01 in (0.254 mm) I .02 in (0.508 mm) 1 .03 in (0.362 mm) .04 in (1.016 mm} 19990011 1.999001. 1.9790 in‘ 1.9690011 1.9590111 (50.775 mm); (50. 521 mm) (.50 2617 mm) (50. 0113 turn) (49.159 mm) 1.9999 in 1.9998 in 1.9199 in ‘ 1.9698 in to 1.9591T in (30.795 111.111) (50.541 mm)!(50.287 mm)i (50.033 mm) (49.719 mm] Page 10-58 )l \. 1.7913 m., 45,493 uu 1.7920 m, 45,513 Im rJIOZ m rum: H.181 m. l mass m r2] um rmnu r10!” r 3.0HM 1.9990 In.. 50,775“ 1.999: m, 50,795“ SPECIFICATIONS OF CRANKSHAFT JOURNALS, CRANKPINS AND SHOULDER RADll After journals have been ground to size and polished, crankshaft must be thoroughly cleaned to remove all metal and abrasive particles. To clean oilways properly, welch plugs must be removed. Then ream plug bores using reamer A.94016. Thoroughly flush oilways with solvent and blow dry with compressed air. After completing above operations, drive new welch plugs into place with driver A.8601D l1) and stake them with a punch. 1. Driver A.8601D Checking Crankshaft Balance Place two parallel blocks (2) on a surface plate. Set crankshaft—flywheel-clutch assembly (1) on parallel blocks. If assembly shows a tendency to roll towards one side, stick some putty on opposite side until assembly stops moving. Weighing amount of putty used will provide an indication of unbalanced weight. To correct situation. drill holes on flywheel at point D (next figure} as required to remove corresponding weight of metal. 1. Crankshaft-flywheel-clutch assembly 2. Parallel blocks Crankshaft and Flywheel 101.03 Page 10-59 Flywheel and Ring Gear Inspect condition of ring gear teeth. If there is any obvious damage, replace ring gear. in an oil bath. A hydraulic press should be used to install new ring gear onto flywheel, after heating gear to 176°F (80°C) or scores. SurMake sure flywheel contact surfaces with crankshaft and clutch driven disc are smooth and free from scratches axis. rotation flywheel to angles faces should also be perfectly flat and at right in excess of .004 Flotate flywheel centered on crankshaft: a dial indicator resting at points B and C should not show variations in. [0.1 mm). .0137IN. sasmmr .0137 IN. fl 0.35m .0012 m. 0.03MM l .0012 iii 0.0s l .0012 m. 0.03 MM l Maximum allowable misalignment of journals and crankpins, and diagram for checking flywheel contact surfaces with clutch disc and crankshaft flange. assembly {A-B-C—E = points for checking alignment and squareness with respect to rotation axis; D = crankshaft—flywheel-clutch balancing holes.) attacking Main Bearing Journals and Crankpins for Misalignment Rest crankshaft ends on two parallel blocks and check the following with a dial indicator. Main journal misalignment: maximum allowable tolerance .0012 in. (0.03 mm) (total dial gauge reading). Crankpin misalignment: maximum allowable tolerance, with respect to journals. t .0137 in. (i 0.35 mm]. in. (0.005 mm). Main bearing journal and crankpin out-of—round: maximum allowable tolerance after regrinding, .0002 mm). Main bearing journals and crankpins taper: maximum allowable tolerance after regrinding, .0002 in. (0.005 laterally some resting indicator dial a crankshaft, Squareness of flywheel resting face to crankshaft centerline: when rotating mm). (0.025 in. .001 of excess in variations show not should 1.34 in. (34 mm) from crankshaft centerline, straightened using a If inspection of main bearing journals and crankpins alignment reveals distortions. the shaft should be structure. internal its damage hydraulic press, taking care not to subject shaft to excessive stress which could Page 10-60 Main Bearings if inspection shows hearings to be scored or have signs of seizure or abnormal wear, they should be replaced. No recon. ditioning or adaptation of damaged bearings is possible. If inspection proves their condition to be satisfactory and fit for further service, check clearances betwaen bearings and journals as follows. Place a length of calibrated wire (1), such as ”Plastigage", along journal being checked. 1. Plastigage wire lnstall caps, complete with bearing shells. Tighten cap mount- ing screws to a torque of 59 ft. lbs. (8.2 kgml. Remove caps and using scale on Plastigage envelope (1) measure width of flattened wire (2). Numbers on envelope show value of existing clearance. Normal clearance between main bearings and crankshaft journals is .0019 to .0037 in. (0.050 to 0.095 mm). If clearance does not fall within maximum allowable limit of .006 in. (0.15 mm), bearings must be replaced with undersize ones after regrinding crankshaft journals. 1. Measuring envelope 2. Plastigage wire When checking and replacement procedures have been carried out. install caps and tighten bolts to 59 ft. lbs. (8.2 kgm) torque. Free crankshaft rotation is an indication that assembly has been performed correctly and bearing clearances conform to specifications. Crankshaft and Flywheel 101.03 Page 10-61/62 Crankshaft End Play Once crankshaft has been installed, check end play between thrust rings on rear saddle bore and crankshaft shoulders. lnstall magnetic base dial gage and wedge two screwdrivers as shown. Using screwdrivers, pry crankshaft back and forth and check dial gage to see if endwise movement falls within .0021 to .104 in. (0.055 to 0.265 mm). Should end play prove to be more than maximum allowable limit of .0137 in. (0.35 mm), replace thrust rings with .005 in. (0.127 mm) oversize rings. When installing service thrust rings, make sure that grooves cut on one ring side are facing crankshaft shoulder. 1. Th rust ring 2. Crankshaft Oil Seals is advisTwo metal cased spring loaded rubber seals are fitted at both crankshaft ends. Whenever crankshaft is being serviced. it seals. oil able to replace both 101.05 Connecting Rods and Pistons 1. Page 10-63 omsewewwd . Piston Pin . Big-end cap Bearings Cap nut Connecting rod shank Cap bolt . Smell-end bushing . Circlip ROD-PlN-PISTON ASSEMBLY PISTON CHECKING PISTON CLEARANCE IN CYLINDER BORE AND PIN CLEARANCE IN PISTON Checking piston clearance in cylinder bore should allow for class selection. Namely, only pistons and bores belonging to same class should be matched. Standard pistons are selected in three classes, according to piston bore diameter. The same selection applies to piston pins, which must be fitted to pistons belonging to same class. The letter and number showing piston class (2] and piston pin bore class (1} are stamped on underside of piston bosses. Piston pin class is also stamped on pin surface. 1. Piston pin bore class 2. Piston class 3. Matching number of connecting rods to cylinder Piston pin clearance in boss bore is .0004 to .0007 in. (0.010 to 0.018 mm}. To check pin fit, lubricate pin with light engine oil and insert it into piston bore. If fit is correct, pin should slide in by thumb pressure and when holding piston with pin in vertical position, pin should not fall from piston under its own weight. Clearance of pistons in cylinder bores, measured at right angles to the piston pin and 1.08 in. (27.5 mm) from piston skirt edge, is .0011 to .0019 in. (0.030 to 0.050 mm). Be sure to always add piston skirt wear to cylinder wall wear to determine actuai clearance between parts. Piston clearance in bore must not exceed .006 in. (0.15 mm). Oversize pistons are available in three oversizes of .0078 — .0157 4 .0236 in. (0.2 — 0.4 — 0.6 mm). Oversize pins are only available in .0078 in. (0.2 mm) oversize. 3.4015 IN. 86 400 MM ' ' 3.4035 IN., 86,450 MM .1562 IN., 3.967 MM .1570 IN.,l3.98'l MM .0582 IN. 1.478 MM .osarm. — 3:] 1.490 MM .0779 IN. 1.97:; MM .0733 m. 1.990 MM 5’ .1545m. J .2 MM_. _. ._.-..2 .155 m. I_ —'—---3.937 MM _ _ 27.5 MM / .0604 IN., 1.535 MM .0612 IN., 1.555 MM .0799 IN., 2.030 MM .0807 IN., 2.050 MM 1] ‘ D SPECIFICATIONS OF CYLINDER BORE, PISTON AND RINGS 3.3999 A = 86.360 8 TO 3.4003 IN. T0 86.370 MM = 3.4007 T0 3.4011 IN. 86.380 T0 86.390 MM 3.4015 0 = 86.400 T0 3.4019 IN. T0 86.410 MM 101.05 Connecting Rods and Pistons ,___ Before assembly, check that the four pistons have the same Weight; maximum permissible tolerance is i .088 02. (i 2.5 g). If four pistons are not available whose weight comes within this tolerance, remove metal from base of piston bosses by milling. Milling should not be done beyond a depth of .177 in. (4.5 mm) compared to nominal piston height of 2.232 in. (56.70 mm] and milling diameter should be limited to 2.775 in. (70.5 mm). Milling diagram for balancing piston weights. a = 2.232 in (56.70 mm) nominal piston height. h = 2.055 in (52.20 mm) minimum height after milling. c = 2.775 in (70.50 mm) maximum milling diameter. Piston Ring Side Clearance Side clearance of piston rings in grooves is checked by installing ring (1) and using feeler gage to measure clearance. Maximum wear limit is .006 in. (0.15 mm). 2. Piston 3. Feeler gage Piston ring fit (side clearance for new parts). —first: compression ring ............ 0.0018 to 0.0030 in 0.045 to 0.077 mm —second: oil ring ................ 0.0016 to 0.0028 in 0.040 to 0.072 mm —-third: scraper ring ............... 0.0011 to 0.0024 in 0.030 to 0.062 mm Ring End Gap Prior to installing rings on pistons, push them down squarely into bores and check ring and gap, which should correspond to values shOWn. If gap is less than specified, grind ring ends as required. When installing rings on pistons, stagger and gaps 120° apart. Ring end gap in bore. -—first: compression ring . . . ......... 0.0118 to 0.0177 in 0.30 to 0.45 mm wsecond: oil ring ................ 0.0118 to 0.0177 in 0.30 to 0.45 mm to 0.0157 in 0.0098 ..... .......... ring —third: scraper 0.25 to 0.40 mm __ a l'"— _i!.__ _... u=a .. a c alls} if Checking Piston Weight 1. Ring Page 10-65 Page 10-66 CONNECTING RODS REMOVAL AND INSTALLATION OF SMALL-END BUSHING Bushing is removed and installed on a suitable press with tool A.60054, as shown. 1. Drift A.60054 2. Connecting rod 3. Small-end bushing CONNECTING ROD-PlN-PISTON ASSEMBLY ASSEMBLY Check alignment of big-end and small-end axis measured at 4.92 in. (125 mm) from shank. Maximum allowable misalignment is i .004 in. (i 0.10 mml. 1. Square 2. Connecting rod and pin 4. Arbor look 3. Expandable blade arbor Piston bore is .08 in. (2 mm) offset (2). Position rod to piston so that number stamped on rod (1 ) faces towards side of piston bore offset and away from auxiliary shaft {3}. 1. Connecting rod to cylinder matching number 3. Auxiliarylr shaft 2. Piston pin offset 101.05 Connecting Rods and Pistons Page 10-67/68 To fit piston pin circlips (3), use tool A.60303 (1) as shown. After installation, ensure that circlip end gap is not in line with slot provided in piston, to make removal of circlip easier. 2. Piston 3. Circlip 4. Circlip groove in piston 35089 1. Tool A.60303 Connecting Rod Bearings if there is evidence of deep scoring or excessive wear, replace bearing inserts (2). Check for correct clearance between inserts and crankpins with "Plastigage" method. Clean parts thoroughly and connect rods to relative crankpins. Place length of plastigage wire (11 along crankpin. Install caps (31 and tighten nuts to 38 ft. lbs. (5.2 kgm) torque. Remove caps and using scale on envelope (4), measure width of compressed wire. lf clearance is between .0014 to .0034 in. (0.036 to 0.086 mm), bearings are fit for service. 1. Plastigage wire envelope 2. Bearing insert 3. Big-end cap 4. Measuring CRANKPIN DIAMETERS If clearance is in excess of_ limits, bearings should be replaced with undersize bearings. Crankpins must be reground to an undersize such as to restore clearance of .0014 to .0034 in. (0.036 to 0.086 mm). Undersizes Standard .01 in ( 0.254 mm) .04 in .03 in .02 in (0.508 mm) (0.152 mm) (1.015 mm.) 1.7513 in 1.7613 in 1.7713 in 1.7813 in 1.7913 in (45.498 mm) (45.244 mm) (44.990 mm) (44.736 mm] (44.432 mm) 1.7520 in 1.7620 in 1.7720 in 1.7320 in 1.7920 in (45.518 mm) (45.264 mm) (46.010 mm) (44.756 mm) (44.502 mm) CONNECTING ROD BEARING THICKNESSES Undersizes Standard .01 in (0.254 mm] .0603 in .0653 in .02 in (0.508 mm) .0703 in .04 in .03 in (0.762 mm) (1.016 mm) .0753 in .0803 in (1.531 mm) (1.658 mm) (1.783 mu] (1.912 mm) (2.039 mm) (1.665 mm) (1.792 mm) (1.919 mm) (2.046 mm) .0606 in (1.538 mm) .0656 in .0706 in .0756 in .0806 in Camshaft Drive 101.06 Page10-69/70 REPLACING TIMING BE LT (Engine in ear] renew belt. Under no circumstances CAUTION: Timing belts cannot be reused. Following belt removal or slackening, always n. installatio initial its following must belt tension be adjusted cover bolt must be removed from under Disconnect battery cable. Remove spark plugs. Remove timing belt covers (lower vehicle). {7), and cam sprocket mark (ll is aligned Crank engine with tool A.50459 until pulley mark (3) is aligned with TDC indicator with mark on belt guard l2). pulley drive belt (10). Loosen alternator and NC compressor (if equipped with NO) mounting bolts and remove place with nut. Remove belt. Loosen idler pulley nut l4) and move pulley in direction of arrow as far as possible. Secure in are perfectly coupled with sprockets. Install new timing belt with slack on tensioner side. Ensure that timing belt teeth position to 33 ft. lbs. (4.5 kgm}. Loosen idler pulley nut and tensioner will tighten belt. Torque idler pulley nut in this Check that timing marks are still correctly aligned. Reinstall removed components. HmtM-l . Camshaft sprocket mark . Reference mark on timing belt guard . Crankshaft pulley mark . Idler pulley nut . Auxiliary shaft sprocket bolt . Camshaft sprocket bolt .TDC timing mark 8. Auxiliary shaft sprocket 9. Timing belt 10. Pulley drive belt 101.07 Valve Mechanism 1. 2. 3. 4. 5. 6. Seal Dowel Plates for adjusting valve clearance Tappets Locks Upper cups 7. 8. 9. 10. 11. 12. inner springs Outer springs Lower cups Exhaust valve guide Exhaust valve Flat washers VALVE M ECH AN ISM COMPONENTS CAMSHAFT HOUSING Check that camshaft bores in housing are not out-of-round. Inner surfaces should be smooth and show no signs of seizure; if they do, replace housing. NOTE: When servicing camshaft it is advisable to replace driveend seal. CAMSHAFT Camshaft journal and lobe surfaces should be absolutely smooth and in perfect condition. Should traces of seizure or scoring be found which cannot be dressed off with an extrafine abrasive stone, camshaft is not fit for further service and should be replaced. Make sure journal oil holes are not stopped up. To remove camshaft welch plug, use a standard punch; for reassembly use installer A.86013 (1). 1. Installer A.86018 Page 10-71 13. 14. 15. 16. Intake valve Intake valve guide Oil seal Camshaft 17. Welch plug Page 10-72 | Rest camshaft on two parallel blocks placed on a surface plate, and check with a dial gage that center journal (1) runout does not exceed .008 in. (0.2 mm). Also check that lobe height (2) is 0.362 in. (9.2 mm) for intake and 0.364 in. (9.25 mm) for exhaust lobes. 1. Center journal 2. Cam lobe 1.9047 lN., 48,380 MM 1.9057 lN., 481405 MM 1.8988 lN., 48,180 MM 1.8978 lN., 48,205 MM / 1.8890 lN., 47,980 MM 1.1807 lN., 29,989 MM 1.8900 lN., 48,005 MM 1.1816 lN., 30,014 MM / L/ . O 1.9128 lN., 48,580 MM 1.9139 lN., 48,805 MM 1.9114 lN.,48,550 MM 1.9108 lN., 48.535 MM 1.9035 lN., 48,350 MM 1.9030 ”11., 48,335 MM 1.8957 lN., 48,150 MM 1.8951 lN., 48,135 MM 1.88781N.,47,950 MM 1.8872 lN., 47,935 MM 1.1795 lN., 29,960 MM 1.1787 lN., 29,944 MM SPECIFICATIONS OF CAMSHAFT AND BORES IN HOUSING TAPPETS AND PLATES Make sure tappet plate surface in contact with camshaft lobes is glass-like and shows no signs of dishing or pitting. Minor imperfections can be removed using an extra fine abrasive stone. Tappet outside surfaces, as well as tappet bores in camshaft housing, should not show evidence of undue wear, taper of scoring. ll Check tappet diameter and tappet bore diameter in camshaft housing using micrometers. Values read on micrometers should meet specifications as shOWn. If they do not, replace worn parts. Tapper plates are available for service in a range of thickness from .1457 to .1850 in. (3.70 to 4.70 mm) with .002 in. {0.05 mm] increments. 1: 11557111.,37300 1111 11577 lN., 31.025911 1.4557 111,311,975 1111 1.4565 11,35,995 11111 "" Valve Mechanism CHECKING AND ADJUSTING VALVE CLEARANCE Adjustment of clearanca between camshaft lobes and tappets does not require camshaft removal. Correct clearance with engine cold is: intake valves — .011 to .014 in. (.24 to .32 mm) and exhaust valves — .015 to .018 in. (.34 to .42 mm). Remove camshaft cover. Turn crankshaft until lobe (1) controlling tappet (3) being checked is pointing upwards and is at right angles to tappet plate (2). Using a feeler gage (4), measure clearance between tappet plate and camshaft lobe to determine if plate has become worn. 1. Lobe 2. Plate 3. Tappet 4. Fealer gage NOTE: Remove oil from around tappets with syringe to simplify plate removal. Empty syringe into oil drain passages. If clearance is not as specified, insert tool A.60421 (3) on both intake and exhaust valve tappets (2). Remove plate (1) from its seat on tappet using pincer A.87001. After determining needed thickness, install new plate. Tappet clearance plates are available for service in a range of thicknesses from .1457 to .1850 in. (3.70 to 4.70 mm) with a difference between each of .002 in. (0.05 mm). The thickness of plate is shown on one of the plates flat surfaces and this should be assembled towards tappet. Valve Timing Diagram for a Theoretical Tappet Clearance of: — 0.60 mm, inlet valves —- 0.65 mm, exhaust valves 101.07 Page 10.73/74 Auxiliary Drives REPLACING AND ADJUSTING DRIVE BELTS Vehicles With Air Pump, Without A.C. To replace drive belts, loosen alternator mount bolts. Remove belt (6). Loosen air pump (3) mount bolts. Remove belt (1). install new belt on water pump (4) and air pump (3). Fully tighten air pump belt (1) and air pump mount bolts. Check for about '19 inch belt deflection with moderate finger pressure. install new belt (6) on crankshaft pulley (5), water pump pulley (8), and alternator pulley (7). Fully tighten belt (6) and alternator mount bolts. Check for about ‘A inch belt deflection with moderate finger pressure. 1. Air pump belt 2. Air pump pulley 5. Crankshaft pulley pulley 3. Air pump 6. Alternator/water pump belt 8. Water pump pulley 4. Water pump 7. Alternator Vehicles With Air Pump and A.C. To remove compressor belt (6), loosen both compressor and alternator mount bolts. Remove belt (6). To remove alternator water pump belt (8), remove belt (6) and then belt (8). To remove air pump belt (1), loosen both air pump (3) and alternator. Remove belt (8) from water pump (4) and then remove belt ( 1). After installing new belts, adiust tension on compressor belt (6) first, if necessary. Adjust tension on belt (8) second and the air pump belt (1). Belt Tension A.C. compressor belt (6) Alternatoriwater pump belt (8) Air pump belt (1) Lb. 90-110 75-95 About 1/8 inch deflection with moderate finger pressure Run engine for 15 minutes with air conditioning on. Readjust belts. A.C. compressor belt (6) to 70 to 90 lbs. Alternator/water pump belt (8) to 50 to 65 lbs. 1. Air pump belt 2. Air pump pulley 3. Air pump 4. Water pump 5. Crankshaft pulley 6. Compressor belt 7. Compressor clutch B. Altematorlwatar pump belt 9. Alternator pulley Vehicles Without Air Pump and A.C. To remove alternator/water pump belt (1), loosen alternator (6) mount bolts. Install new belt (1) and fully tighten belt and alternator mount bolts. Check for about V; inch belt deflection with moderate finger pressure. 1. Alternator/mater pump belt 2. Water pump pulley 3. Water pump 4. Crankshaft pulley 5. Alternator pulley 6. Alternator 101.15 Page 10-75 Page 10-76 Vehicles With Fuel Injection and A.C. To remove belts, loosen three nuts (3) and remove water pump belt [2]. Install new compressor belt. Install compressor lower mount bolt. Adjust belt tension to 70 to 90 lbs. and fully tighten compressor bolts. To install water pump belt (2) loosely slip alternator belt (7) over inner groove of water pump pulley (1). Remove nuts (3) holding crankshaft outer pulley half {12) and remove pulley half. CAUTION: Shims will be re-used. Do not discard shims. Install water pump belt (2) over outer groove of water pump pulley {11) and crankshaft pulley. Install original shims and reinstall crankshaft pulley half. Check that water pump belt tension is 60 to 80 lbs. If it is necessary to readjust belt tension, a shim change of 0.5 mm (0.020 in.) causes a change in belt tension of 17 to 22 lbs. Fully tighten nuts (3). If replacing alternator belt (7), remove water pump belt (2). Loosen alternator tensioner bolt (8) and remove belt. Install new belt and adjust tension to 3D to 50 lbs. Fully tighten alternator bolts. Install water pump belt as directed above. 1. A.C.. compressor belt 2. Water pump belt 3. Nuts 4. Shims 5. Crankshaft pulley assembly 6. Water pump 1‘. Alternator belt 8. Tensioner bolt 9. Alternator 10. Compressor 11 . Water pump pulley 12. Crankshaft pulley half A If replacing A.C. compressor belt (1), loosen compressor tension bolt and remove lower mount bolt. Slide compressor toward crankshaft pulley and remove belt (1). 102.01 Fuel Tank and Lines Page 10-77 3 1. 2. 3. 4. Carburetor Charcoal canister Separator Fuel tank 5. Separator 6. Two-way valve % ' _ _ ' '' . _ FUEL VAPOR LINES _ ' ' (VEHICLES WITH CARBURETOR) . _ _ _ ‘ ‘ @ ='\ Page 10-78 1. Air intake 2. Charcoal mnister 3. Two-way valve 4. Separator 5. Fuel tank 6. Separator 7. Twomy safety relief valve 8. "Y" connector 9. Air supply hose FUEL VAPOR LINES (VEHICLES WITH FUEL INJECTION) Fuel Tank and Lines 102.01 Page 10—79 #ommymmt—u . Filler lines . Rubber ring . Check valve . Carburetor _ Fuel filter , Fuel pump Check valve Gasket dd . Sending unit 00m VEHICLES WITH CAHBURETOR ommum5n¢mna . Sanding uni1 . Gasket . Rubber ring . Filler lines Fuel tank . Fuel filter . Fuel pressure regulator . Fuel manifold d , Fuel pump . Brackets VEHICLES WITH FUEL INJECTION FUEL TANK AND. LINES . Fuel tank . Brackets FUEL TANK REMOVAL AND INSTALLATION Empty all fuel from fuel tank. 0n vehicles with fuel injection, disconnect air hoses from both sides of air flow sensor. Disconnect electrical connector from sensor. Remove two nuts and two bolts holding sensor bracket to firewall. Remove bracket with air flow sensor attached and set to one side. Cut hose clamps and disconnect two fuel hoses (lllcerburetor vehicles only) and two vapor hoses (5). Remove four screws (2 and 3) holding rubber cover (4) and remove cover. Disconnect three wires from sending unit assembly. 1. Fuel hoses 2. Screw 3. Screw 4. Cover 5. Vapor hoses Raise and support rear of vehicle. On vehicles with fuel injection, remove protective cover and fuel inlet and return hoses (1). On all vehicles. support fuel tank (5) and remove bolts (3 and 6) and support straps i2 and 4). Lower tank from vehicle. Installation is reverse of removal. 1.Fue|hoses 6.Bolts 2.5upportstrap 3. Bolt 4. Supportstrap 5.Fueltank Fuel Pump and Lines 102.02 Page 10-81 FUEL PUMP REMOVAL AND INSTALLATION [Vehicles With Carburetor) Disconnect and plug fuel hoses (1). Remove two nuts (2) and washers holding fuel pump (3) to engine. Remove fuel pump. two gaskets and insulating support. Installation is reverse or removal. 1. Fuel hose 2. Nuts 3. Fuel pump INSPECTION Check attachment screws (4) of upper and lower bodies and cover screw (1) for tightness. Ensure fuel hoses and filter are not deteriorated or clogged and that diaphragm is not hardened or cracked. Check for weakness or distortion of control lever and diaphragm springs. When assembling, cost control lever and pivot with oil. Use new gaskets lightly coated with grease. 1. Cover screw 2. Lockwasher 3. Cover 4. Screw 5. Filter 6. Upper body 7. Diaphragm 8. Spacer 9. Spring 11. Pivot pin 12. Control lever 13. Spring 10. Lower body ADJUSTMENT Place outer gasket (2) and insulating support (4) on engine. Place a .012 in. (.3 mm) gasket on support. Install rod (5) in engine. Check that dimension A is .59-.61 in. (15-155 mm). Install a thicker or thinner gasket to meet this dimension. After adjusting the dimension, place inner gasket (3). insulating support and outer gasket on engine. Install rod (5) in engine, and install fuel pump (1). NOTE: Gaskets (3) are supplied in .12. .027, and .047 in. (.3, .7. and 1.2 mm) thicknesses. 1. Fuel pump 2. Gasket 3. Gasket 4. Insulating support 5. Rod REMOVAL AND INSTALLATION _(Vehicles With Fuel Injection) --._.- CAUTION: Relieve fuel system pressure before disconnect- ing fuel hoses. Refer to RELIEVING FUEL PRES- SURE in Section 102.26. Raise and support rear of vehicle. Remove panel protecting fuel pump. Disconnect and plug fuel hoses (1). Disconnect electrical leads (4) from fuel pump (3). Remove two nuts (2) retaining fuel pump and remove pump. Installation is reverse of removal. 1. Fuel hoses 2. Nuts 3. Fuel pump 4. Electrical leads FUEL FILTER REMOVAL AND INSTALLATION (Vehicles with Carburetor) Disconnect fuel inlet (1) and outlet (5) hoses from filter by removing clamps (2 and 4) and pulling hoses off filter (3). install new filter with arrow on filter pointing in direction of fuel flow to carburetor. 1. Fuel inlet hose 2. Clamp 5. Fuel outlet hose 3. Fuel filter 4. Clamp REMOVAL AND INSTALLATION (Vehicles With Fuel Injection) CAUTION: Reiieve fuel svstem pressure before disconnect- ing fuel hoses. Refer to RELIEVING FUEL PRES- SURE in Section 102.26. Disconnect fuel inlet (3) and outlet (5) hoses from filter by removing clamps (1) and pulling hoses off filter (2). Remove two nuts (4) holding fuel filter to body, and remove fuel filter. Installation is reverse of removal. 1.Clamp 2.Fualfilter 3. Fuel iniethose 4. Nut 5.Fueloutlethose Carburetor and Air Cleaner 102.04 Page 10-83 AIR CLEANER REMOVAL AND INSTALLATION (Vehicles With Carburetor) Loosen clamp (1) holding fresh air duct (2) to fan. Disconnect hoses (5) from side at air cleaner (3). Remove three nuts (4) and washers holding cover (6) on air cleaner. Remove filter element. Remove four nuts holding air cleaner on carburetor. Lift air cleaner and disconnect hose from bottom. Remove air cleaner with fresh air duct attached. Installation is reverse of removal. Make sure metal bushings are installed in rubber spacer. 1. Clamp 2. Duct 3. Air cleaner 5. Hose 4. Nut 6. Cover REMOVAL AND INSTALLATION (Vehicles With Fuel Injection) Loosen clamps (2) and remove air supply hose (1 ). To remove filter element. remove wing nut (6) and top of air cleaner. Remove two nuts (3 and 5) holding air cleaner assembly (4) to body and firewall. Remove air cleaner assembly. Installation is reverse of removal. 1. Air supply hose 5. Nut 6. Wing nut 2. Clamps 3. Nut 4. Air cleaner assembly CARBURETOR COOLING FAN REMOVAL AND INSTALLATION Remove four screws (3 and 5) holding fan duct to fan mount~ ing plate. Separate duct from mounting plate with duct hose (2) attached and set to one side. Disconnect wire at connector. Remove four nuts (1 and 4) holding mounting plate to body and remove fan assembly. install in reverSe order. Make sure ground wire is installed under mounting nut. 1. Nut 2. Duct hose 3. Screws 4. Nut 5. Screws CARBURETOR REMOVAL AND INSTALLATION NOTE: Mark lines. hoses. and wires prior to removal to identify for installation. Remove air cleaner. From carburetor. disconnect fuel inlet and return hoses (4), charcoal canister hose (2), and all remaining vacuum and coolant hoses. Disconnect three electrical connectors (1) from carburetor. Disconnect throttle linkage (Slat carburetor. Remove four nuts (3) holding carburetor. Remove carburetor and spacer. Installation is reverse of removal. Connect vacuum, fuel and water lines to connections as shown below. 1. Electrical connectors 5. Throttle linkage 2. Hose 3. Nut 4. Fuel hose F LOAT BOW L VAPOR OUTLET COOLANT HOSE CONNECTION VACUUM ACCELERATOR PUMP CONNECTION FUEL INLET CONNECTION FUEL RETURN CONNECTION CHARCOAL TRAP PURGE CONNECTION A.C. FAST IDLE CONNECTION EGR SIGNAL CONNECTION DISTRIBUTOR SIGNAL CONNECTION CRANKCASE VENT CONNECTION POWER VALVE CONNECTION 102.04 Carburetor and Air Cleaner Page 10—85 .x \\\\\\\\\\\\\\\\“ AUTOMATIC CHOKE CHECK AND ADJUSTMENT Remove carburetor from vehicle. Remove three screws holding automatic choke cover and gasket. . ‘. ‘o. 4 Choke Fest Idle Set fast idle screw (2) on second step of cam (1). Check that primary throttle opening (gap A) is 0.033 to 0.037 in. (0.85 to 0.95 mm). If gap A is not correct. adjust screw (2). ..o o t‘. \ \\\\\\\\\\\\\\\“‘ 1. Fast idle earn 2. Fast idle adjustment screw 3. Primary throttle plate Choke Unloeder Lever Clearance Release Pull fast idle linkage (2) back. Close choke plate (1). linkage (2). Measure gap B between (ever (4) and shoulder of type can bushing (3). A spark plug gap gage of the bent wire be used. is Gap should be 0.012 to 0.039 in. (0.3 to 1.0 mm). If gap not correct, carefully bend tang (4). ‘ — 1. Choke plate 2. Festldlelinkage 3. Spring 4. Tang 5-1 1—_ I [Ill], I, ”11¢ .11.'a .” 9: I f o'1'1111 O I ’15-" Check that gap C is 0.098 to 0.118 in. (2.5 to 3.0 mm). If 1. Choke plate 2. Fast idle screw 3. Fast idle com s‘ gap C is not correct, bend lever (4). 4. Lever ‘0 ‘- in direction of arrow. s“.‘ Set screw (2) on third step of cam (3). Make sure screw is in proper contact with third step. If necessary, move earn (3) #1“‘\\\\‘\\\‘\\\\\‘ Fast ldle Cam Intermediate Setting Page 10-86 Choke Unloader Minimum Opening With linkage (3) on second step of cam (2), position tool No. 4460 on rod (7). Push tool to left until rod contacts stop screw (6). Hold it there. NOTE: Make sure tool is not touching bushing (5) in housing. This would restrict travel of rod (7). Measure gap D. Gap should be 0.128 to 0.147 in. (3.25 to 3.75 mm). if gap is not correct, adjust travel of rod (7) by turning screw (6). Clockwise to decrease gap-counterclockwise to increase gap. 1. Choke plate 2. Fast idle cam 3. Fast idlelinkege 4. Tool No.4460 5. Bushing 6. Stop screw 7. Fiod F LOAT LEVE L ADJUSTMENT Remove six screws holding carburetor top cover. Carefully remove coverlfloat assembly and gasket. Check that needle valve seat (2) is tight in cover. Check that float (9) is free of dents or punctures. Check that float can move freely on hinges. Hold dual float assembly in vertical position with needle valve lightly seated. Measure distance A between each float and cover gasket. Distance should be .266 to .285 in. (6.75 to 7.25 mm). Make sure floats are same distance from gasket. if not, bend float arm (8). Then if float assembly is not at specified distance, carefully bend tang (7) to obtain adjustment. To obtain float drop distance B of 0.354 in. (9 mm), bend lug (3). Carefully replace cover/float assembly and secure with six screws. 1. Caboretor cover 2. Needle valve seat 3. Float drop lug 4 Needle verve 5. Return hook 6. Damper ball 7. Float tank 8. Floatarm 9. Float 10. Gasket CARBUFIETOR ADJUSTMENT NOTE: For proper specifications, always refer to EPA Conformity Tag in engine compartment. Apply hand brake. Start engine and allow warm up. Insert CO tester probe in tailpipe. Connect a tachometer. On vehicles without air pump, pinch off—the supply line to reed valve. On vehicles with air pump, pinch off air injection supply line upstream of check valve. Adjust carburetor idle speed adjusting screw (1) to set engine speed to 800 to 900 rpm. Adjust idle mixture adjusting screw (2) to set CO to 2.0%. Turn screw clockwise to decrease C0 or counter-clockwise to increase CO. Recheck idle speed and if necessary, repeat adjusting idle speed and mixture to obtain both the proper idle speed and CO reading. Shut engine off. Remove tool used to pinch off air injection hose or supply line. 1. Idle speed adjusting screw 2. idle mixture adjusting screw 102.04 Carburetor and Air Cleaner 29. Primary throttle plate 30. Primary throttle shaft 1. Carburetor cover 2. Breather valve 31. Accelerator pump actuating cam 3. Choke plate 32. Fast idle control lever lA/C only) 33. Power valve cover 4. Gasket 5. Choke linkage 6. Choke plate shaft 7. Filter 8. Float assy 34. Bowl vent valve rod 35. Power valve return spring 36. Power valve diaphragm . 37. Accelerator pump jet .f 9. Center venturi 10. Idle jet housing } 12. Secondary throttle vacuum diaphragm assy 13. Secondary throttle shaft 14. Secondary throttle plate l l 5 38. Main fuel jet 39. Main emulsion tube l 11. Idle jet 40. Main air jet 41. Vacuum accelerator pump cover 42. Vacuum accelerator pump return spring 43. Vacuum accelerator pump diaphragm 44. Automatic choke hot water cover 45. Gasket 15. Throttle actuating lever assembly 16. Choke fast idle screw 17. Progressive throttle linkage 18. Return spring 19. Stop lever, Primary shaft 46. Automatic choke hot water backing plate 47. Bimetallic spring case 48. Gasket 20. Return spring 3 22. Idle speed screw 23. Fast idle diaphragm assy (A/C only) 1 ‘ 21. Carburetor body assy 24. ldle shut off solenoid 25. Idle mixture screw 1‘ 49. Automatic choke assy I ' 52. Choke unloader return spring 53. Choke unloader diaphragm 50. Choke unloader adjustment screw 51. Choke unloader cover 54. Fast idle cam return spring 55. Needle valve assy 26. Accelerator pump cover 27. Pump diaphragm 28. Diaphragm return spring Specifications (mm) j Carburetor Model 21 Primary venturi 4.00 Main fuel jet (primary) A/C Vehicle only . ‘ ’. ' Main fuel jet (secondary) ldle jet (primary) Idle jet (secondary) Accelerator pump jet Air jet (primary) Air jet (secondary) ' Emulsion tube (primary) Emulsion tube (secondary) Needle valve )/279 l 21 ' 22 4.00 ' 4.00 1.05 1 1.05 22 Secondary venturi .’ . 7/179 Primary throat Secondary throat . Page 10-87/88 § 4.00 10/179 21 22 10/279 7/1 80 7/280 22 22 22 21 21 4.00 4.00 4.00 4.00 4.00 1.10 1.10 1.05 .1 4.00 21 4.00 4.00 1.05 1.10 0.50 0.05 ( 1 l 1.10 0.50 0.50 1.05 0.50 0.50 1.05 0.50 0.50 1.05 0.50 0.50 1.05 0.50 0.50 2.50 l 2.50 2.40 2.40 2.30 2.30 F25 F30 1.75 1 F25 F30 1.75 0.50 1.75 g 0.50 ‘j 1.75 0.50 1.70 F25 F30 1.75 0.50 1.70 F25 F30 1.75 WEBER 28/30' DHTA CARBURETOR 0.50 1.80 F25 F30 1.75 0.50 1.80 F25 F30 1.75 Accelerator Linkage dddfl uudopmummywne . Bushing . Spring . Awelerator table Clip . Support . Cable end . Clip . Bellcrank Lever . Throttle rod . Carburetor . Pedal cover . Accelerator pedal upwewewpe . Bushing Spring . 10. 11. 12. 13. 14. Accelerator ceble Clip Support Cable end Clip Plate Bellcrenk Support Stop bolt Lever Throttle cable Throttle housing 15. Lever 16. Pedal cover 17. Accelerator pedal 102.21 Page 10—89/90 ,.. Fuel Injection System 102.26 Page 10-91 FUEL SYSTEM The fuel system consists of: 0 Fuel tank 0 Fuel pump 0 Fuel filter 0 Fuel manifold 0 Pressure regulator O Injectors 0 Cold start valve FUEL FILTER FUEL TANK FUEL RETURN LINE FUEL MANIFOLD FUEL PUMP INTAKE MANIFOLD COLD START VALVE FUE L PRESSURE REGULATOR FUEL SUPPLY LINE FUEL INJECTORS RETAINERS Page 10-92 AIR INTAKE SYSTEM The air intake system consists of: 0 Vacuum signal for fuel pressure regulator 0 Air filter 0 Air flow sensor 0 Bypass channel for air conditioning 0 Auxiliary air regulator Am CONDITIONER INTAKE MANIFOLD POWER COLD START E: i PRESSURE l? III E LE REGULATOR CARBON / CANISTER FUEL MANIFOLD : \ Cl, AC IDLE STEP UP ELECTRO VALVE AIR FILTER lessees ' ) FUEL DISTRIBUTOR VACUUM J AUXILIARY AIR REGULATOR —U—-I.I-I.I—“ AIR FLOW SENSOR NOTE: Air leaking into the system after the air flow sensor will not be sensed. This will result in a wrong fuel/air mixture and will affect engine operation. 102.26 Fuel Injection System Page 10—93 ELECTRICAL SYSTEM The electrical system consists of: I Relay set 0 Electronic control unit I Throttle plate switch 0 Air temperature sensor 0 Battery 0 Ignition switch cranking position 0 Inline fuse 0 Coolant temperature sensor 0 Air flow sensor 0 Cold start valve and thermo time switch circuit In addition to the fuel injection electrical system, the following items are used: 0 Ignition coil 1 HIGH ALTITUDE "1— \ i Iggg'ifgggé l ., | \ I“ a: 1': 1 i -; . AUXILIARV AIR REGULATOR 45 15 mfg” SWITCH "> 2' > 2=> 35> 1/ A—lan i " I2)..—. . 4‘ H, 45 mi COLD START 3 VALVE (.54. :- 4 :>< ’ “T ———>‘<°‘°€" 3.4.5“ 4'— mt « ?( "’ D ‘ m)— I iii 9%. 5‘ l T 2! \ All I ”(— Am FLOW SENsOR IE> .1) >96: F ’ ’ I FUSE ’°,0 finch—r n RELAY SET i BATTERY -. 29 Is). A 30) I5 A 3' INJECTOR FUEL pump (5 ‘ ? ’ . 2 > a) 3 > ll 3 (.l—g" THROTTLE PLATE SWITCH IS“ {I3 , x A u) . I ‘1’ -Il-< .— Pill, I . I ‘ ' ‘— _ _______________________ . COOLANT TEMPERATURE SENSOR [— «4—4? l ' 4: LAMBDA - SENSOR IGNITION SWITCH \No—Ma: )- 9 a as 26) 24>- COIL r an: Page 10-94 RELIEVING FUEL PRESSURE CAUTION: Relieve fuel system pressure before disconnecting fuel lines. Remove vacuum hose (3) from fuel pressure regulator (2). Connect vacuum pump (1) to regulator (2). Pump vacuum up to 20 inches. 1. Vacuum pump 2. Pressure regulator 3. Vacuum hose FUEL PRESSURE CHECK NOTE: Use this check to determine if fuel pump is operating properly and to check for restrictions in fuel lines. Relieve fuel system pressure as directed in above procedure. Provide a container to catch any fuel. Use caution to prevent any dirt from entering system. Loosen clamp holding fuel hose (3) to cold start valve (1). off valve. CAUTION: Use care in pulling hose off valve. Valve body is plastic. Connect "Y" fitting (2) on gauge assembly A.95874 (4) to fuel hose. Secure hose with clamp. Connect hose on gauge assembly to cold start valve. Secure hose with clamp. Disconnect vacuum hose from fuel pressure regulator. Disconnect hose from airflow sensor. With ignition key switched to ”MAR" (on) position, move air flow sensor until fuel pump is energized. Check pressure reading. Pressure should be 33 to 39 psi (23 to 2.7 bar). Start engine and operate at idle. Connect vacuum hose to pressure regulator. Check pressure reading. Pressure should be approximately 28 psi (2 bar). Relieve fuel system pressure. Remove gauge assembly and reconnect hoses. NOTE: Fuel pump output pressure is 39-45 psi (2.7 to3.2 bar). To check pressure, connect gauge directly to fuel supply line. Leave remainder of system disconnected. 3 1. Cold start valve 2. "Y” fitting 3. Fuel hose 4. Gauge assembly Fuel Injection System 102.26 Page 10-95 IDLE SPEED ADJUSTMENT NOTE: Engine must be at normal operating temperature with cooling fan off when adjusting idle Speed. Connect tachometer. Run engine until it reaches normal operating temperature. Adjust idle speed adjustment screw (1) to obtain 800 to 900 RPM. 1. Idle Speed adjustment screw MIXTURE CHECKING AND ADJUSTMENT To check mixture, first connect test equipment as follows: Remove plug (1) from C0 pickup fitting. Install adapter probe 4467 in pickup. Connect hose from CO analyzer to probe. Turn analyzer on to allow for proper warmup of equipment. Start engine and allow it to reach normal operating temperature. NOTE: Engine is at normal Operating temperature when cooling fan has been on twice. 1. Plug Zero analyzer amording to manufacturer's instructions. Disconnect harness wire (1) from Lambda sensor connector (2). making sure that wire cannot ground out. Check CO reading. Reading should be 0.5% to 0.9%. 1. Lambda sensor harness wire 2. Lambda sensor connector Page 10-96 To adjust mixture. proceed as follows: NOTE: On 1981 and later models, Federal law prohibits routine adjustment of mixture. Adjust mixture only if major engine repairs have been performed or main fuel injection components have been replaced. If mixture screw is concealed by a plastic plug, remove plug. if mixture screw is concealed by an aluminum plug, refer to MIXTURE ADJUSTMENT SCREW PLUG REMOVAL AND INSTALLATION betore performing this procedure. Turn adjustment screw clockwise to increase CO level, and counterclockwise to decrease CO level. install plug in air flow sensor (1). WARNING: In the next step. be very careful in removing probe and installing plug. Exhaust pipe could be very hot. Remove CO analyzer, remove probe. and install plug in exhaust pickup. 1. Air flow sensor 2. Screwdriver MIXTURE ADJUSTMENT SCREW PLUG REMOVAL NOTE: On 1981 and later models. Federal law prohibits routine adjustment of mixture. Remove aluminum adjustment screw plug to adjust mixture only if major engine repairs have been performed or main fuel injection components have been replaced. Center punch aluminum plug [1) sealing mixture adjustment screw in the air flow sensor (2). Drill a 3/32 in. (2.5 mm) hole, approximately 9/64 to 5/32 in. [3.5 to 4 mm} deep. in the center of plug. NOTE: Clean all metal shavings from around area. 1.Aluminum plug 2. Air flow sensor 3. 3/32 in. (2.5 mm) drill Screw a 1/8 in. (3 mm) sheet metal screw(1)into drilled hole. Grasp the screw with a pair of pliers and lift screw and aluminum plug (2) out from air flow sensor. 1. Va in. {3 mm] screw 2. Aluminum plug .‘ Fuel Injection System INSTALLATION NOTE: To comply with Federal law. replacement plug must be installed after mixture adjustment. Seat new replacement plug (1) in recess of air flow sensor (2). Use a hammer to drive plug in flush with unit. 1. Plug 2. Air flow sensor ELECTRONIC CONTROL UNIT REMOVAL AND INSTALLATION Working behind passenger's seat. remove spare tire cover and spare tire. Push in clip holding electrical Connector (1) to electronic control unit (2), and unplug connector from unit. Remove two nuts (3) holding control unit to body. and remove control unit. Install in reverse order. 1. Electrical connector 2. Electronic control unit 3. Nut FUEL INJECTOR COOLING FAN REMOVAL AND INSTALLATION Loosen clamp (1) holding fresh air duct (2) to fan duct. Disconnect wire (3) at connector. Remove four bolts (5 and 6) holding fan mounting plate (4) to body and remove fan assembly. Install in reverse order. Make sure ground wire is installed under mounting bolt. 1. Clamp 2. Fresh air duct 6. Bolt 3. Wire 4. Mounting plate 5. Bolt 102.26 Page 10-98 LAMBDA SENSOR REMOVAL AND INSTALLATION NOTE: The Lambda sensor must be replaced every 30.000 miles. Allow exhaust system to cool. Disconnect cable (2) from sensor (1). Remove sensor from exhaust pipe (3). 1. Lambda sensor 2. Cable 3, Exhaust pipe Coat threads of new Lambda sensor with anti-seize, antr- rust grease. CAUTION: Do not allow grease to get on sensor surface. This will contaminate sensor and require re- APPLY ANTI-SEIZE COMPOUND HERE placement. Thread sensor into exhaust pipe. Torque sensor to 30 to 36 ft. lbs. (4.2 to 5.0 mkg). Connect cable to sensor. M\ _//"" INDICATOR RESET NOTE: Lambda sensor indicator comes on at 30.000 miles to indicate replacement of sensor. To turn indicator off, the switch unit must be reset. Working from passenger's side footwell, reach behind center console {3} to gain access to switch unit (1). Remove wire securing cap screw (2). Remove cap screw. Insert a small screw driver through housing and press on switch contact. Contact will reset to high point on wheel. install cap screw. Secure screw with new wire. 1. Switch unit 2. Cap screw 3. Center console DO NOT _ APPLY HERE Fuel Injection System THROTTLE PLATE SWITCH REMOVAL AND INSTALLATION Disconnect electrical connector to throttle plate switch. Remove two screws (1) and washers holding switch (2) to throttle housing (3). Remove switch by slowly pulling switch out from housing. Install in reverse order. making sure switch is pmperly aligned with throttle shaft (4). l. Screws 2. Switch 3. Throttle housing 4. Throttle shaft ADJUSTMENT Make sure idle speed is correct. Disconnect electrical connector from throttle plate switch. Connect an ohmmeter between terminals 2 and 18 of the throttle plate switch. Loosen two screws (1 ) holding throttle plate switch (3) to throttle housing (2). With engine oil, rotate switch clockwise until ohmmeter indicates a closed circuit. At the exact point the ohmmeter indicates a closed circuit. tighten the two screws holding switch. Recheck the adjustment and replace the connector to the throttle plate switch. 1. Screws 2. Throttle housing 3. Throttle plate switch 102.26 Page 10-99 Page ‘I 0- 1 00 FUEL PRESSURE REGULATOR REMOVAL AND INSTALLATION Relieve fuel pressure as directed under RELIEVING FUEL PRESSURE. Provide a container to catch any fuel. Use care to prevent any dirt from entering system. Disconnect vacuum hose (2) and fuel return hose (6) from pressure regulator (3). Disconnect fuel manifold connection (1 I from pressure regulator. Remove nut I5) holding regulator to fuel manifold. Remove pressure regulator. Install in reverse order. Check all fuel connections for leaks. 1. Fuel manifold 2. Vacuum hose 5. Nut 6. Fuel return hose 3. Pressure regulator 4. Bolt COLD START VALVE REMOVAL AND INSTALLATION Relieve fuel pressure as directed under RELIEVING FUEL PRESSURE. Provide a container to catch any fuel. Use care to prevent any dirt from entering system. Disconnect electrical connector [3) from cold start valve (1). Remove clamp (6} holding fuel hose (5) on valve. Pull fuel hose off valve. CAUTION: Use care in pulling fuel hose off valve. Valve body is plastic. Using a 5_mm Allen wrench, remove two screws (2 and 6) holding valve in intake manifold (7). Remove valve and ”O” ring {3). Install in reverse order. Make sure fuel hose is completely installed on valve and hose clamp is tight. Check fuel connections for leaks. 8, “O" ring AUXILIARY AIR REGULATOR REMOVAL AND INSTALLATION Disconnect regulator air hose from intake manifold near cold start valve. Disconnect regulator air hose and charcoal canister hose from fitting in bottom of main air supply hose. Disconnect electrical connector (1} from regulator {8). Using a 5 mm Allen wrench, remove two bolts (4) and washers holding regulator to cylinder block. Remove regulator with hoses (2 and 6) attached. and remove hoses from regulator. Install in reverse order. Make sure air hose connections are tight and that clip (5) is installed under clamps on regulator. 1. Electrical connector 6. Air hose 7. Clamp 2. Air hose 3. Clamp 4. Allen bolt 8. Auxiliary air regulator 1. Cold start valve 2. Allen screw 3. Electrical connector 4. Allen screw 5. Fuel hose 6. Clamp 7. Intake manifold 5. Clip 1 I Fuel Injection System y AIR FLOW SENSOR REMOVAL AND INSTALLATION ! Disconnect both air hoses from each side of air flow sensor (1 ). | Disconnect electrical connector from sensor. | Remove bolt (2) and lockwasher holding clamp (3) to bracket (5). Remove clamp and spacer (8). Remove two bolts (7) Iockwashers, washers. and bushings (6) holding air flow sensor to bracket. Be careful not to drop washers on either side of rubber bushing under front side of sensor. Install in reverse order. making sure rubber bushing is installed under sensor and air hose connections are tight. I 1. Air flow sensor 5. Bracket 2. Bolt 6. Bushings 3, Mounting clamp 4. Bushing 7. Bolts 8. Spacer FUEL INJECTORS REMOVAL Relieve fuel system pressure as directed under RELIEVlNG FUEL PRESSURE. Provide a container to catch any fuel. Use care to prevent any dirt from entering system. NOTE: Before disconnecting any fuel hoses, place a rag beneath them to catch any spilled fuel. Disconnect the following: Fuel supply hose (2) from tube. fuel return hose (5) from pressure regulator (7). vacuum hose {6) from pressure regulator, fuel hose from cold start valve (1 ), and main air supply hose (3) from throttle housing (4). CAUTION: Use care in pulling fuel hose off of cold start valve. Valve body is plastic. 1. Cold start valve 2. Fuel supply hose 3. Main air supply hose 4. Throttle housing 5. Fuel return hose 6. Vacuum hose 7. F ual pressure regulator Disconnect the following: accelerator cable (1) from linkage. electrical connectors from throttle plate switch (2) and cold start valve (4), auxiliary air regulator hose (5) from intake mani— fold, and crankcase evaporative bypass hose (3) from intake manifold. Remove two bolts (6) holding fuel manifold and pressure regw later to air intake. Remove washers from either side of bushings in fuel manifold brackets. 1. Accelerator cable 2. Throttle plate switch 3. Bypass hose 4. Cold start valve 5. Auxiliary air regulator hose 6. Bolt 102.26 Page 10-101 Page 10-102 Remove two nuts (8i and washers holding intake manifold cooling air duct (6) to studs (4) on manifold (5). Disconnect cooling air hose from duct. Remove duct. Remove four nuts (2) and washers holding air intake to mani— fold. Carefully lift air intake off studs (4) in manifold. Tilt air intake backwards. 1. Air intake 2. Nut 3. Gasket 4. Stud 5. Cooling air duct 7. Nut 8. Nut 5. Manifold Disconnect electrical connectors from fuel injectors. Using a 4 mm Allen wrench, remove two bolts (4) and washers holding fuel injectors (3) in intake manifold (2). Remove fuel injectors and adapters (1) from manifold. Be careful not to damage bushings and "0" rings on injectors and adapters. Remove fuel manifold. 1. Adapter 2. Intake manifold 3.‘Fuel injectors 4. Allen bolts Remove small [5] and large (2) rubber bushings and retainer s {6) from injectors {1 ). Remove “0“ ring (3) from adapter (4). Inspect bushings and ”0" rings for cracks and damage. 1. Fuel injector 5. Small bushing 2. Large bushing 6. Retainer 3. "O" ring 4. Adapter Fuel Injection System 102.26 Page 1 0-1 03 IINSTALLATION NOTE: When replacing a defective injector. replace both the injector and hose. To replace injector (1), pull hose (3) off fuel manifold (5). Use a twisting, rocking motion while pulling on hose. To replace a damaged hose on a good injector, cut hose at both ends and remove it. When installing new hose on injector, place collar (2 and 4) over shoulder of injector and manifold. Push hose on injector and manifold until hose end is inside collar and collar is tight against shoulder. To complete installation. reverse removal procedure. Make sure retaining bolts are tight. Check all fuel and air connections for leaks. 1. Injector 2. Collar 3. Hose 4. Collar 5. Fuel manifold THROTTLE PLATE REMOVAL AND INSTALLATION NOTE: The upper air intake should be removed for ease of access to throttle plate. Mark lines, hoses and wires prior to removal to identify for installation. Loosen clamp (2) and disconnect air supply hose (1) from throttle housing (12). Disconnect electrical connectors (3 and 7) from throttle plate switch (4) and cold start valve (6). Disconnect vacuum hoses (8, 10, and 11) from air intake (5). Remove clamp (9) holding fuel hose on cold start valve. Pull fuel hose off valve. CAUTION: Use care in pulling fuel hose off valve. Valve body is plastic. 1. Air hose 2. Clamp 3. Cennector 4. Throttle plate switch 5. Air intake 6. Cold start valve 7. Connector 8. Vacuum hose 9. Clamp 10. Vacuum hose 11. Vacuum hose 12. Throttle housing Disconnect throttle shaft cable (2) from linkage (4) by remov- ing spring clip (3). Disconnect cable from throttle lever (8). Disconnect vacuum hoses (6 and 7) from air intake (9). Remove two bolts (1) holding fuel manifold and pressure regulator (5) to air intake. 1. Bolt 2. Throttle shaft cable 3. Spring clip 4. Throttle linkage 5. Fuel pressure regulator 6. Vacuum hose 7. Vacuum hose 8. Throttle lever 9. Air intake Page 10-104 Remove two nuts (8) and washers holding intake manifold cooling air duct (6) to studs (4) on manifold (5). Disconnect cooling air hose from duct. Remove duct. Remove four nuts (2) and washers holding air intake to mani- fold. Carefully lift air intake off studs (4) in manifold. Tilt air intake backwards. 1.Air intake 2. Nut 6. Cooling air duct 3. Gasket 7. Nut 4. Stud 5 Manifold 8. Nut Remove two screws and washers and remove throttle plate switch. Working through throttle housing, remove two screws (6) and washers and remove throttle plate (5). If necessary to remove throttle shaft (2), remove two springs (1 and 11). Pull throttle shaft out of housing. 1. Spring 6. Screw 2. Throttle shaft 3. Seal 4. Bushing 5. Throttle plate '1'. Bushing 8. Seal 9. Cam 10. Plate 11. Spring Assemble and install in reverse order. Check all fuel connections for leaks. After installation, adjust throttle plate as follows: NOTE: Engine must be at normal operating temperature and cooling fan off when adjusting idle speed. Connect tachometer. Run engine until it reaches normal operating temperature. Turn idle speed adjustment screw (2) in all the way. Adjust stop screw (1) to obtain 700 to 800 RPM. Hold stop screw and tighten locknut. Adjust idle speed adjustment screw (2) to obtain 800 to 900 RPM. Hold adjustment screw and tighten locknut. Check that throttle plate switch is adjusted properly as direct- ed under THROTTLE PLATE SWITCH ADJUSTMENT. 1. Throttle stop screw 2. ldle speed adjustment screw Exhaust and Emission Control System 102.58 Page 10405 1. Engine air cleaner 2. Air distribution line 3. Vacuum tapping line far thermovalve 22 4. Heated water line for thermovalves and automatic choke 5. EGR valve control line 6. 6q valve control elactrovalve-three-wav '1'. Gulp valve 8. EGFI valve 9. Automatic choke 10. Exhaust gas line from EGR valve to intake manifold and gulp valve line to intake manifold 11. Air pump and pressure relief valve 12. Power valve 13. Vacuum accelerator pump 14. Vacuum tapping lines for alectrovalves 6 and thermovalves 20—21 15. Advance capsule vacuum tapping line 15. Check valve lwith air pumpI reed valve (without air pump) 1?. Vacuum advance capsule 18. Electrovalve 6 control thermoewitch 19. EGR valve tapping line 20. Vacuum accelerator pump control thermovalve 21. Power valve control thermovalve 22. EGR valve control tharmovalve 23. Electrovalve 6 vacuum tapping line 24. Catalytic converter AIR INDUCTION l??- “K u'llil'lvml'lfllflllflfll'flflfllllliflifll.II'IIIIII'II'MIE "'14” ll- EXHAUST EMISSION CONTROL SYSTEM (VEHICLES WITH CARBURETOR) l/J AIR INJECTION Page 10-106 DISTRIBUTOR VACUUM CAPSULE I O CARBURETOR \ VACUUM ACCELERATOR EMISSION VACUUM CONTROLS Exhaust and Emission Control System 102.58 Page 1 0-1 07 1. Outlet 2. Flame trap 3. Bypass 4. Valve 5. Intake 6. Hose 7. Cvclonic trap 8. Return Iine 1. Intake maniiold 2. Throttle plate 3. Bypass hose 4. Flame trap 5. Hose 6. Cyclonic trap 7. Return line VEHICLES WITH FUEL INJECTION CRANKCASE EMISSION CONTROL SYSTEM Page 10-108 1. Fuel filter 2. Carburetor 3. Charcoal canister 8 4. Filler cap 5. Two-way valve 6. Separator 7. Check valve 7 I f 0 ¢ 1 2 8. Fuel pump 9. Fuel tank 0 \ 6 ul— FFIONT ‘ ...___ 9 i --—I-- I T :P / ——-- 5 4 3 VEHICLES WITH CARBURETOR 1, Fuel injectors 2. Fuel manifold 3. Charcoal canister 4. Intake manifold 5. Cold start valve 6. Fuel pressure regulator 7. Filler cap 8. Two-way valve 9. Twu-way safety relief valve 10. Separator 11. Fuel pump 12. Fuel filter 2 3 FRONT VEHICLES WITH FUEL INJECTION FUEL EVAPORATIVE EMISSION CONTROL SYSTEM Exhaust and Emlsslon Control System 102.58 Page 10409 AIR PUMP REMOVAL AND INSTALLATION Remove three bolts (1) holding upper half of timing belt cover (2) to engine and remove cover. Loosen clamps (3) retaining air pump intake (5) and pressure (4) hoses and remove hoses. 1. Bolts 2. Timing belt cover 3. Clamps 4. Pressure hose 5. Intake hose Remove adjusting bolt (4) and slip drive belt (3) off of pulley. Remove pivot through bolt (2) and remove air pump (1). Installation is reverse of removal. To adjust belt, refer to 101 .15. 1. Air pump 2. Pivot bolt 3. Drive belt 4. Adjusting bolt GULP VALVE REMOVAL AND INSTALLATION Remove two vacuum hoses (4) from gulp valve (1). Remove air hose (2) lrom gulp valve. Remove nut (3) and washer holding gulp valve to bracket and remove gulp valve. Installation is reverse of removal. I. Gulp valve 2. Air hose 3. Nut 4. Vacuum hoses Page 10-110 EGR VALVE REMOVAL AND INSTALLATION Remove access panel from inside trunk. Remove three nuts (1 ), bolt (5) and washers to remove tube (2), spacer (21 ) and gasket(20). Remove two nuts(4), washer and shieldi3). Unscrew fitting (19) to remove tube (6). Remove gasket (7) and seal (18). Disconnect vacuum line (17) from EGR valve (9.). mseeswvr Remove bolts (8 and 14) and washers to remove EGR valve and gasket (13). Loosen clamp (15) to disconnect water hose (16) from water manifold. Remove two bolts (10) and washers to remove mounting base (11) and gasket (12). Installation is reverse of removal. Replace all gaskets. Nut Tube . Shield Nut Bolt Tube Gasket . Bolt ”Nddflfifldddd—i dawmummw-aoo . EGR valve . Bolt . Mounting base . Gasket . Gasket . Bolt . Clamp . Water hose . Vacuum line . Seal . Fitting . Gasket . Spacer Exhaust and Emission Control System 102.58 Page 10-111 CHECK VALVE OR REED VALVE REMOVAL AND INSTALLATION Remove clamp (2) holding hose (1) to valve (3). Loosen locknut (4) and unscrew valve from engine. Installation is reverse of removal. 1. Hose 2. Clamps 3. Valve 4. Locknut CHARCOAL CANISTEFI REMOVAL AND INSTALLATION Cut off clamps (1) retaining vacuum hoses (4 and 5) to charcoal canister (2). Remove two nuts (3) and washers holding charcoal canister to bracket and remove canister. Installation is reverse of removal. Use new clamps on vacuum hoses. ‘l. Clamp 2. Charcoal canister 3. Nut 4. Vacuum hose 5. Vacuum hoses CATALYTIC CONVERTER REMOVAL AND INSTALLATION (Vehicles With Carburetor) WARNING: Make sure converter has cooled down before working on it. Straighten lock tabs and remove four nuts (6) and bolts attaching exhaust pipe flange (3) to converter outlet flange (7). Remove bolt (1) holding support bracket (3) to muffler. Straighten lock tabs and remove four nuts (5) attaching converter inlet flange (4) to exhaust pipe flange. Remove support bracket. Separate exhaust pipe flange and converter outlet flange. then pull converter ( 1) off of studs and out of vehicle. Installation is reverse of removal. 1. Catalytic converter 2. Bolt 3. Bracket 7. Outlet flange 8. Flange 6. Nuts 4. Inlet flange 5. Nut Page 10-112 REMOVAL AND INSTALLATION (Vehicles With Fuel Injection) WARNING: Make sure converter has cooled down before working on it. Straighten lock tabs and remove four nuts (1) and bolts attaching exhaust pipe flange (2) to converter inlet flange (3). Remove two bolts (5) holding exhaust system bracket (6) to transmission bracket (4). Straighten lock tabs and remove four nuts (8) attaching converter outlet flange (7) to exhaust pipe flange. Remove exhaust system bracket. Maneuver converter (9) off of studs and out of vehicle. Installation is reverse of removal. 1. Nuts 2. Exhaust pipe flange 3. Converter inlet flange 4. Transmission bracket 5. Belts 6. Bracket 7. Outlet flange 8. Nuts 9. Catalytic converter EXHAUST SYSTEM REMOVAL AND INSTALLATION (Vehicles With Carburetor) Remove rear access panel from inside trunk. Remove two nuts (3) and clamp (2) attaching exhaust pipe (4) to manifold (1). 1. Exhaust manifold 2. Clamp 3. Nuts 4. Exhaust pipe Raise and support rear of vehicle. Remove six screws and four bolts retaining rear grille assembly and remove grille assembly. Disconnect six springs (1 and 3) supporting muffler (2) and lower complete exhaust system out vehicle. Installation is reverse of removal. 1. Springs 2. Muffler 3. Springs Exhaust and Emission Control System 102.58 Page 1‘04 13 1O 6. Flange 7. Bracket 1. CIamp 2. Flange 3. Stud 8. Catalytic converter 9. Bracket 4. Exhaust pipe 10. Muffler assembly 5. Locking ring EXPLODED VIEW OF EXHAUST SYSTEM (VEHICLES WITH CARBURETOR) REMOVAL AND INSTALLATION (Vehicles With Fuel Injection) From inside trunk. remove floor mat. insulation panel. and access panel. Unplug Lambda sensor connector and remove Lambda sensor {4) from exhaust pipe [3). Remove three nuts (2) attaching exhaust pipe to manifold (1). 1. Exhaust manifold 2. Nuts 3. Exhaust pipe 4. Lambda sensor 11. Springs 12. Looking ring 13. Looking ring 14. Stud 15. Spring Page 10-114 Raise and support rear of vehicle. Remove six screws and four bolts retaining rear grille assembly. and remove assembly. a Remove two bolts l2l holding exhaust system support bracket {3) to transmission bracket. Disconnect six springs (1 and 4) supporting muffler (5) and lower complete exhaust system out from vehicle. installation is reverse of removal. 2. Bolts 3. Support 4. Springs 5. Muffler . Locking ring seasons- 1. Springs . Exhaust pipe . Lock plate Muffler assembly Springs Flange . Bracket 8 . Catalytic converter . Stud EXPLODED VIEW OF EXHAUST SYSTEM (VEHICLES WITH FUEL INJECTION) 1. 2. 3. 4. 5. 6. 7. 3. 9. Breather hose Flame trap Seal Blow-by gas and oil vapor hose Oil filler cap Oil pressure switch Breather oil return pipe Cyclonic trap Dipstick ‘ Lubrication 103.01 Page 10-115 11. 12. 13. 14. 15. 16. 1?. 13. 19. Oil filter connector Dipstick seal Oil pump Bushing Oil pump drive gear Oil filter Auxiliary shaft Bushings Gasket 10. Gasket LUBRICATION SYSTEM COMPONENTS Paoe10-116 £25 5:..3 at 83.5 BE :0 oni :263 9:3 .5 can: 3:! 2885 :0 QE3 :0 9.9; 309.5 N— .2. .2 .m .N .h ZOFiOEflDJ mZEZm :0 .95.... .m 0:: 5.6 .3 an: 9:2. __o .m 9 52.: =0 30:43". an. 239... .23::% Edmwsa 2ft 8:30:83 £558 uni 32:6 33% as... 3.63:5 .3 .v .m 25:55 £21.50 uca 8:2 .— :0 .u 3.3.5 SE Lubrication OIL PUMP ASSEMBLY comma-rho)» 1. Pump housing . Cover plate . Pressure relief valve . Spring . Washer . Drive gear . Driven gear . Oil intake pickup REMOVAL AND INSTALLATION (Engine in vehicle) Drain oil sump. Remove bolts and washers holding sump to engine and remove sump. Remove three bolts (2) and washers holding oil pump (3). Remove pump and gasket. Installation is reverse of removal. When installing pump, make sure it is seated before tightening bolts. Clean sump gasket surfaces thoroughly. Install all new gaskets. 1. Oil return pipe from breather 2. Bolt 3. Oil pump INSPECTION Carefully clamp pump body in a vise. Remove three bolts holding pickup housing to pump housing {5) and remove. Remove spring (3), relief valve (4) and cover (2). Slide drive shaft with drive gear and driven gear out of housing. Clean all disassembled parts in solvent and blow dry with compressed air. Check housing and cover for cracks. Check intake pickup and oil duct for clogging. Blow clear with compressed air. 1. Pump shaft 2. Cover 3. Spring 4. Reiiefvalve 5. Pump housing 103.01 Page 10-117 Page 10-113 Examine gears for wear. Backlash between gears is .006 in. (0.15 mm) when new. Maxi- mum allowable clearance is .010 in. (0.25 mm). Check gear tooth to pump housing clearance with feeler gage as shown. New clearance ranges from .004 to .007 in. (0.11 to 0.18 mml. Maximum allowable clearance is .010 in. (0.25 mm). Replace housing and or gears if clearances are exceeded. Check clearance between gears and cover mating face. Using a straightedge and feeler gage as shown, clearance range should be .0008 to .0041. in. (.020 to 0.150 mm). if a value of more than .006 in. (0.15 mm) is found, either the gears and or pump housing must be replaced. To determine if gears are worn, measure their length. The range for new gears is 1.101 to 1.102 in. (27.967 to 28.000 mm). The drive gear is mounted on its shaft with an interference fit, check for signs of slack. Clearance between driven gear and its shaft is .0006 to .0022 in. (0.017 to 0.057 mm]. Maximum allowable clearance is .004 in. 0.10 mm). Check clearance between pump drive shaft and pump housing. Clearance range is .0006 to .0023 in. (0.016 to 0.060 mm). Maximum allowable clearance is .004 in. (0.10 mm). Relief Valve Inspection _ Relief valve should be carefully cleaned and inspected. NOTE: Particular care should be given to ensuring that dirt 827 in 21 mm .H- 886 in 22,5 mm Check load characteristics of spring as shown. _ 1 583 In 40.2 mm and residue are removed from between valve and pump housing, otherwise valve may stick. 10.16 $.33 lbs Y kg 4,61 i0,15 11.023 1.33 lbs kg 5 10,15 103.01 Lubrication Page 10-119/120 1.2m 0.32.000 mm 1.2006 01.31020 mm ‘ F ‘13: 1.4041 in. 35,050 mm 1,4049 in. 35,684 mm A - _ f 1.2515 in. 31,940 mm 1.2503 in. 31,900 mm 1.4013 in. 35,593 mm 1.4023 in. 35,510 mm - 1—1‘k SPECIFICATIONS OF AUXILIARY SHAFT AND BORES IN BLOCK AUXILIARY SHAFT Auxiliary shaft (for oil pump, and ignition distributor on non A/C vehicles) should have an absolutely smooth journal. If signs of scuffing or scoring are found, which cannot be removed by an extra-fine abrasive stone, replacement of shaft is recommended. inspect oil pump and ignition distributor drive gear teeth for evidence of chipping or excessive wear. if these are found. replace shaft. Check that auxiliary shaft journal diameters conform to specifications shown. AUXILIARY SHAFT JOURNALS AND BUSHINGS FIT SPECIFICATIONS Bushing inside Auxiliary shaft journal diameter Clearance 1.4041 in (35.604 mm) 1.4013 in (35.593 mm) .0018 in (0.046 mm) 1.4049 in 1.4023 in .0036 in diameter (finish reamed) 10 (35.684 mm) 1.2598 in to (35.618 mm) 1.2575 in to (0.091 mm) .0016 (32.000 mm) (31.940 mm) (0.040 mm) 1.2606 in 1.2583 in .0031 in to (32.020 mm) 1) 10 (31.960 mm) Drive end bushing to (0.000 mm) 2) Inside bushing. Radiator and Fan 104.01/.09 Page 10-121 msewewwd . Fan shroud Thermostatic switch Relay . Radiator Support bracket Bleed screw Fan assembly . Rubber pad EXPLODED VIEW OF RADIATOR AND ELECTRIC FAN RADIATOR REMOVAL AND INSTALLATION NOTE: If vehicle is equipped with air conditioning, remove and install as directed in CONDENSER REMOVAL AND INSTALLATION. Refer to 501.03. Raise and support front of vehicle. Drain cooling system. Disconnect connector (4) for electric fan (3). Disconnect connector for thermostatic switch (8). Loosen clamps (1 and 7) and disconnect radiator hoses (2). Remove two nuts (9) holding support bracket (5), and lower radiator out of vehicle complete with fan. Install in reverse order. 1. Clamp 2. Hosa 3. Electric fan 4. Connector 5, Support bracket 6. Radiator 7. Clamp B. Thermostatic switCh 9. Nut Page 10-122 FILLING AND BLEEDING Remove rubber plug (1) from front of luggage compartment. Using an 8 mm hex wrench, loosen radiator bleed screw. Pour coolant slowly into expansion tank until coolant begins to run out of bleed screw. Close bleed screw. Complete filling of expansion tank. Start engine and move heater temperature control lever to warmest position. Accelerate engine to circulate coolant. Turn engine off. Bleed system through bleed screw until coolant is free of bubbles. 1. Rubber plug TESTING Attach tester (I) to expansion tank. Pump in air'until pressure of 14 psi is built up. If system does not hold pressure, check for leaks. Test cap (3) by applying pressure with tester as shown. Check that vent valve opens at 11 psi. 1.Tester 2. Union 3. Radiator cap ELECTRIC FAN REMOVAL AND INSTALLATION Disconnect connector (1) for fan (2). Remove four nuts (3) holding tan assembly to radiator (4) and remove Ian assembly. Install in reverse order. 1. Connector 2. Fan 3. Nut 4. Radiator 104.02 Water Pump and Ducts Page 10-123 FROM BLOCK Thermostat starts to open at 172° to 183°F (78° to 84°C]. Thermostat is fully open at 194° to 201°F (90° to 94°C]. 3 1. Union for coolant reservoir 2. Union for water pump inlet pipe 3. Union for water inlet hose from radiator 4. Union for water outlet hose to radiator \ I / THERMOSTAT FULLY OPEN 3 OPERATION OF BYPASS THERMOSTAT Page 10-124 WATER PUMP REMOVAL AND INSTALLATION If equipped with air pump, remove top half of timing belt cover. Remove air pump and drive belt. Remove alternator (1}, drive belt, and alternator mount (2). 1. Alternator 2. Alternator mount If equipped with air conditioning, remove compressor with hoses attached and set to one side. Remove compressor mount. Remove two bolts (2) holding water pipe (3) to water pump l4) and disconnect pipe. Remove four bolts (5) holding pump to block and remove pump and gasket. Installation is reverse of removal. Use new gaskets. 1.A/C compressor mount 2. Bolt 3. Water pump 4. Bracket 5. Bolt THERMOSTAT ASSEMBLY REMOVAL AND INSTALLATION Drain cooling system to below thermostat assembly level. Remove clamps (2, 5. and 7) from three large hoses and two coolant recovery hoses (3). Remove hoses from assembly. On fuel injected vehicles, remove coolant temperature sensor connector (6]. Remove three bolts (1) holding thermostat assembly (4) to cylinder head. Remove assembly and gasket. 1. Bolt 2. Clamp 5. Clamp 3. Coolant recovery hoses 5. Coolant temperature sensor 4. Thermostat assembly 7. Clamp Water Pump and Ducts 104.02 Page 10-125/126 To remove thermostat from assembly. remove three bolts (6) and washers holding housing cover (5) to housing (1). -Remove thermostat l3) and seal (2) from housing. Installation is reverse of removal. Use new gaskets. 1. Housing 2. Seal 3. Thermostat 4. Gasket 5. Housing cover d 6. Bolt 1_. Hose 2. Hose 3. Hose 4. Thermostat assembly 5. Hose 6, Water manifold 7. Gasket 8. Water pump 9. Gasket EXPLODED VIEW OF WATER PUMP AND DUCTS ‘ Service Tools 10A Page 10-127 w k a 4467 A.50113 Oil sump drain plug spanner A.50‘|21 Crankshaft pully nut spanner Exhaust gas analyzer adapter for fuel—injected vehicles wax 4852 A.50131 Adapters for tightening 19 mm hex cylinder head nuts. intake side A.50132 Adapter for tightening camshaft box bolts A.50172 Adapters for tightening 17 mm hex cylinder head bolts. intake side A.60041 Cylinder head support A/C belt tension tool A.10061 Engine stand A.40026 Extractor for water pump Impeller A.40052 Cylinder head extractor Page 10-128 A.6031‘l Oil filter remover Valve leak test tools E l. A.60054 WW - A.60041/2 i 3 " ‘” -.0I.*- A.60313 Drift for inserting valve guide seals A.60326 Drift for removing oil pump distributor drive gear bushing A.60368 Flange and bushing for positioning crankshaft on grinder Driit for removing and inserting smal|~end bushing A.60183 Expanding tool for piston rings A.60303 Tool for inserting gudgeon pin circlips an 9;. iiiiiiiliii A.60370 Tool kit for testing cylinder head for leaks gm A5031 1 Valve spring compressor A.60372 Drift for removing and fitting auxiliary shaft bushing 10A Service Tools Page 10-129 _______fl A.60459 Engine cranking tool ' “ Marten-neon: A.60373 Tool for removing and fitting water pump pully and positioning impeller A.60395 Drift for removing valve guides A.60421 Tappet pressure lever ‘ A.60442 A.60462 m-m.,m Cylinder head base plate A.60473 ._ J .. Drift for fitting valve guides a; t Camshaft sprocket lock ”PM“ /' A.60455 Cylinder head support for removing tappet shims A.60498 Auxiliary shaft sprocket lock Page 1 0-130 H m M A.60592 Lifting tackle for removing and refitting engine _"l A.601001/231 Engine mounting bracket, flywheel side, for rotating engine stand A.70577 Support for removing and refitting power unit - Use with hydraulic jack A.76036 Jumper cables with starter motor attachment terminals for rotating engine during tappet adjustment A3064!) "'_— I'- Flywheel leek A.86010 Drive (10 mm) for fitting crankshaft G“ welch plugs A.61001/27 Engine mounting bracket, valve gear slide, for rotating engine stand A.87001 Special pliers for removing tappet shims 10A Service Tools Page 10-131 lit-£14134. .W A.90308 Expanding reamer (22 mm) for small- end bushings A.94016/10 Seat cutter (10 mm) for crankshaft plugs (use with A.94016l W A.90310 Finishing reamer (8 mm) for valve guide bores A.95113 Feeler gages for checking tappet clearance A.90365 Auxiliary shaft bushing raamer A.95|24 Set of calibrated wires for adjusting throttle valve A.94016 Mandril for operating reamer A.95136 Gage for checking float level Page 10-132 AS5751 Tool for checking toothed timing belt tension A.9_5868 Valve seat tester A.96‘l48 Standand bore gage (86 mm) A.96219 Gage for checking valve stem height A.96238 Combustion chamber depth gage :- X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 CLUTCH - 18 PARTS CATALOG. SERVICE MANUAL & SERVICE TIME SCHEDULE CODE 18 18 181.03 181.09 18A specifications...............................' ..... Torque Specifications ............................. Clutch Hydraulic Release Control ................... Clutch ............................................ Service Tools ...................................... Page 18-1 18-1 18-3 18-7 18-9 18 Clutch . Page18-1 V/“*" c SPECIFICATIONS MM IN. DESCRIPTION Type ............................................. .......... Dry, single plate, diaphragm spring. Hydraulically controlled. Selfadjusting, with no pedal free travel. Clutch disc. ............................................... With friction linings Lining O.D ................................................ 7.5 190 Lining l.D .................................., ................ 5 .1 130 Max. runout of disc linings ................................ 0.008 0.2 0.335 to 0.374 8.5 to 9.5 Master cylinder bore ...................................... 3/4 19.05 Operating cylinder bore ................................... 3/4 19.05 Diaphragm spring travel corresponding to a minimum pressure plate travel of not less than .067 in. (1 .7 mm) ............................ TORQUE SPECIFICATIONS TOROUE FIGURE Ft. Lb. Kgm DESCRIPTION THREAD N-m Bolt, clutch to flywheel ............................ M 8 38.2 3.9 28 Bolt, clutch release fork ........................... M 8 26.5 2.7 19.5 Bolt, operating cylinder ............................ M 8 26.5 2.7 19.5 Bolt, operating cylinder support plate to transmission case. . . . . ...................... M 8 26.5 2.7 19.5 Nut, master cylinder to support bolt ................ M 8 24.4 2.5 18 Page 1 8-2 CLUTCH COVER AND CLUTCH DISC Clutch Hydraulic Release Control /’-\» 181.03 Page 18-3 CHECKING FLUID LEVEL Remove cap from reservoir (1 ) and check fluid level. Fluid should be up to neck of reservoir. lf level is low, check fluid lines, master cylinder and operating cylinder for leakage. 1. Clutch fluid reservoir BLEEDING CLUTCH CIRCUIT Connect a hose to bleeder screw (1) on operating cylinder (2). Place other end of hose in a container filled with fluid. Loosen bleeder screw. Have an assistant pump clutch pedal until all air bubbles stop. With pedal held to floor, remove hose and tighten bleeder screw. Fill reservoir. 1. Bleeder screw 2. Operating cylinder ADJUSTING PEDAL RELEASE TRAVEL Clutch pedal travel should be about 6.7 in. (170 mm). If travel is incorrect, loosen Iocknut (2)' and turn screw (1)‘in or out as necessary to obtain proper pedal travel. 1. Adjustment screw ,/\ 2. Locknut 3. Clutch pedal , l l r Page 18-4 _|_| 1. 2. f3 . 4. 5. 6. 7. 8. 9. O. 1. Reservoir Bracket Lockwasher and nut Hose Connector Cla mp Washer Throwout bearing Bolt Clutch assembly Spring clip 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Bushing Seal Spring Cotter pin Washer Spnng Washer Lever Threaded block Nuts Operating cylinder CLUTCH RELEASE CONTROL COMPONENTS 23. Support plate 24. Union bolt 25. Gasket washer . Gasket washer 27. Bolt and lockwasher 28. Hose 29. Clip 30. Release fork 31. Rubber ring 32- Hydraulic line 33. lWaEteE cylinder 34. Clutch pedal Clutch Hydraulic Release Control /*‘\‘ 181.03 Page 1 8-5 MASTER CYLINDER REMOVAL AND INSTALLATION Remove lower steering column cover. Disconnect hydraulic line (1) from master cylinder (2). Cap line. Remove two nuts (5) and washers. Slide bolts (4) out until cylinder can be pulled out and off of cylinder rod. Loosen hose clamp and remove hose (6). Drain fluid into container. Remove master cylinder. Install in reverse order. Use new hose clamp. Fill reservoir, bleed clutch circuit, and check for leaks. 1. Hydraulic line 5. Nut 6. Hose 2. Master cylinder 3. Brake line bracket 4. Bolt OVERHAUL Remove boot (3), lock ring (1) and seal (2). Remove remaining internal parts (items 8 through 12) from cylinder (7). Carefully inspect cylinder bore and piston surfaces. They should have a mirror-like finish without any kind of roughness. The cylinder bore can be honed to prevent leaks or exCessive wear of seals and pistons. Do not increase size of bore. Replace seals and boot. Clean all parts with denatured alcohol and lubricate with brake fluid. Reassemble in reverse order of disassembly. 1. Lock ring 2. Seal 3. Boot 4. Gasket 5. Connector 6. Lock plate 7. Cylinder 8. Spring 9. Seal 10. Seal 11. Gasket 12. Piston EXPLODED VIEW OF MASTER CYLINDER OPERATING CYLINDER REMOVAL AND INSTALLATION On vehicles with carburetor, remove carburetor cooling duct. On vehicles with fuel injection, remove air cleaner. Refer to 102.04. Remove union bolt (1) from operating cylinder (2). Hold spring (5) compressed and remove cotter pin, washer, spring and remaining washer from end of cylinder rod (4). Remove two bolts (3) and washers holding cylinder to support plate (6). Pull cylinder out. Install in reverse order. Use new copper gasket washers on union bolt. Bleed cylinder and fill reservoir. 1. Union bolt 2. Operating cylinder 5. Spring 6. Support plate 3. Bolts 4. Cylinder rod‘ OVERHAUL Remove bleeder screw(5). Remove cylinder rod (6) and boot (7). Remove remaining internal parts(items 8 through 11 and 1 through 3) from cylinder (4). Carefully inspect cylinder bore and piston surfaces. They should have a mirror-like finish without any kind of roughness. The cylinder bore can be honed to prevent leaks or excessive wear of seals and pistons. Do not increase size of bore. Replace seals and boot. Clean all parts with denatured alcohol and lubricate with brake fluid. Reassemble in reverse order of disassembly. 3 2 1 1. 2. 3. 4. Spring Washer Lock ring Cylinder 5. 6. 7. 8. Bleeder screw Cylinder rod Boot Seal 9. Piston 10. Seal 11. Bushing EXPLODED VIEW OF OPERATING CYLINDER Clutch 181.09 Page 18-7 REMOVAL Remove transmission as specified in Section 21. If same clutch assembly is to be installed, mark position on flywheel so that correct balance will be maintained. Remove clutch assembly (2 and 3) by gradually loosening and then removing six bolts (1 ). 1. Bolt 2. Pressure plate 3. Disc INSPECTION Disc Check that surface of friction material is not less than 1/16 in. from rivet heads and is not cracked or glazed. r-‘x Check that disc is not warped. ' Check that springs (3), plate (4) or splines (5) are not damaged. Replace disc if damaged. 1. Friction material 2. Rivet head 3. Spring 4. Plate 5. Splines Pressure Plate Check that fingers (1) of diaphragm spring are not broken, cracked or misaligned. Check facing (2) for heat cracks, scoring or burns. For minor imperfections, dress with medium grit emery cloth. Replace if damaged. Check mounting hardware for damage. Replace if damaged. 1. Fingers ‘r‘x 2. Facing Flywheel Inspect flywheel (3) for grooves, gauling, burns or heat cracks. For minor imperfections, lightly dress with medium grit emery cloth. For severe damage, replace flywheel. affected. _ _ Check pilot bearing (6) for wear. Replace if worn. Check ring gear (1) for damaged teeth. Replace if considered not serviceable. 1. Ring gear 2. Pin 3. Flywheel 4. Plate 5. Bolt ' (‘KK / : \ . L /) 1 / ' L f: l :7“; 1:" ”Q. J' ‘5‘ \bk” - Check mounting bolt holes for stripped threads. Repair with helical insert. Do not use oversize bolts, as balance will be Ly / 6. Pilot bearing Throwout Bearing, Fork and Lever Check throwout bearing (7) for serviceability. Replace if worn. Check that spring clips (8) are properly installed. Check that lever (1) moves freely and does not bind. If binding, disassemble by removing bolt (5) and lockwasher (6). Clean bearing surfaces, and check that bushing (3) is not worn. Replace if bushing is worn. VI Check that fork (4) is not cracked or worn. Replace if damaged. When replaced, torque bolt (5) to 19.5 ft. lbs. (2.7 kgm). 1. Lever 2. Seal 3. Bushing 4. Fork 7. Throwout bearing 8. Spring clip 5. Bolt 6. Lockwasher INSTALLATION lf flywheel was removed, torque mounting bolts to 61 ft. lbs. (8.5 kgm). Make sure clutch and flywheel surfaces are clean. If old clutch assembly is reinstalled, align marks made during removal. With protruding part of disc facing away from flywheel, loosely assemble clutch assembly (1) on flywheel. Using pilot tool A.70210 (3), center disc in pressure plate. Gradually torque mounting bolts (2) to 28 ft. lbs. (3.9 kgm). Remove pilot tool. Lightly coat transmission shaft with white grease, then install transmission as specified in Section 21. 1. Clutch assembly 2. Bolt 3. Pilot tool \J” Service Tools 18A Page 1 7877-7572/10 A.70210 Tool for centering driven plate on flywheel FIAT-$AT-A.702l0 X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION DIFFERENTIAL AXLE 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 TRANSMISSION - DIFFERENTIAL AXLE - 21/27 PARTS CATALOG. SERVICE MANUAL 81 SERVICE TIME SCHEDULE CODE 212.00 Specifications ....................................... Torque Specifications ............................... Transmission ........................................ Page 21 -1 21-2 21 -5 212.33 274.02 21 A Speedometer Drive .................................. Axle Shafts ......................................... Service Tools ........................................ 21 ~29 21 -31 21 -33 21 21 _ ,3‘ '91-." 212.21 Gearshift Controls ................................... 21 -25 21 Transmission Page 21-1 SPECIFICATIONS Gears ................................................. 5 forward, 1 reverse Synchronizers Blocker type, conventional cone .................. Porsche type ...................................... 1st and 2nd 3rd. 4th and 5th first ............................................... second ............................................ third ........ . ..................................... fourth ............................................. 1979-80 3.583 2.235 1 .454 1 .042 1981-82 3.583 2.235 1.461 1 .033 reverse ........................................... 3.714 3.714 Gear ratios to 1 fifth ............................................... 0.863 0,863 Backlash between gears .............................. .004 in. (0.1 mm) Alignment tolerance of shafts ......................... .002 in. (0.05 mm) Clearance between reverse gear shaft and bush fitted to gear ...................................... .003 to .006 in. (0.08 to 0.15 mm) DRIVING AXLE Final drive gear set .................................... Helical, cylindrical Final drive ratio ....................................... Oil type ........................................... Quantity .......................................... 13/53 (4.077 to 1) SAE 80/90W 3.2 qt. (3.0 It) Differential case bearings ............................. 2 Type of bearings ...................................... Tapered roller Adjustment for preload of differential case bearings. . . Through shims Pinion to side gears backlash adjustment .............. NONE Power drive to rear wheels ............................. By axle shafts connected to final drive and to wheels through constant-velocity ball joints Page 21—2 TORQUE SPECIFICATIONS DESCRIPTION THREAD N-rn Bolt retaining internal selector and spring cover .................................... M 8 24.4 Lower nut retaining cover to plate .................. M 6 9.5 Nut for bolt retaining bell housing to engine ....................................... M 12 x 1.25 Nut retaining plate to gearbox ...................... M 6 Bolt retaining gearbox cover and plate .............. TORQUE FIGURE Kgm Ft. Lb. 2.5 18 TRANSMISSION 1 7 8 58 9.5 1 7 M 6 9.5 1 7 Bolt retaining power unit su5pension plate, cover, and bracket to gearbox ................... M 8 24.4 2.5 18 Bolt retaining bell housing to engine ............... M 12 x 1.5 79 8. 58 Bolt retaining starter motor to bell housing ......... M 8 24.4 2.5 18 Bolt retaining gearbox front cover .................. M 6 .8 8 6 Bolt retaining bell housing to gearbox .............. M 8 24.4 2.5 18 Bolt retaining reversing shaft plate ................. M 6 19.5 Lock nut for 5-speed main and layshaft ............. M 20 x 1.5 Bolt retaining gearshift fork and lug ................ M 6 Bolt retaining crown wheel ........................ M 10 x 1.25 Bolt retaining differential case flange to gearbox housing ............................... Bolt retaining bearing retainers to support ......... 79 118 1 12 7 87 17.6 1.8 13 88 9 65 M 6 24.4 2.5 18 M 6 9.5 1 7 21 Transmission Page 21-3/4 TOROUE FIGURE Kgm Ft. Lb. THREAD N-m Bolt retaining gearshift lever ....................... M 6 19 Boit retaining gearshift lever support ............... M 6 9.5 Bolt retaining transmission link to transmission rod ............................... M 8 24.4 2.5 18 Bolt retaining transmission link to selector rod ..... M 8 24.4 2.5 18 DESCRIPTION TRANSMISSION EXTERNAL CONTROLS 2 14 1 7 212.00 Transmission W\\\\\\ _ Page 21-5/6 Le; S ER! my > k. , 4 54‘ q E3 Cross Section through Gear Engagement Lever I ‘ II 11 ‘Ifé!!!’o Longitudinal Section through Forked Levers and Internal Selector Rods .0. k‘ “‘ . 'Ig“ e O CO 6i g T ("—IDI I Section thrIough Detent Springs for Gear control Rods 34868 1 ‘ Speedometer Sprocket Support Section: .. E E i SECTIONS THROUGH} MANUAL TRANSMISSION i I Transmission 212.00 Page 21 -7 REMOVAL AND INSTALLATION Disconnect battery ground cable. On vehicles with fuel injection. remove air cleaner. On vehicles with carburetor, remove carburetor cooling duct. Refer to 102.04. Hold spring (2) compressed and remove cotter pin, washer. Spring and remaining washer from end of cylinder rod (3). Remove two bolts (5) holding cylinder (4) to support plate. Move cylinder out of way. Disconnect speedometer drive (1) from transmission. Install engine support bar A.70526. CAUTION: Be certain that support is attached to engine and not to transmission. Remove nuts and bolts holding transmission to crankcase accessible from above. 1. Speedometer drive 2. Spring 3. Cylinder rod 4. Cylinder 5. Bolts Raise vehicle. Remove rear wheels. Remove left side shield. Disconnect reverse light switch connector (2). Remove three bolts (1) holding starter to transmission. Move starter out of transmission. 1. Bolts 2. Connector Using a scribe. mark position of transmission link (3) in relation to gear selector rod (5). Remove two bolts (4) holding transmission link to selector rod. Loosen bolt (2) at transmission end of transmission link. Swing link out of way. NOTE: Transmission link on vehicles with carburetor does not have flexible rubber coupling (1). 1. Flexible coupling 5. Selector rod 2. Bolt 3. Transmission link 4. Bolts Disconnect ground strap (1) from chassis. Remove six Allen head bolts (3) from each end of left side half-shaft (4). Remove half-shaft complete with CV joints (2 and 5). Repeat above procedure to remove right side half-shaft and CV joints. NOTE: Discard Allen head bolts and replace with new ones for installation. Torque new bolts to 31 ft. lbs. (4.3 kgm). 1. Ground strap 5. Outer CV joint 2. Inner CV joint 3. Allen bolts 4. Half-shaft Place transmission support under transmission. 0n vehicles with fuel injection, remove nuts attaching exhaust system bracket (9) to exhaust flange. Remove nut (5) and two bolts (8) holding transmission support bracket (7) to transmission. Loosen out (2) attaching shield to crosspiece (3). Remove four crosspiece bolts (1 and 8). Remove crosspiece. transmission support bracket and exhaust system bracket (if so equipped) from vehicle as an assembly. Remove remaining bolt holding flywheel guard (4) and remove guard. 1. Bolts 2. Nut 3. Crosspiece 7. Support bracket 8. Bolt 4. Flywheel guard 5. Nut 6. Bolt 9. Exhaust system bracket Remove remaining nut (1) and bolts holding transmission to engine. Lower transmission out from under vehicle. Install in reverse order. If difficult gear shifting or jumping out of gear is experienced after installation. adjust gearshift linkage. Refer to 212.21. 1. Nut 2. Transmission Transmission 212.00 Page 21-9 DISASSEMBLY Install transmission (1) in suitable work stand. Drain transmission oil through filler (2) and drain (3) openings. Remove reverse switch (4). Remove fifth gear cover (6) by removing four bolts (5) and one nut. 1.1‘ransmission 2. Oil filler 5. Bolt 6. Fifth gear cover 3. Oil drain 4. Reverse switch Remove both axle shafts (1) with side hammer puller (2). NOTE: Replace axle shaft circlips with new ones for installation. -\ 1. Axle shaft 2. Puller Remove bolt from fifth speed fork (4). Remove fork. Engage fifth speed manually by pressing sliding sleeve (2) down. Engage transmission in another gear by moving shift lever. This will lock shafts so that retaining nuts (3 and 5) can be removed. Remove nuts. 1. Fifth gear 2. Sliding sleerre 3. Retaining nut 5. Retaining nut 6. Drive gear 4. Fork Page 21-10 Remove fifth gear sliding sleeve and syncro hub (4). Puller A.40005f002 (1) may be required for hub removal as shown. 1. Puller AAOOOEIOM 4. mncro hub 2. Arms A.40005f302 3. l__ay shaft Remove two bolts (1) holding detent spring cover (2). Carefully remove cover so that springs (3) do not fall out. Note color coding and location of springs before removing. If colors are not visible, mark springs so that they will be assembled in same location. NOTE: Short thick spring is for fifth and reverse rod. On 1980 and up, all springs are same size. With a magnetic tool (4} remove detent balls (5) as shown. 1. Bolt 2. Detent spring cover 3. Detent springs 4. Magnetic tool 5. Detent ball Transmission Slide driven gear and drive gear off. Remove lock key. Slide fifth gear bushing (1) off. Remove intermediate cover by removing two bolts (6). 1. Fifth gear bushing 2. Layshaft 3. Fifth and reverse gear selector rod 4. Mainshaft 5. Intermediate cover 6. Bolt To remove main case (3), first remove bearing snap rings (6). Remove three bolts inside of bell housing and nine bolts (7) on outside of case. Remove main case. 1. Countershaf‘t bearing 5. Mainshaft bearing 2. Countershaf't 3. Main case 4. Meinshaft Remove mainshaft (1) and countershaft (2) bearings with puller (3} as shown. Note that bearing with split bushings is installed on main shaft. 1. Mainshaft bearing 2. Countershaft bearing 3. Puller 212.00 Page 21-11 Page 21-12 Loosen five bolts holding forks (6) to selector rods. First remove fifth and reverse selector rod (2). Carefully remove center rod (third and fourth) (3) with its lock pin. Remove re maining rod (first and second) (4). After each rod is removed, remove related forks. Pull out two lock pins (8) from rod housing with magnetic tool (9). Remove bolt and clamp (7) holding reverse gear shaft (1). Remove shaft. Remove three bolts and holding gearchange lever support bracket (5). Remove bracket and reverse lockout assembly. 1. Reverse gear shaft 2. Fifth and reverse gear selector rod 3. Third and fourth gear selector rod 4. First and second gear selector rod 5. Gearchange lever support bracket and reverse lockout assembly 6. Fork 7. Bolt and clamp 8. Lock pin 9. Magnetic tool Remove countershaft (2) and mainshaft (1) by lifting out as shown. Remove main and layshaft bearings (3). Remove differential assembly by lifting out. 1. Mainshaft 2. Countershaft 3. Bearings Transmission Loosen bolt (1) holding speedometer drive gear assembly (2) and pull assembly out. 1. Bolt 2. Speedometer drive gear assembly Remove bolt (1) holding shift lever (2) to shift shaft (3). Slide shaft out of housing. 1. Bolt 2. Shift lever 3. Shift shaft Remove two clips (1) holding throwout bearing (2) to clutch lever (3), as shown. Remove bearing. 1. Clip 2. Throwout bearing 3. Clutch lever 212.00 Page 21-13 Page 21-14 Remove bolt (1) holding throwout bearing lever [2) to shaft {3). Slide shaft out of housing and remove lever. 1. Bolt 2. Throwout bearing lever 3. Throwout lever shaft Disassemble countershaft as follows, noting order for reassembly. Remove fourth gear bushing (1) as shown. Slide off fourth gear and syncro, third and fourth gear sleeve, third and fourth gear center hub, third gear and syncro assembly, and third gear bushing. Remove second gear bushing with puller. Slide off second gear and syncro, first and second gear sleeve, v first and second gear center hub with syncro rings, first and first gear bushing. 1. Fourth gear bushing ' "9* \\\_- \\\\\\\\\ f ti: ' ‘( H \ INSPECTION Main Case, Housing and Cover Check main case for cracks. Check bearing seats for wear or damage that might cause bearing cups to rotate in theirseats. Main case to housing and cover mating surfaces should not show signs of damage, otherwise assembly will be misaligned and oil leakage will result. Minor imperfections can be removed with a file. in cases of extensive damage or excessive wear, replace affected parts. Make sure oil breather opening on cover is not clogged. NOTE: Upper and lower case sections are line bored matched, and as such are not interchangeable with a half from another transmission. Seals Replace all seals. Transmission Shafts 212.00 Page 21 ~15 . Inspect mainshaft gears for signs of chipping or excessive wear. Countershaft surfaces must not be damaged or excessively worn. Splines should be free from nicks and burns, so that hubs may slide freely. measured Check countershaft centering by placing it between two centers and rotating it by hand ; maximum permissible runout, with dial indicator, is .001 in (.025 mm). The surface of reverse shaft should be smooth and free from nicks and burrs. up with extra-fine emery Minor imperfections on working surfaces, that do not render parts unfit for service, may be dressed cloth. If shafts are badly distorted, Minor distortions of shafts can be corrected with a small press, taking care not to damage surfaces. they must be replaced. Gears surface. Inspect Gears should not show damage or excessive tooth wear. Gear tooth contact pattern must extend to entire working pattern for roughness or signs of excessive wear. Gear lash should be .004 in (0.10 mm) for new parts; maximum allowable lash is .008 in (0.20 mm). beyond specified Fit clearance between bushings and countershaft gears is .001 to .003 in (0.04 to 0.08 mm). Replace gears worn limits. Hubs —- Sleeves — Synchronizer Rings especially on sleeve slidCheck that sliding sleeve hubs for engagement of first-second, third-fourth and fifth gears are not nicked, ing surface. that mesh with sliding sleeves. Ring Synchronizer rings must not be excessively worn, either on their inside surface or on teeth must not be loose in its gear seat. first and second gears; 2.607 The outside diameter of seated synchronizer ring when new is 3.004 1 .008 in (76.31 i 0.2 mm) for gears. 1 .008 in (66.22 1' 0.2 mm) for third, fourth and fifth When replacing a synchronizer ring, check that its diameter in its gear seat conforms to specifications. If splined parts do not slide smoothly, remove imperfection with a fine file. Parts worn beyond limits should be replaced. Bearings bearing firmly and turn it both ways to Bearings must be in perfect condition. End play must not exceed .020 in (.050 mm). Hold check for roughness. Replace bearings that are not in perfect condition. Rods — Forks excessive play, in transmission case Shift control forks should not be distorted and control rods should slide freely, but without and housing guide holes. Detent balls and rollers should slide freely in their seats. Any sign of seizure could cause engagement or disengagement problems. Wear patterns should be the same on both sides of forks. REASSEMBLY Reassemblv is reverse of disassembly with special attention to following Notes, Cautions and Procedures. CAUTION: During reassembly of countershaft, be certain that first and second gear sliding sleeve hub reverse gear (1) faces first gear as shown. If this part is to be replaced, make certain that correct sliding sleeve hub is installed since four speed transmission sliding sleeve hub can be installed, but is incorrect, and will result in locked transmission. 1. First and second gear sliding sleeve hub reverse gear Installation of Shift Rods Install support bracket (2) so that gear shift lever (B) is posi- tioned as shown. 1. Selector lever 4. Pewl support 2. Support bracket 3. Reverse lockout pawl 5. Pewl return spring 6. Gear shift lever Place forks ill in position on sliding sleeves/hubs. Install first and second shift rod (2). With magnetic tool {3), install lock pin (4) down into its slot in bore as shown. Insure that pin is fully seated. 1. Fork 2. First and second shift rod 3. Magnetic tool 4. Lock pin ‘ Transmission 212.00 Page 21-1 7 Before installing third and fourth shift rod (1), install pin (2) in rod as shown. Insert rod into bore. 1. Third and fourth shift rod 2. Pin lllflth magnetic tool (1) insert last lock pin (2) as shown. Insure that pin is fully seated. Install reverse idler assembly (3) with fork (4) installed. Install fifth and reverse shift rod. 1. Magentic tool 2. Lock pin 3. Reverse idler assembly 4. Fork NOTE: 0n reassembly of fifth gear, synchro hub (2) oil groove should face fifth gear (1) as shown. 1. Fifth gear 2. Synchro hub 3. Sliding sleeve CAUTION: Position bearing snap rings (2) as shOWn or bearings will not seat properly. 1. Bearing 2. Snap ring 3. Mainshaft 4. Countershaft To torque main and oountershaft Iocknuts, transmission must first be locked-up. Remove fifth speed fork (3) bolt and engage fifth speed manually by pressing hub (2) down. Engage transmission in another gear by moving shift lever, this will lock shafts. Nuts can now be torqued to 86.8 ft lb (12 kgml as shown. Disengage hub and reinstall fork bolt. 1.Locknut 2.Hub 3.Fork DIFFERENTIAL D ISASSEMB LY To remove crown gear (4) remove eight bolts (6) attaching it to case (2}. 1. Differential bearing 2. Differential case 4. Crown gear 5. Speedometer drive gear 3. Pinion shaft Transmission 212.00 Page 21-19 To remove both differential bearings (4), use puller A.40005/ 002 (1) together with arms A.40005/302 (2) and spacer A.45023 (3) as shown. 1. Puller A.400051002 4. Bearing 2. Arms A.40005/302 3. Spacer A.45028 35051" To remove speedometer drive gear (4), use puller A.40005/002 (1) together with arms A.40005/302 (2) and spacer A.45028 (3) as shown. 1. Puller AADDOSIDO‘Z 2. Arms A.40005/302 4. Speedometer drive gear 3. Spacer A.45028 35058 To remove differential pinion shaft (5) and gears (2 and 3), drive out retaining pin (4) and then slide shaft out. Remove gears through large opening in case (1). 1. Differential case 5. Pinion shaft 2. Side gear 3. Pinion gear 4. Retaining pin Page 21-20 INSPECTION Check teeth for scoring or signs of abnormal wear and make sure contact pattern extends to entire thrust surface. If excessive wear is found, replace affected parts. Gears with chipped teeth should be replaced and mating gears carefully examined for damage. Inspect pinion shaft and pinion bores for scoring or nicks. Minor damage can be dressed off with extra-fine emery cloth; otherwise replace parts. Follow a similar procedure for inspecting side gears and counterbores in case. Inspect roller bearings, these should be in perfect condition with no signs of wear and should have perfectly smooth surfaces. If there is any doubt as to their serviceability, replace them, as faulty operation of hearings will result in gear noise and/or seizure. Fl EASSE MB LY Refit differential gears to case as follows; place side gears (1) in case directly opposite each other, seated in their counterbores. Place pinion gear in mesh with side gears. Carefully rotate assembly so that pinion gear is directly opposite large opening in case and place second pinion gear in mesh. 1. Side gear 2. Differential case Rotate assembly so that pinion shaft (3) can be inserted through pinion gears. Line up pinion shaft pin hole with hole in case and insert retaining pin (2}. 1. fide gear 2. Retaining pin 3. Pinion shaft Transmission 212.00 Page 21-21 Using a suitable installer. refit Speedometer drive gear, Using installer A.70190 (1) refit bearing (2). Install crown gear (5) with eight bolts (6). 1. Installer A.70190 2. Bearing 4. Speedometer drive gear 3‘ Differential case 5. Crown gear 6. Bolt LONGITUDINAL SECTION THROUGH FINAL DRIVE UNIT Page 21-22 DIFFERENTIAL BEARING SETTING NOTE: Bearing preload must not be changed unless the bearings or transmission housing has been replaced. The bearing on the differential must be preloaded. Preload is obtained by placing shims between outer ring of the bearing and the sealing cover. To set preload, do one of the following: if fixture A.95655 is not available, place outer ring of carrier bearing in its seat. Place shims on top of bearing. Place retaining flange on shims. Using feeler gauge measure clearance between flange and transmission housing. If clearance is not 0.003 to 0.005 in. (0.08 to 0.12mm), add or remove shims to obtain this clearance. Install two nuts on studs thru flange and tighten nuts. Turn transmission one full turn to set bearings. Loosen nuts and check clearance. Install nuts on studs. Torque nuts to 18 ft. lbs. (2.5kgml. 1. Shims 2. Retaining flange 3. Transmission housing 4. Bearing 212.00 Transmission Page 21-23/24 If fixture A.95655 is available, apply a load of 770 lbs. (350kg) to settle bearings. Place fixture A.95655 with dial indicator on surface for sealing cover. Set dial indicator finger against outer ring of bearing. Zero indicator. Without changing the indicator, place fixture on sealing cover with finger on cover and case surface. Value on indicator is differ- ence between distance ”P" and height ”H". Add 0.0031 in. (0.08mm) to value on indicator to determine thickness of shims. Choose a shim with a thickness as close as possible to this value. 0.60, NOTE: Shims are supplied in the following thicknesses; 0.0196. 0.0236, 0.0275, 0.0315, 0.0354, 0.0394, 0.0433 in. {0.50, 0.70, 0.80, 0.90, 1.00, 1.10mm). 2|??? 2‘7 18 1. Bearing 2. Dial indicator 3. Transmission case 4. Differential case 5. Tool A.95655 6. Sealing cover P = Distance between mounting surface for cover (6) and outer ring of bearing (1). H = Height of sealing cover. Gearshift Controls REMOVAL AND INSTALLATION Unscrew gearshift knob (1 ). Remove five screws (2 and 4) holding lower console (3). Ti)! and of console up until it clears gearshift lever and lay it to one side. 1. Gearshift knob 2. Screws' 3. Lower console 4. Screw Remove three bolts (1) and washers retaining support (2). 1. Bolts 2. Support Lift support. Remove nut (2) and bolt holding selector rod (1) to gearshift lever (3). Lift gearshift lever out of vehicle. 1. Selector rod 2. Nut 3. Gearshift lever 212.21 Remove bolt (3} and nut holding transmission link (4) to transmission rod (2). Remove boot (5]. Pull selector rod out of vehicle from rear. NOTE: Transmission link on vehicles with carburetor does not have flexible rubber coupling (1). Install in reverse order. 1.Flexible coupling 5. Boot 2. Transmission rod T33“ 3. Bolt 4. Transmission link 19 f 21 20 22 3 2 1 1. Bolt 2. Bushing 3. Locknut and lockwasher 4. Gearshift lever 5. Gearshift knob 6. Gearshift boat 7. Bolt 3. Washer 9. Cover 10. Bushing 11. Grommet 12. Support 13. Plate 14. Nut 15. Transmission link 16. Washer EXPLODED VIEW OF GEARSHIFI' CONTROL ASSEMBLY (VEHICLES WITH CARBURETOFI) 17. Bushing 13. Bolt 19. Bolt 20. Clamp 21. Boot 22. Selector rod 212.21 Gearshift Controls Page 21-27/28 ADJUSTING GEARSHIFI' LINKAGE Place transmission in neutral. Loosen two bolts (3) holding selector rod (4) to transmission lint-2(2). Shift transmission link in the elongated holes until gearshift lever is in center of support and is straight up and down, Tighten bolts. NOTE: Transmission link on vehicles with carburetor does not have flexible rubber coupling (1). 1. Flexibie coupling 2. Transmission link 3. Bolts 4. Selector rod 3“ I! 1E 7.: 9. Cover 1. Bolt 2. Bushing 3. Locltnut and Lockwasher 4. 5. 6. 7. Gearshift lever Gearshift knob Gearshift boot Bolt 8. Washer ‘IO. Bushing 11. Grommet 12. 13. 14. 15, Support Boot Plate Nut 3 _>2s 19 §\ 20 22 2f 1 3 18 .-'- 21 17. Washer 18. Bushing 19. Bolt 20. Plates 21. Bolt 22. Selector rod 16. Transmission link EXPLODED VIEW OF GEARSHIFT CONTROL ASSEMBLY (VEHICLES WITH FUEL INJECTION) 212.33 Speedometer Drive Page 21-29/30 REMOVAL AND INSTALLATION Unscrew speedometer cable (2) from speedometer drive assembly (3). Q 2 Remove locking bolt (1) holding speedometer drive in transmission housing. Withdraw speedometer drive assembly. Installation is reverse of removal. 1 . Locking bolt 2. Speedometer cable 3. Speedometer drive assembly ‘9 /' ""-.. EEK» 77““721 274.02 Axle Shafts Page 21-31 HALF—SHAFT REMOVAL AND INSTALLATION Raise vehicle and remove wheel. Remove six Allen head bolts (2) at each end of half-shaft. Remove hall-shaft (4) complete with CV joints (1 and 5). NOTE: Discard Allen head bolts and replace with new ones for installation. Installation is reverse of removal. Torque new Allen head bolts to 31 ft. lbs. (4.3 kgml. 3. Protective boot 4. Half-shaft tomuaaotgapoioa . Clamp . Protective boot Clamp Ring Cover . Washer . Constant velocity joint . Circlip . Stub shah . Allen bolt N-‘O .s-s.‘ 1. Inner CV joint 2. Bolts 5. Outer CV joint EXPLODED VIEW OF AXLE SHAFT . Plate . Half-shah Page 21-32 CONSTANT VELOCITY JOINT REMOVAL To remove either CV joint. remove large clamp holding protective boot on CV joint. Remove circlip (2) with pliers A. 31115 (1). Slide CV joint off half-shaft (5). 1. Pliers A. 81115 5. Hail-shalt 2. Circlip 3. Spherical ball 4. Socket INSTALLATIO N Slide CV joint onto half-shaft (1). ensuring that side with reference groove (5) faces toward and of shaft. Install circlip on and of shaft with pliers A. 81115. Grease CV joint socket and inside of protective boot (2). Use no more than 3.2 025. (.10 kg) of grease. Slide boot over joint and secure clamp (3) with pliers A.81118 l4!- 1. Half-shaft 2. Boot 5. Reference groove 3. Clamp 4. Pliers A.B111B Service Tools 21A Page 21 -33 A.70100 Tool for installing circlip in 5th gear synchromesh unit A.40005/003 Special puller and arms for removing differential bearing inner race A.45028 Knurled spacer for extraction of differential bearing inner race A.70190 Tool for fitting differential bearing inner race A.55035 Spin wrench for removing bell housing to engine bolts ‘CTF‘T— _Fm-_\:-:-ar lg, —'—— ——_ 3 , / A5508? Ring spanner for oil level and drain plug of final drive unit A.70225/23 Tool for installing circlip on 3rd and 4th gear synchrornesh units Page 21-34 _ I“ \ _______m . *"fl l h» A.70296 Tool for fitting gear selector rod oil seal. __ . a,l ( A.70526 Engine support cross rail A.70301 Pilot for fitting gear selector rod oil seal \ a m1 I A.70575 Support used in conjunction with hydraulic jack when removing or replacing transmission unit A.70375 Pilot for fitting seal and bushing on CV joint rubber protectors A.71001/4 Transmission support for rotating stand Ar.22204 n" murmur“ m AJOSTQ A.70379 Tool for fitting oil seal on transmission front cover A.81118 Pliers for fitting CV joint protector boot retaining clamps “’" Service Tools 21A Page 21-35/36 !_—-— ‘ ‘ FIAT'SAT-AJBO‘IE ' A.86016 Drift (16 mm) for fitting internal selector rod plugs A31 124 Pliers for cv joint circlips ‘i‘ / - ') a" ‘0 Purser-masses A.86014 Drift (14 mm) for fitting internal selector rod plugs A.95655 Tool for determining thickness of differential bearing adjusting shims X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 BRAKES - 33 PARTS CATALOG. SERVICE MANUAL 8r SERVICE TIME SCHEDULE CODE Page 33 33 331 .01 331.02 331.17/.25 331.17 331.25 331.35 33A Specifications ................................ Torque Specifications .......................... Brake Pedal Mechanism ........................ Hydraulic Brake System ........................ Front and Rear Wheel Brakes .................... Front Brake Calipers .......................... Rear Brake Calipers ........................... 33—1 33-1 33-5 313-? 33-9 3343 33-15 Hand Brakes ................................. Service Tools ................................ 33-17 33-19 33 Brakes Page 33-1/2 SPECIFICATIONS MM IN. DESCRIPTION Disc brakes on all four wheels. Type ....................................................... Disc diameter .............................................. 8.937 227 Disc thickness: — When new ............................................. — Minimum after refacing ................................ — Minimum allowed for wear ............................ 0.421 to 0.429 0.368 0.354 10.7 to 10.9 9.35 9 Maximum runout (at 2 mm from outer edge) ............... 0.010 0.25 Minimum permissible friction material thickness .......... 0.059 1.5 Caliper cylinder bore diameter: — Front ................................................... — Rear ................................................... 1.889 1.338 48 34 Master cylinder bore diameter ............................. 3/4 19.05 Hand brake for parking ..................................... Mechanical, acting on rear wheels. Brake fluid ................................................. DOT 3 Motor Vehicle Brake Fluid to F.M.V.S.S. No. 116 TORQUE SPECIFICATIONS TORQUE FIGUR E Kgm Ft. Lb. 24.4 2.5 18 M 10 x 1.25 47 4.7 35 Bolt, hand brake support ........................... M 8 15 1.5 11 Union bolt, front brake hose to caliper .............. 3/8 24 UNF 2A 28 2.8 20 DESCRIPTION THREAD Nut. master cylinder to pedal support bolt .......... M 8 Bolt, brake caliper support bracket ................. N-m #93919 m :0 “_.. 3511.12: 82%;} r1" Saga .. 2, E I11 r a: m > X m (D $38??? (I: g 8 3' (1: o g. :J 3?“: SEMVHH _ '1 17/ 8'88 959d -1 OHnVHGAH Egg-"aw :7 O ¥TW¥~ QE¥§< mm‘bmggamjm GNV 3 O Z > r7151 GNVH HVEIH SEDIVHEI TBEHM g m Qua: Brake Pedal Mechanism BRAKE PEDAL ASSEMBLY REMOVAL AND INSTALLATION Siphon fluid from brake and clutch reservoirs. Remove steering column. Refer to 412.01. Place a container on floor of vehicle to catch fluid. Disconnect brake lines (3 and 7) from junction blocks (2 and 8). Cap lines. Disconnect clutch line (1) from clutch master cylinder (6). Cap line. Remove wires (4) from brake light switch (5). 1. Clutch line 2. Junction block 3. Brake lines 4. Wires 5. Brake light switch 6. Clutch master cylinder 7. Brake line 8. Junction block Remove two nuts (1) and washers holding pedal support bracket (2) to firewall. 1. Nuts 2. Pedal support bracket Lower pedal assembly far enough to allow removal of hose (5) from clutch master cylinder (6) and hoses (2 and 4) from brake master cylinder (3). Remove screw from Strap (1) holding hoses to support bracket. Remove pedal assembly from vehicle. Install in reverse order. Use new hose clamps. Fill reservoirs. bleed brake and clutch systems, and check for leaks. 1. Strap 2. Brake hose 5. Clutch hose 3. Brake master cylinder 4. Brake hose 6. Clutch master cylinder 331.01 Page 33—6 DISASSEMBLY AND REASSEMBLY Remove cotter pin and washer from clevis pin (4). Pry clutch master cylinder rod (5) off cievis pin. Remove spring (1) from clutch pedal (6). Remove not (2) and two washers from end of clutch pedal shaft. Slide clutch pedal and shaft out of nylon bushing (3). 1. Clutch pedal spring 2. Nut 3. Bushing 5. Cylinder rod 6. Clutch pedal 4. Clevis pin Take end of spring (5) out of pedal support bracket (6). Remove screw (2) and retaining plate (3) holding nylon bushing (4). Slide bushing out of support bracket. Remove brake pedal (1) with master cylinder rod attached. Inspect nylon bushing and replace if worn excessively. Lubricate all bearing surfaces with white grease and reassemble in reverse order of disessembly. 1. Brake pedal 5. Spring end 2. Screw 3. Retaining plate 4. Bushing 6. Pedal support bracket Hydraulic Brake System 331.02 Page 33-7 '.‘ MASTER CYLINDER REMOVAL AND INSTALLATION Remove brake pedal assembly. Refer to 331 .01. Disconnect three brake lines (1) from master cylinder (5). Remove nuts from two bolts (4) holding master cylinder. Remove bolts and junction block (2). Pull master cylinder out and off of cylinder rod (3). Install in reverse order, making sure all parts and fittings are clean 1. Brake lines 22. Junction block 3. Cylinder rod 4. Bolts 5. Master cylinder OVERHAUL Remove two connectors (2) and seals (3). Remove dust boot (4). Remove two stop bolts (6) and seals (5); Remove remaining internal parts (items 7 through 19) from Cylinder (1). Carefully inspect cylinder bore and piston surfaces. They should have a mirror-like finish without any kind of roughness. The cylinder bore can be honed to prevent leaks or excessive wear of seals and pistons. Do not increase size of bore. Replace seals and dustcovers. Clean all parts with dental: red alcohol and lubricate with brake fluid. Reassemble in reverse order of disassembly. mumtnppufl . Cylinder body A Connector Seal Boot Seal . Stop bolt . Seal . Rear piston Hmmtd-O-‘O ,5 oer . 5:2: . Spring and cup . Spring 19 13 17 16 . Cup . Flat washer . Front piston . Spring woo . Spring and cup . Spacer . Seal EXPLODED VIEW OF MASTER CYLINDER Page 33-8 BLEEDING When the front or rear hydraulic system is opened for any reason, it must be bled to remove all entrapped air. The front and rear systems are independent and need not be bled together. After all repairs are made, proceed as follows: NOTE: Should the brake system have been completely drained, it is advisable to carry out the following operation before bleeding: Loosen all wheel bleeder screws and pump brake pedal. as fluid begins to escape tighten bleeder screws. Fill brake fluid reservoir with DOT 3 brake fluid. Clean all dirt and foreign material from bleeder screws and remove protective cap. Attach bleeder hose over bleeder fitting in brake caliper or wheel cylinder. Submerge other end of bleeder hose into a clean jar half filled with brake fluid. Loosen bleeder screw one or two turns and press brake pedal down, allowing it to return slowly; do this several times until no more air bubbles escape from rubber hose. Keeping brake pedal depressed, remove bleeder hose and tighten bleeder screw. Refit protection cap. Repeat above on other wheels. making certain that fluid level in reservoir is maintained. After bleeding, tap up reservoir to prescribed maximum level. h. Front and Rear Wheel Brakes 331.17/.25 Page 33-9 CALIPER AND PADS REMOVAL AND INSTALLATION Remove wheel. Remove four cotter pins (2 and 5) from two caliper locking blocks (3). Use a drift to drive out looking blocks. 1. Support bracket 2. Cotter pins 3. Locking block 4. Caliper 5. Cotter pins Separate caliper (6) from support bracket (1 ). On front brakes. to remove caliper for replacement or overhaul. remove bolt (2) holding bracket (3) to caliper. Remove union bolt (5) holding hose (4). Remove gaskets. 1. Support bracket 6. Caliper 2. Bolt 3, Bracket 4. Hose 5. Union bolt On rear brakes. to remove caliper for replacement or overhaul, disconnect hose (1) from caliper (3). Remove gaskets. Disconnect hand brake cable (2) from caliper. 1. Hose 2. Cable 3. Caliper 4. Support bracket Page 33-10 Remove two brake pads (2). Inspect two retainer Springs (1] and two caliper springs (3) for breakage. Replace if necessary. NOTE: Retainer springs on early type brake systems are a different type than those illustrated. See exploded view in Section 331.25. install in reverse order. 1. Retainer spring 2. Brake pad 3. Caliper spring Check disc (1) for runout by placing a dial indicator (2) 0.08 in. (2 mm) from disc outer edge. Runout must not be greater than 0.010 in. (0.25 mm), otherwise relaoe disc. Thickness of disc after refacing must not be less than 0.368 in. (9.35 mm}. Minimum permissible thickness from Wear is 0.354 in. (9 mm). Replace disc if less. 1. Brake disc 2. Dial indicator Install in reverse order of removal. If new brake pads are being installed, it will be necessary to fully seat caliper pistons in bore in order to have installation clearance for calipers. Push in on center of piston with blunt object (hammer handle, etc.) NOTE: Brake fluid will back up into master cylinder and may overflow . Place light coat of grease on locking blocks and contact surfaces of caliper and support bracket. After installing caliper. install lower locking block first, then with hand pressure against front of caliper, force caliper back far enough to insert top locking block. if caliper hydraulic lines have been disconnected, bleed system (refer to BLEEDING HYDRAULIC SYSTEM). CAUTION: Before driving vehicle, pump brake pedal a few times to make cerain caliper pistons are seated against pads and pedal is firm. Front and Rear Wheel Brakes 331.17/.25 Page 33-11/12 DISC AND BACKING PLATE REMOVAL AND INSTALLATION Remove caliper and pads. Refer to Caliper and Pads Removal and Installation. Remove caliper support bracket (1) by removing two bolts and lockwashers on back face of bracket. 1. Caliper support bracket 2. Caliper 3. Disc Remove locating pins (1). Remove disc (2). To remove backing plate (3), remove bolt and washers. Impact disc for scoring or cracks. For runcut greater than 0.010 in. (0.25 mm) and/or scoring, discs can be refaced to a minimum thickness of 0.368 in. [9.35 mm). Replace dises if cracked. Install in reverse order. Torque caliper support bracket bolts to 35 ft. lbs. (4.8 kgm). 1. Locating pins 2. Disc 3. Backing plate 331.17 Front Brake Calipers Page 33-1 3/14 OVERHAUL Remove caliper. Reler to 331.17/.25 Remove dust boot (4). Apply compressed air through brake fluid hose connection to force piston (3) out of caliper (1). WARNING: Apply air pressure gradually or piston will eject at high velocity. Remove seal (2). Check piston and caliper cylinder for scoring or binding. Install seal in caliper. Place piston in caliper. Push piston in until it bottoms. Install dust boot, making sure it is seated in groove in caliper body. 2. Seal 3. Pismn 4. Dust boot mascara-lows:- . Lining retainer spring (early type) _ Lining pad , Caliper Support bracket 9 11 10 , Spring . Lining retainer spring (late type) Lining pad Cotter pin . Caliper locking block . Dust cap . Bleeder screw _._._a_-_u htIJN-‘O 1. Caliper V Caliper body . Piston . Seal . Dust boot EXPLODED VIEW OF FRONT CALIPER AND BRACKET COMPONENTS 331.25 Rear Brake Calipers _ _‘ .me OVERHAUL F Remove caliper. Refer to 331 .17/.25. l Remove dust boot (1). Unscrew piston (2) from plunger. Use screwdriver in slot. Remove seal (3) from caliper (4). 1. Dust boot 2. Piston 3. Seal 4. Caliper To disassemble hand brake mechanism. remove lock ring (7) from shaft (1). Compress plunger (4) to relieve spring tension. then remove shaft. Remove plunger (4), seal (3) and spring washers (6). To reassemble. place plunger with seal and spring washers in caliper (8). Place hand brake shaft in boot (2). Place shaft and pawl (5) in caliper. install lock ring. Cost lever and plunger with grease. 1. Shaft 2. Boot 7. Lock ring 3. Seal 4. Plunger 5. Few! 6. Spring washers 8. Caliper Install seal in caliper cylinder. Screw piston (1 ) on plunger until it is seated. Make sure mark (2) on piston is on side of caliper (5) with bleed fitting (3). Install rubber boot (4). Make sure boot is seated in groove in caliper. ‘l. Piston 2. Mark Page 33-15 3. Bleed fitting 4. Boot 5. Caliper H fem-1... , . A . 01 ill Page 33-16 1. Cotter pin 2. Caliper locking block 3. Spring 4. Lining pads 5. Lining retainer spring 6. Rubber boot 7. Lock ring 8. Spacer 9. Hand brake shaft 10. Pawl 11. Plunger 12. Spring washer 13. Spring washers 14. Seal 15. Caliper cylinder 16. Piston 17. Seal 18. Dust boot 19. Complete caliper 20. Bleeder screw 21. Bleeder boot 22. Support bracket EXPLODED VIEW OF REAR BRAKE CALIPER AND BRACKET COMPONENTS 331.35 Hand Brakes Page 33-17/18 ADJUSTMENT Press brake pedal a few times. Starting from a released position. pull hand brake lever up three or four clicks. From under car, remove rubber cover. Loosen Iocknut (1). Tighten adjusting nut (2) until wheels are locked (try to turn wheels manually). Tighten locknut. Release hand brake. Check that wheels are free to turn. 1. Lockout 2. Adjusting nut 1. Ratchet 9. Cable 2. Rod 3. Spring 4. Button 10. Boot 11. Caliper 12. Pulley 5. Rubber ring 6. Lever 13. Spacer 14. Gasket 7. Washer 15. Support 8. Bolt 16. Washer 17. Bolt 18. 19. 20. 21. 22. 23. 24. Cable Lockwasher N ut Clamp Bolt Nuts Pin EXPLODED VIEW OF HAND BRAKE LINKAGE 25. 26. 27. 28. 29. 30. 31 . 32. Clip Washer Swinging arm Tie rod Clip Washer Lock ring Pin Service Tools 33A Page 33-19/20 A.56125 Wrench for brake line fittings X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 STEERING - 41 PARTS CATALOG. SERVICE MANUAL 8: SERVICE TIME SCHEDULE CODE 41 Specifications ....................................... 41 412.01 412 .02 Torque Specifications ................................ Steering Column ..................................... Steering Box ......................................... 41 A Service Tools ........................................ Page 41 -1 41 -1 41 -3 41 -5 41 -9 41 Steering Page 41-1 SPECIFICATIONS Type .................................................. Rack and pinion Ratio: — Steering wheel turns, lock to lock ................... — Corresponding rack travel .......................... 3 4.6 in. (1 17 mm) Pinion bearings ....................................... Two. ball type Pinion adjustment: H Early type .......................................... .2 Late type ........................................... By shims By threaded retainer Rack adjustment ...................................... By shims Minimum diameter of turning circle ................... 32.5 ft. (9.9 m) Tie rods ............................................... Adjustable, with fixed end ball joints Steering angles: — Outer wheel ........................................ 28° — Inner wheel ........................................ 32° 40‘ Front wheel toe-in .................................... +3/32 to +5/64 in. (+2.5 to +6.0 mm] Steering column .......................... . ........... Breakaway type, two universal joints Steering box capacity ................................. Steering box lubricant ................................. 5.3 oz. (.127 kg) SAE 90 EP oil or lithium-base grease with molybdenum disulphide TORQUE SPECIFICATIONS Ft. Lb. 49 5 36 49 5 36 35 3.5 25. 24.4 2.5 18 24.4 2.5 18 15 1.5 11 THREAD N-m Nut, steering wheel to column .................... M 16 x 1.5 Nut, tie rod ball joint to rack ........................ M 14 x 1 Nut, self—locking, ball joint to steering knuckle ............................... M 10 x 1.25 Nut, steering box to body bolt ...................... M 8 Nut, universal joint ................................ M 8 Nut, upper steering column support ............... M 8 ' TORQUE FIGURE Kgm DESCRIPTION Page 41—2 SECTION A-A ‘ _——-—'—A——" = [I —o'— h—I , —' = I1 U . .4». W 'III' [‘1 @ fl”? ‘ w A = rack travel corresponding to 46 in. (117 mm) @ M3121: a: = 62° + 4" ball joint pin articulation angle CROSS SECTION OF STEERING BOX ’1 , J Steering Column STEERING WHEEL REMOVAL AND INSTALLATION Center steering wheel and front wheels. Disconnect battery ground cable. Pry horn button off steering wheel (3). Remove two horn button springs (4). Remove nut (1) holding wheel (3) to shaft (2). Mark steering wheel and steering shaft for installation reference. Pull wheel off shaft. Install steering wheel in reverse order. Torque nut to 36 ft. lbs. (5 kgm). 1. Nut 2. Steering shaft 3. Steering wheel 4. Horn button springs STEERING COLUMN REMOVAL AND INSTALtATION Center steering wheel and front wheels. Disconnect battery ground cable. Remove four screws (2 and 3) to remove upper and lower steering column covers (1). 1. Steering column covers 2. Screws 3. Screw Remove two nuts (1 ) and washers and two bolts (2) and washers holding steering column support (3) to dash board. Lower column slightly and disconnect five electrical connectors at dash board. Rest steering column on floor. 1. Nuts 2. Bolts 3. Steering column support 412.01 Page 41-3 Page 41 -4 Mark universal joint (2) and steering box shaft {4) for installation reference. Remove bolt and nut (31 holding universal joint to steering box shaft. Slide universal joint off shaft. install in reverse order. Make sure steering wheel is centered with front wheels. Torque nuts and bolts to specifications. 1. Lower shaft 2. Universal joint 3. Nut 4. Steering box shaft 1. Lockwasher 2. Nut . Steering wheel 12. Bushing 3, Bolt 4. Washer 13. Horn contact 14, Bushing 5. Retainer 6. Nut 7. Lockwasher 15. Upper shaft 16 Bushing 17, Bolt 8. Washer 9. Support 10. Nut EXPLODED VIEW OF STEERING COLUMN 18. Lower shaft 19. Steering box Steering Box 412.02 Page 41 -5 REMOVAL AND INSTALLATION Center steering wheel and front wheels. Mark universal joint (1) and steering box shaft (3) for installation reference. Remove bolt and nut (2) holding universal joint to steering box shaft. 1. Universal joint 2. Nut 3. Steering box shaft Raise front of vehicle. Remove nut holding ball joint on tie rod(1)to steering knuckle(3). Install puller A.47035 (2) on ball joint. Tighten bolt on puller to separate ball joint from steering knuckle. Repeat for other side. 1. Tie rod 2. Puller A4703?) 3. Steering knuckle From inside vehicle, remove nuts from four bolts (1) holding steering box {2) to body. Remove steering box from vehicle. Install in reverse order. Torque nuts and bolts to specifications. Check front wheel toe. Refer to 443.01. 1. Bolts 2. Steering box Page 41-6 DISASSEMBLY AND REASSEMBLY ““ Remove four clamps (8. 6 and 16). Remove rubber boots (7 and 17). Unscrew two ball joints (5) from rack (19). Remove two bolts (9), cover (10), shim (1 ). spring (12), seal (13) and thrust block (14). On early type box, remove two bolts (27). seal (26), cover (25), plate (24), shim (23), bearing (22) and pinion (21 ). 0n late type box, remove threaded retainer (2) with seal (1 ), lock ring (3). bearing (4) and pinion (21). On all steering boxes, slide rack (19) from housing (15). Remove bushing (18) from rack. Remove bearing (20) from housing. Before reassembly, coat all bearing and gear surfaces with 90 W oil or pack rack and pinion housings and boots with a total of 5.3 oz. (.127 kg) of lithium—base grease containing molybdenum disulphide. Reassemble in reverse order. Use tool A.74247 to install bushing (18). Ensure that tab on bushing aligns with slot (28) in housing. Perform pinion and rack adjustments. 18 EARLY TYPE 22 ' LATE TYPE 1. Seal . Housing 2. Retainer 16. Clamp 3. Lock ring 4. Bearing 17. Rubber boot 18. Bushing 5. 6. 7. 8. 9. 19. 20. 21. 22. 23. Ball joint Clamp Rubber boot Clamp Bolt Rack Bearing Pinion Bearing Shim 10. Cover 24. Plate 11. Shim 25. Cover 12. Spring 13. Seal 26. Seal 27. Bolt 14. Thrust block _ . “ 28. Slot for tab on bushing 18 EXPLODED VIEW OF STEERING BOX 412.02 Steering Box Page 41.7 INSPECTION (Refer to illustration on previous page) Before inspection, clean all metallic parts in a suitable degreaser. Blow dry. Inspect rack(19), pinion (21 ), bearing (20) and housing (1 5) for wear, scratches. broken teeth or other damage. Replace entire steering box if damaged. Inspect rubber boots (7 and 17) for tears or breaks that would permit moisture entry. Replace if damaged. bearing (4 or 22) inspect bushing (18) and thrust block (1 4) for wear or breaks. Feplace if damaged. Replace spring (1 2) if worn. InSpect own weight. their under (all not should They for wear. Replace if damaged. Check that ball joints (5) move freely in all directions. Replace ii worn. Replace seal (1 or 26) if worn or damaged. ADJUSTMENTS Pinion (Early Type) Remove two bolts. cover with seal, plate, and shim to gain access to pinion bearings. Carefully install shims so they are centered on the pinion. install plate. cover with seal. and two bolts. Pinion (Late Type) With threaded retainer installed over pinion, torque retainer to 22 to 25 ft. lbs. (3.0—3.5 kgm). Check initial turning torque of pinion. Torque should be 4.3 to 14.0 inch lbs. (0.05 to 0.16 kgm). Stake retainer. 1. Torque wrench 2. Socket Jr (dimension X). To dimension X, add 0.003 t 0.002 in. (0.078 f 0.053 mm). Combine shims to make up new dimension. Shims available are 0.0047, 0.008, 0.010. and 0.020 in. (0.12, 0.20, 0.25, and 0.50 mm). I Measure distance from top of bearing to pinion cover facing / C Ix Using a suitable driver. make sure bearing is firmly seated. \ i \ Page 41-8 Hack Center the rack in its travel. Remove two bolts. cover, shims. and spring to gain access to rack trust block. While holding rack trust block against through 180° in both directions to settle fit. rack, turn pinion Measure distance from top of rack thrust block to cover facing # {dimension Y). To dimension Y, add 0.0035 1 0.0015 in. (0.09 1 0.04 mm). Combine shims to make up new dimension. Shims available are 0.0039 and 0.0059 in. (0.10 and 0.15 mm). install spring. shims. cover, and two bolts. LUBRICATION If steering box is being lubricated with grease. lubricate as specified in STEERING BOX DISASSEMBLY AND REASSEMBLY. if steering box is being lubricated with oil. check that steering box {rubber boots) is empty of oil. Turn steering fully to the right. Lift up left side of steering box. Loosen clamp on left rubber boot. Using a syringe, add 5.3 oz. [.127 kg) of 90 W oil to left rubber boot. Tighten clamp. ALIGNMENT After the steering box has been installed. set toe-in as specified in SUSPENSION section. % K L \ \ f "‘ l x Y Q \ \ A A.47038 Puller for separating tie rod ball joints A.74247 Tool for fitting rack bush 41A Page 41-9/1 O _' - Service Tools v.--.- .- X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND WHEELS 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 SUSPENSION - 44 PARTS CATALOG. SERVICE MANUAL 8: SERVICE TIME SCHEDULE CODE 44 44 443.01 443.02/.06 443.05 Specifications ....................................... Torque Specifications ................................ Front Suspension .................................... Front and Rear Shock Absorbers and Bars .............. Rear Suspension ..................................... Page 44-1 44-2 44-3 44-1 5 44-1 9 44A Service Tools ........................................ 44-29 44 Suspension Page 44-1 SPECIFICATIONS FRONT SUSPENSION Type: lndpendent, control arm. strut bar, knuckle pillar and strut assembly with integral shock absorber and coil spring. Caster: Unladen .................................. — Adjustment by shims set between reaction struts and supports Camber: Unladen. ................................ — Non-adjustable Toe-in1Unladen .................................. — Adjustment through threaded tie rods on each end of steering box ‘ Coil Springs: — Yellow-marked spring (1): length under a load of 474 lbs..... ......................... — Green-marked Spring (1): length under a load of474 lbs............................. — Lowest load permissible to compress spring to a length of 6.693 in. (1 70 mm) .......... +6°10' to +7°20 I 0° to -1° +3/32 to +15/64 in. (+2.5 to +6.0 mm) >6.693 in. (>170 mm) <6.693 in. (<170 mm) 441 lbs. (200 kg) REAR SUSPENSION Type: Independent, control arm, knuckle pillar and strut assembly with integral shock absorber and coil Spring. Adjustable cross tie rods. Camber: Unladen ................................. — Non-adjustable Toe-in: Unladen .................................. — Adjustment by threaded sleeves on tie rods Coil springs: — Yellow-marked spring (l): length under a load of 562 lbs-(255 kg) ................... — Green~marked spring (l): length under a load of 562 lbs. (255 kg) ................... — Lowest load permissible to compress spring to a length of 7.874 in. (200 mm) .......... -0°45' to -1°45' +13/64 to +11/32 (+5.0 to +8.5 mm) >7.874 in. (>200 mm) <7.874 in. (< 200 mm) 518 lbs. (235 kg) WHEELS AND TIRES Wheel rim type ................................... Tires: — Type: .......................................... ~ Inflation pressure: Front .................... Rear ..................... (‘) Springs must always be fitted in matched pairs. 5J x 13 in. 165/70 SR 13 in. 29 psi (2.0 kg/cm’) 32 psi (2.2 kg/cmz) Page 44-2 TORQUE SPECIFICATIONS DESCRIPTION TORQUE FIGURE THREAD N -m Stud bolt, wheel ................................... M 12 x 1.25 87 Nut, wheel hub (stake) ............................. M 20 x 1.5 216 22 balljoint ........................................ M 12 x 1.25 79 8 58 Nut, self-locking, strut bar to support .............. MI 12 x 1.25 69 7 51 Nut, strut bar to control arm ........................ M 12 x 1.25 69 7 51 Nut, self-locking control arm to body ............... M 10 x 1.25 40 4 29 Nut, strut assembly upper mount to body ......................................... M 6 1 7 Nut, self-locking, strut assembly to steering knuckle bolt ........................... M 10 x 1.25 59 6 43 Nut, strut assembly top mounting .................. M 12 x 1.25 59 6 43 Stud bolt, wheel ................................... M 12 x 1.25 87 9 64 Nut, stub shaftlstake) .............................. M 20 x 1.5 216 22 159 Nut, self—locking, control arm pivot bolt ............. M 14 x 1.5 98 10 72 Nut, self-locking, ball jointto pillar .................. M 14 x 1.5 83 Nut, self-locking, tie rod to control arm bolt ........................................ M 14 x 1.5 69 Nut, self-locking, strut assembly upper mount to body .................................. M 6 Kgm Ft. Lb. FRONT SUSPENSION Nut, self-locking, steering knuckle 9 9.5 . 64 159 REAR SUSPENSION Nut, self-locking, strut assembly to 9.5 8.5 4.! ' 61.5 7 51 1 7 pillar bolt ....................................... M 10 x 1.25 59 6 43 Nut, strut assembly top mounting .................. M 12 x 1.25 59 6 43 Ring nut, wheel bearing, (stake) .................... M 75 x 1.5 59 6 43 1| 5 Front Suspension 443.01 Page 44-3 R EM OVAL Remove wheel. It brake caliper (1) needs inspection, leave caliper attached to suspension. To do this, plug outlet from brake fluid reservoir and disconnect brake fluid hose (2) from caliper. To remove caliper from suspension, refer to 331.17/.25. 1. Caliper 2. Brake hose Remove bolts (5) and plate holding strut bar (3) to control arm(4). Remove bolt (2) holding control arm to bracket (1). 1. Bracket 2. Bolt 3. Strut bar 4. Control arm 5. Bolts Remove nut l1) holding tie rod ball joint (3) to steering arm (2). Use tool A.47038 to separate ball joint from arm. 1. Nut 2. Steering arm 3. Ball joint Page 44—4 Disconnect strut assembly (1] by removing three nuts (2) and washers. 1 . Strut assembly 2. Nuts Lower suspension assembly out of vehicle. To replace coil Springs. refer to 443.02/.06. If hub bearing must be replaced. refer to STEERING KNUCKLE OVERHAUL in this section. 1. Strut assembly 4. Control arm 2. Steering arm 3. Steering knuckle INSTALLATION Place suspension assembly in vehicle. install washers and g nuts {2) on three bolts on tap of strut assembly (1). Torque nuts to 7 ft. lbs. (1 kgml. 1 . Strut assembly 2. Nuts Front Suspension 443.01 Page 44-5 Place control arm (4) in bracket (1). Install bolt (2). washer and nut. Place strut bar (3) on control arm. Place plate on strut. Install bolts (5) through strut bar and control arm and install nut. 1. Bracket 2. Bolt 3. Strut bar 4. ControI arm 5. Bolts Place tie rod ball joint (3) in steering arm (2). Install nut (1). Torque nut to 36 ft. lbs. (5 kgm). Install brake caliper. If caliper was disconnected, attach brake hose and bleed brakes. Install wheel. 1. Nut 2. Steering arm 3. Ball joint Lower vehicle. With vehicle on ground, torque bolt (1) and nuts (2 and 3) to specifications. 1. Bolt 2. Nut 3. Nut Page 44-6 Section through shock absorber top mouniing. CROSS SECTION OF FRONT SUSPENSION Front Suspension 443.01 Page 44-7 STEERING KNUCKLE REMOVAL AND INSTALLATION Raise vehicle and remove wheel. Remove bolts (1) holding caliper support (2) to knuckle (3). Remove caliper support with caliper attached without disconnecting brake hose. Wire assembly out of way. Remove disc and backing plate. Refer to 331 .17/.25. l. Bolts 2. Caliper support 3. Knuckle Remove nut (3) holding lower ball joint (1) to knuckle (2). Separate ball joint from knuckle. 1. Ball joint 2. Knuckle 3. Nut Remove nut (4) holding tie rod ball joint (6) to steering arm (5). Separate ball joint from arm. Remove two nuts (2) and bolts attaching strut assembly (1) to knuckle (3). Remove steering knuckle from vehicle. Installation is reverse of removal. Torque bolts and nuts to specifications. ‘I. Strut assembly 6. Ball joint 2. Nuts 3. Knuckle 4. Nut 5. Steering arm Page 44-8 OVERHAUL Unstake and remove hub out (1}. Remove washer (2) with gasket attached‘ 1, Nut 2. Washer 3. Steering knuckle Use a puller {3) or press to remove hub (1) from knuckle (2). 1. Hub 2. Knuckle 3. Puller If bearing inner race (2) remains on hub (1). drive race off hub far enough to attach a puller (3), and remove race from hub. A press may also be used. _.__-,_,‘__i. _‘___ 1. Hub 2. Inner race 3. Puller 443.01 Front Suspension Page 44-9 1'1 Remove internal lock ring (2) from knuckle (1). ' 1. Knuckle 2. Lock ring Remove thrust ring from inner side of knuckle. “K Place a suitable mandrel [2) on bearing inner race. Use a puller (3) or press to remove bearing assembly from knuckle {1). 1. Knuckle 2. Mandral . ‘\ 3. Puller pmwummhpnd . Steering knuckle . Thrusr ring Nut . Washer . Gasket . Bearing .a . Gasket . Lock ring . Thrust ring Hm EXPLODED VIEW OF STEERING KNUCKLE 3- Page 44-10 To reassemble knuckle [1), place bearing assembly in outer side of knuckle. Place a suitable mandrel (2) on hearing inner race. Use a puller (3) or press to install bearing assembly in knuckle. Press bearing in until seated against lip in knuckle. 1. Knuckle 2. Mendrel 3. Puller Install internal lock ring (1) in groove in knuckle (2) Install inside and outside (3) thrust rings in knuckle. 1. Lock ring 2. Knuckle 3. Thrust ring install gasket (1) on hub shaft [3]. Use a puller (2) or press to press hub into place. 1. Gasket 2. Fuller 3. Hub shaft Front Suspension Install gasket (2), washer (3) and nut (4) on hub shaft (1). Torque nut to 159 ft. lbs. (22 kgm). Stake nut. 1. Hub shaft 2. Gasket 3. Washer 4. Nut CONTROL ARM INSPECTION Ii control arm ball joint is worn, replace entire control arm. Check control arm (1) for cracks or signs of distortion. Replace if damaged. Check swivel joint (2) and protective boot (3) for cracks or breaks that might permit mositure or dirt entry. Replace entire control arm if damaged. Check rubber bushings (4) for wear or deterioration. Overhaul control arm if damaged. 1. Control arm 2. Swivel joint 3. Boot 4. Bushing OVERHAUL Using a drill press. machine off paened area of spacer (either and) as shown. Using a press. drive out Spacer first. then remove rubber bushing. 443.01 Page 44-11 Page 44-12 Coat new bushing (4) with silicone grease. Using assembly tool A‘74225 (items 1. 2 and 5). install new bushing (4) into control arm (3). 1. Installer. tool A.74225 2. Pilot. tool A7422?) 4. Rubber bushing 5. Base. tool, A.74225 3, Control arm Assemble spacer (71 on installer (1), then screw on tip (6). Coat new Spacer (7) with silicone grease. Using assembly tool A.74255 (items 1, 2, 5, 6 and 7), install new spacer {7) into bushing i4). Position washers on both ends of spacer, then peen over spacer to lock washers in place. memeeewe 1. installer, tool A.74255 2, Pilot, tool A.74255 3. Control arm 4. Rubber bushing 5. Base. tool A74255 6. Tip. tool A.74255 I Spacer Nut Washer Bushing Spacer Bolt . Steering knuckle Nut . Control arrn EXPLODED VIEW OF CONTROL ARM COMPONENTS Front Suspension 443.01 Page 44-1 3/14 FRONT SUSPENSION ALIGNMENT Before aligning the front suspension, it must be checked for possible worn or misadjusted components. Check the following: r Tire pressure (29 psi front, 32 rear). — Tire radial and lateral rmout. Runout should be less than 0.118 in. (3 mm). — Wheel bolt tightness. — — — — — Wheel bearing end play (if perceptible). bearing may be worn. or bearing may need tightening). Lower ball joint (may be worn). Also check ball joint nut tightness. Torque should be 58 ft. lbs. (8 kgm). Control arm to chassis mounting nut tightness. Torque should be 29 ft. lbs. (4 kgm). Control arm rubber bushings for deterioration (overhaul or replace control arm). Strut assembly to knuckle nut tightness. Torque should be 43 ft. lbs. (6 kgm). — Steering box tie rod ball joints (replace if worn). Caster (Unladen) +6°10‘ to +7°20‘ (+6°45‘ preferred) To adjust, vary thickness of shims (1) at front of strut bar (2). Camber (Unladen) 0° to -1° (-Vz° preferred) Non-adjustable 2. Strut bar 1. Shims Toevin (Unladen) +3/32 to +15/64 in. (+2.5 to +6.0 mm) (+5/32 in., +4.0 mm preferred) To adjust. make sure steering box and steering wheel are centered. then loosen nut (1). Turn steering box ball joint (2) in or out to obtain ad- justment. Tighten nut. Repeat for other side. 1. Nut. 2. Ball joint H4 Front and Rear Shock Absorbers and Bars 443.02/.06 Page 44—15 STRUT ASSEMBLY REMOVAL AND INSTALLATION Flem0ve three nuts (2) and washers holding strut assembly (1] at top. 1. Strut assembly 2, Nuts. Remove two nuts (2) and bolts attaching strut assembly (1) to su3pension. Remove strut assembly from vehicle. Install in reverse order. Torque upper mount nuts to 7 ft. lbs. (1 kgml and lower mount nuts to 43 ft. lbs. (6 kgm). 1. Strut assembly 2._Nuts COIL SPRINGS REMOVAL AND INSTALLATION Set up strut assembly (1 ) in coil Spring compressor A.74277 (2). 1. Strut assembly 2. Tool A7427? Page 44-1 6 12 1. Nut 2. Lockwasher 3. Washer 4. Nut 5. Cup 5. Pad 7. Rubber pad 8. Plate 9. Rubber ring 10. Spring 11.. Rubber ring 12. Shock absorber 13. Nut 14. Bolt 14 EXPLODED VIEW OF STRUT ASSEMBLY Front and Rear Shock Absorbers and Bars Tighten three spring plate bolts (1) until they contact spring plate (2) on strut assembly. Crank tool A.74277 until spring (3) is compressed about one inch. 1. Spring plate bolts 2. Spring plate 3. Spring Using a shank wrench (3) to hold shock absorber stud. remove nut holding support to shock absorber. Carefully uncrank tool A.74277 until spring is fully relaxed. Remove strut assembly from tool A7427? and separate parts. To install coil spring, reverse removal procedure. Torque nut to 43 ft. lbs. (6 kgm). 1. Spring plate bolts 2. Spring plate 3. Shank wrench FRONT STRUT BAR REMOVAL AND INSTALLATION Remove nut (5). two bolts (3) and plate (2) attaching strut bar (1) to control arm (4). ‘l. Strut bar 2. Plate 3. Bolt 4. Control arm 5. Nut 443.02/.06 Page 44-17 Page 44-18 Remove nut l1}, outer washer (2) and rubber grommet (3) tron-i end of strut bar {4). Remove strut from vehicle. Install in reverse order, Torque nuts and bolts to specifications Check wheel alignment. 1. Nut 2. Washer 3. Rubber grommet 4. Strut bar 12 13 14 15 1. Nut' 6. Lockwasher 11. Lockwasher 2. Washer 15. Nut 7. Bolt 12. Bolt 3. Cup 8. Rubber ring 13. Bolt 16. Bolt 17. Washer 4. Rubber pad 5. Spacer 9. Strut bar ' 10. Lock plate 14. Pillar 18. Support EXPLODED VIEW OF STRUT BAR ATTACHMENTS TO BODY AND CONTROL ARM Rear Suspension 443.05 Page 44-19 R EM OVAL Remove wheel. if brake caliper (2) needs inspection, leave caliper attached to suspension. To do this, plug outlet from brake fluid reservoir and disconnect hose (1) from caliper. To remove caliper from suspension, refer to 331.17/25. 1. Hose 2. Caliper 3. Cable Remove six Allen bolts (1i attaching half-shaft outer CV joint (2) to stub shaft. 1. Allen bolts 2. Outer CV joint Remove catalytic converter. Refer to 10258. Note number and position of shims at front control arm mounting point. Remove nut, washer and bolt (2) holding control arm (1) to bracket (3) at front of suspension. Retain shims between arm and bracket. 1. Control arm 2. Bolt 3. Bracket Page 44-20 Note number and position of shims at rear control arm mount: ing point. Remove nut washer, and bolt (2) holding control arm to bracket (3) at rear of suspension. 1. Control arm 2. Bolt 3. Bracket Remove 3 nuts (1) and washers holding strut assembly (2) at top. Remove suspension assembly from vehicle. To replace coil spring. refer to 443.02/.06. 1. Nuts 2. Strut assembly INSTALLATION Place suspension assembly in vehicle. Install washers and nuts (1 l on three bolts on too of strut assembly (2). Torque nuts to 7 ft. lbs. (1 kgm). 1. Nuts 2. Strut assembly Rear Suspension 443.05 Page 44-21 Install shims noted during removal between control arm (3) and front and rear mounting brackets (2 and 4). Install bolts, nuts (1) and washers holding control arm to brackets. NOTE: Torque control arm nuts to 72 ft. lbs. (10 kgm) when installation is complete and vehicle is on ground. Install catalytic converter. 1. Nut 2. Front bracket 3. Control arm 4, Rear bracket Install six new Allen bolts (1) to attach half-shaft outer CV joint (2) to hub shaft. Torque bolts to 31 ft. lbs. (4.3 kgm). Install brake caliper. If caliper was left on suspension, connect hose and parking brake cable, Bleed caliper. Check wheel alignment. 1. Allen bolts 2. Outer CV joint HEAR WHEEL ALIGNMENT install and adjust alignment equipment. Follow instructions provided with equipment. Set up equipment to check camber. Camber should be -O°45' to -1°45‘. Check toe-in. Toe—in. unladen vehicle, should be +13/64 to +11/32 in. (5.0 to 8.5 mm). Adjust toe-in by lengthening or shortening rear tie rod (1). 1. Rear tie rod Page 44-22 1. Shock absorber front mounting adiustment shims. 2‘ Shock absorber rear mounting adjustment shims‘ CROSS SECTION OF REAR SUSPENSION , 443.05 Rear Suspension Page 44-23 CONTROL ARM REMOVAL AND INSTALLATION Remove rear suspension from vehicle. Refer to REAR SUSPENSION REMOVAL AND INSTALLATION. Unstake stub shaft nut (1). Remove nut, washer and stub shaft from pillar. Remove nut (4) washer and bolt attaching rear tie rod (6) to control arm (5). Remove cotter pin and nut (7) holding tie rod ball joint (8) and remove ball joint from pillar. Remove nut (3) holding lower ball joint (2) to pillar (9). Separate ball joint from pillar. Remove control arm. Installation is reverse of removal. Torque nuts and bolts to specifications. Stake stub shaft nut. 1. Nut 3. Nut 2. Bell joint 4. Nut 5. Control arm 6, Tie rod 7. Nut 8. Ball ioint 9. Pillar 2 3 1 Q 15 1. 2. 3. 4. Nut Washer Washer Washer 5. 6. 7. 8. Bolt Nut Washer Washer 9. 10. 11. 12. Bolt Pillar Nut Boot EXPLODED VIEW OF CONTROL ARM 13. Bushing 14. Control arm 15. Bushing Page 44—24 REAR PlLLAFl REMOVAL AND INSTALLATION Remove wheel. Remove bolts holding brake caliper support to pillar. Remove caliper support with caliper attached without disconnecting brake hose and hand brake cable. Wire assembly out of way. Remove disc and backing plate. Refer to 331.25. Remove six Allen bolts (1) attaching half—shaft outer CV joint [2) to stub shaft. NOTE: Discard Allen bolts and replace with new ones for installation. Torque nuts to 31 ft. lbs. (4.3 kgm). 1. Allen bolts 2. Outer CV joint Unstake stub shaft nut (1). Remove nut, washer and stub shaft from pillar (2). 1. Nut 2. Pillar Remove two nuts (2) and bolts attaching strut assembly to pillar (1}. 1. Pillar 2. Nuts Rear Suspension 443.05 Page 44-25 Remove nut [‘l) holding lower ball joint (2) to pillar (4). Tilt pillar outward and separate ball joint from pillar. Remove cotter pin and nut holding rear tie rod ball joint (3) to pillar. Separate ball joint from pillar. Remove pillar from vehicle. Installation is reverse of removal. Torque nuts and bolts to Specifications. Stake stub shaft nut. 1. Nut 2. Ball joint 3. Ball joint 4. Pillar OVERHAUL Remove thrust ring (1) from pillar (2). l. Thrust ring 2. Pillar Place 3 Suitable mandrel (2) on hub (1). Use a puller (41 or press to press hub out of inner race and out of pillar (3). 1. Hub 2. Mandrel 3. Pillar 4. Puller Page 44-26 If bearing inner race [2) remains on hub (1 ). drive race off hub far enough to attach to puller (3), and remove race from hub. A press may also be used. 1. Hub 2. Inner race 3. Puller Unstake ring nut (21. Use tool AS7149 (3) to remove ring nut from pillar (1). 1, Pillar 2. Ring mu 3. Tool A.57149 .owmrdsnrakwro“ . Stub shaft . Pillar Seal .- . Bearing Plate Hing nut Seal Hub . Washer Nu! EXPLODED VIEW OF REAR PILLAR Rear Suspension Place tool A.74377 (2) on bearing inner race. Use a puller (3] or press to remove bearing assembly from pillar“). 1. Pillar 2. Tool A1437? 3. Puller To reassemble. place bearing assembly (2) on pillar (1). Use tool A7437? (3) and a puller (4) or press to install bearing assembly in pillar. 1. Pillar 2. Bearing assembly 3, Tool A.74377 4. Puller Screw a new ring nut (13) into pillar (2). Using tool AS7149 (l) and a torque wrench (4), torque nut to 43 ft. lbs. (6 kgm). Stake nut. 1. Tool A57149 2. Pillar 3. Ring out 4. Torque wrench 443.05 Page 44-27 Page 44-28 Support bearing inner race with tool A.74377 (3). Use a driver [5} to install hub (4) into pillar (2). A press may also he used. Install thrust plate. 1. Seal 2. Pillar 3. Tool A7437? 4, Hub 5. Driver 44A Service Tools A.47038 Puller for separating tie rod ball joints AS7149 Rear pillar ring nut wrench A7425?) Tool for inserting front control arm rubber bushings A7427? Coil spring compressor A7437? Tool for removing and refitting rear pillar bearing Page 44—29/30 A. 57149 X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES 50 ELECTRICAL ELECTRICAL 55 55 BODY BODY 70 70 ACCESSORIES - 50 PARTS CATALOG. SERVICE MANUAL 8: SERVICE TIME SCHEDULE CODE Page 501.01 501.03 Ventilation and Heating ............................... Air Conditioning ..................................... 50—1 50-5 Ventilation and Heating 501.01 Page 50-1 TROUBLESHOOTING Insufficient heat or ventilation may be caused by problems other than a faulty heater. Before disassembly, check for the following: Leaves or other debris blocking radiator. Leaves or other debris blocking fresh air inlet. Faulty coolant thermostat. Blown fuse or faulty electrical system components. Low coolant level. Kinked or otherwise blocked heater hoses. Cooling system contamination. CONTROL PANEL REMOVAL AND INSTALLATION Disconnect battery ground cable. Remove radio knobs. Remove two nuts (3) and washers retaining radio. Remove radio fascia panel (2) and remove radio. Remove tour knobs [4) from levers. Remove control panel fascia panel (5). Remove and disconnect clock (1). or remove clock opening cover plate. 1. Clock 2. Fascia panel 3. Nuts 4. Knobs 5. Fascia panel Remove screw [3) holding control panel (2) to support (6). Remove four screws [4 and 5) holding support to instrument panel (1}. Maneuver support out of instrument panel. leaving control panel in position. 'I.|nstrument panel 6. Support 2, Control panel 3. Screw 4. Screws 5. Screw Remove connectors (1) from fan switch and light. Remove three screws (3) and clamps holding cables (4). Disconnect cables from levers (5) and remove control panel (2). install in reverse order. 1. Electrical connectors 4. Cables 2. Control panel assembly 5. Levers 3. Screws BLOWER REMOVAL AND INSTALLATION Disconnect battery ground cable. Disconnect end of cable (4) from heater door (5) and remove screw and clamp (1) holding cable to |owar housing (3). Pull cable out of lower housing. At left side of housing, disconnect three blower leads. Remove four clips (2 and 6) holding lower housing. Maneuver lower housing out of vehicle complete with duct for center vents. 1.Clamp 2.Clip 3.Lowerhousing 4.Cable 5.Healerdoor Remove blower fan shroud. Remove tvvo clips (3) holding blower assembly (2). Remove blower assembly from lower housing (1). Install in reverse order. 1. Lower housing 2. Blower assembly 3. Clip 6.Clip Ventilation and Heating 501.01 Page 50-3 HEATER CORE REMOVAL AND INSTALLATION Disconnect battery ground cable. Drain cooling system. Disconnect end of cable (4) from heater door (5) and remove screw and clamp (1) holding cable to lower housing (3). Pull cable out of lower housing. At left side of housing. disconnect three blower leads. . Remove four clips (2 and 6) holding lower housing. Maneuver lower housing out of vehicle complete with duct for center vents. LCIamp 2.Clip 3.l.ovverh0using 4.Cable 5.Heaterdoor 6.Clip Place container on floor to catch coolant. Flemove two nuts (6) holding water valve (5) to heater core (3) and separate valve from core. Remove two nuts (2) holding pipe (1) to heater core and separate pipe trom core. Slide heater core out of upper housing (4) and remove from vehicle. Install in reverse order. Use new gaskets. 4. Upper housing 1. Water pipe 2. Nut 3. Heater core 5. Water valve 6. Nuts WATER VALVE REMOVAL AND INSTALLATION Disconnect battery ground cable. Drain cooling system. Remove screw and clamp holding control cable to valve (1). Disconnect cable end from valve. With container on floor to catch coolant, loosen clamp (2) and disconnect hose (3) from valve. Remove two nuts (4) holding valve to heater core and remove valve. Install in reverse order. Use new gasket. 1. Water valve 2. Clamp 3. Hose 4. Nut Page 50-4 ‘l. Diffuser 2. Duct 3. Gasket 4. Duct 5. Cables 6. Control panel 7. Fascia panel 8. Knobs 9. Cable 10. Clip 1 'l . Upper housing 12. Fan shroud 13. Vent assembly 14. Gasket 15. Due! 16. Lower housing 17. Heater door 18. Hinge 19. Clip 20. Pad 21. Blower motor EXPLODED VIEW OF HEATER ASSEMBLY 22. Fan 23. Nut 24. Heater core 25. Gasket 26. Water valve 27. Pipe 28. Gasket 29. Pad 30. Gasket 31. Air intake door 501.03 Air Conditioning Page 50-5 SERVICING Insufficient air conditioning may be caused by problems other than A/C components. Before removing any components, check for the following: Leaves or other debris blocking radiator or condenser. Leaves or other debris blocking fresh air inlet. Blown fuse or faulty electrical system components. Low freon charge. Kinked or disconnected vacuum lines. Observe following precautions before any service operations that require opening up freon system. WARNING: Wear protective eye equipment while purging system. Do not discharge freon near open flame, a toxic gas may result. CAUTION: Purge system slowly to prevent excessive loss of system oil. NOTE: Whenever system is purged, it must be evacuated and recharged. Purging System With both valves closed on A/C manifold gauge set, attach red hose (high pressure) to discharge fitting (2) and blue hose [low pressure) to suction fitting (1). 1. Suction fitting 2. Discharge fitting Place yellow hose in a clean rag. Slowly open low and high pressure valves on gauge set. Allow freon to bleed off through yellow hose. CAUTION: Open valves only enough to bleed off freon slowly. Flapid bleeding will draw excessive oil from system. Check rag for signs of oil, a small amount is to be expected. Replace oil if loss is excessive. When both gauges read zero. system is purged. Close valves on gauge set, and leave lines connected for evacuating. } - 0TH GAUGES READ ZERO Page 50—6 Evacuating System CAUTION: System must not be operating and must be purged before starting evacuation. LOW PR ESSUR E GA UG E Connect yellow hose from A/C gauge set to vacuum pump. Start vacuum pump. Open low pressure valve. Check that low pressure gauge indicates a slight vacuum. After a few minutes check that low pressure gauge reads about 24" Hg, and high pressure gauge reads slightly below zero. If high pressure gauge does not read below zero. check system for blockage. \‘ ABOUT 29" H91 After about 10 minutes of operation. low pressure gauge should read about 29" Hg. If gauge rises check system for leakage. Any leak must be repaired. Operate vacuum pump for a minimum of 30 minutes at about 29" Hg (maximum vacuum will be 1" less for each 1000 ft. above sea level). LOW PR ESSUR E VALVE OPEN Close low pressure valve. Check low pressure reading. it should not rise faster than 1“ in five minutes. If reading rises faster. check system for leak. Shut off vacuum pump. Disconnect yellow hose from pump. System is now ready to be charged with freon. PRESSURE RISE 1" IN 5 MINUTES MAX. LOW PRESSURE VALVE CLOSED Charging System Using Freon Pound Cans NOTE: A/C gauge set is connected same as in preceding instructions. WARNING: Wear protective eye equipment. 00 not discharge freon near open flame. a toxic gas may result. Avoid heating freon container. System charge is about 2 lbs. Place adapter on freon can. Attach yellow hose to adapter. Make sure both valves on A/C gauge set are closed. BOTH VALVES CLOSED Pierce freon can and allow freon to enter yellow hose. Loosen yellow hose connector at gauge set and allow gas to escape for a few seconds to purge air in line. Retighten connector. REFRIGERANT CAN Air Conditioning 501.03 Page 50-7 Make sure both valves on gauge set are closed. Start engine. Push "MAX A/C" button and set fan Speed at "Hi" Set engine at fast idle (1500 to 2000 rpm). With freon can upright. gradually open low pressure valve to allow freon into system. LOW PRESSURE VALVE HIGH PRESSURE VALVE DO NOT OPEN CAUTlON: Do not open high pressure valve. If pressure on low pressure gauge drops below 40 psi, freon can may be inverted momentarily for faster charging. Do not hold can inverted for more than a few seconds since excessive amounts of liquid will be drawn into compressor and damage it. To determine when can is empty tap it on bottom. A hollow ring should be heard when empty. REFRIGERANT CAN Repeat above with additional cans to charge system with a total of about 2 lbs. Whether just adding freon to a low system, or fully charging, check sight glass (1) on receiver/dryer (2) to determine when system is completely charged. When freon passing through sight glass is clear and free of bubbles, system is completely charged. Close low pressure valve. Disconnect yellow hose from can. As quickly and carefully as possible, disconnect red and blue hoses from system connectors. Replace caps on connectors. 1. Sight glass 2. Receiver/dryer Charging System Using Test Stand Refer to test stand manufacturer's instructions. Connect high pressure hose from test stand to discharge fitting (2). Connect low pressure hose from test stand to suction fitting (1!. Set charge indicator to about 2 lbs. 1. Suction fitting 2. Discharge fitting Page 50-8 OPERATIONAL CHECKS BOTH GAUGES 70 TO 85 PSI Connecting Test Equipment Close both valves on A/ C gauge set. Remove caps from discharge and suction fittings (refer to preceding iigurel. Connect blue hose (low pressure) to suction fit- ting and red hose (high pressure) to discharge fitting. Check that both gages read 70 to 85 psi at 68° to 78°F. NOTE: Pressure reading will vary according to ambienttemperatures, relative humidity. and atmOSpheric pressure. Provide a fan to flow air over front of vehicle during following checks. BOTH VALVES CLOSED Normal System Operation Set A/C controls to "MAX A/C" with fan switch on "Hi“ Accelerate engine and allow it to decrease to idle. On vehicles with carburetor, check that idle is between 950 and 1050 rpm. On vehicles with fuel injection,_check that idle speed does not decrease with A/C on. Accelerate engine to 1500 rpm. Check that low pressure gauge reads between 7 and 42 psi and high pressure gauge reads between 142 and 248 psi. Check that freon passing through sight glass is clear and free of bubbles. 1. Idle speed step-up control 2. Carburetor Compressor Clutch and Minimum Pressure Switch Check - 35-45 PSI Shut off engine. Turn ignition switch on. Push “STOP" button and check that compressor clutch dis— engages. ' Push ”MAX AC" button and check that clutch engages. Open low pressure valve on gauge set and slowly bleed freon until clutch disengages. Clutch should disengage at 40 j: 5 psi on low pressure gauge. Close low pressure valve. Recharge system. Evacuating system is" not required since . ‘ system was not completely discharged. - L'ow Air Conditioning 501.03 Page 50-9 Condenser Fan Switch. Check NOTE: Do not“ use fan in front of vehicle unless ambient temperature is over 80°F. Start engine and set A/C controls for maximum cooling. Run engine at about 2000 rpm. Check that condenser fan comes on between 240 to 280 psi on high pressure gauge. This indicates that switch closed. Allow engine speed to slow down. Check that fan goes off between 160 and 140 psi. This indicates that switch opened. High Pressure Switch Check Connect test light to wire on frost prevent valve. Do not disconnect wire from valve. Disconnect connector for condenser fan. Increase engine speed to increase pressure Check that test light comes on between 340 and 360 psi. This indicates that high pressure switch closed. Check that pressure starts to drop. This indicates that frost prevent valve works. ' Reconnect condenser fan connector. Check that test light goes out between 210 and 195 psi. This indicates that high pressure switch opened. GROUND Frost Prevent Switch Check Leave test light connected to frost prevent valve wire. Run engine at fast idle. Place jumper wire into frost prevent switch connector. Check that test light comes on and pressure starts to drop. This indicates that system wiring is good. Shut engine oft. Remove jumper and test light. GROUND FROST PR EVENT SWITCH VALVE JUMPER Page 50-10 Remove frost prevent switch. OHMMETER Provide ice cold water about 32°F. Connect ohmmeter to terminals on switch‘ Place switch in water. Check that switch closes. Remove switch from water‘ Check that switch opens as it warms up. Install switch making sure surface of switch and pipe are clean. FROST PREVENT SWITCH 501.03 Page 50-11/12 A/C-HEATER VACUUM SYSTEM Component Test To test each vacuum component, apply vacuum to vacuum motor and check operation. If vacuum motor does not operate, check for binding linkage or broken vacuum motor. System Test To test the vacuum system (engine running), press each push button on A/C-Heater Control, then check each component for the condition indicated. Test for vacuum at each component by removing vacuum hose from component, then manually blocking the hose. A/C-HEATER CONTROL PUSH BUTTONS COMPONENT STOP 'X'fg COMPRESSOR Off On BLOWER (30) Off On . Closed-NV Closed-NV ‘ Open-NV Closed—V Closed FRESH AIR DOOR (13) RECIRCULATED AIR DOOR (11) DEFROSTER DOOR (4) WATER VALVE (33) (Controlled by HEAT lever) A/C HEAT DEF On Off Off On Off/On* Off/On* Open-V Open—V Open-V Open-NV Closed-V Closed—V Closed-V Closed-V Closed-V Closed»V Open-NV Closed Closed/Open* Open Open * — Optional V - Vacuum to vacuum motor NV - No vacuum to vacuum motor FAN O L0 STOP Af‘é‘ M A/C HEAT DEF ME ”' HEAT ON-OFF C 1 . Duct 2. Duct tube 3. Vacuum motor for defroster door 4. Defroster door 5. Diffuser 6. Duct 7. Gasket 8. Duct tube 15‘. Expansion valve 22. Plate 29. Clip 9. Duct 10. Defroster duct 16. Upper housing 23. Duct 24. Gasket 11 . Recirculated air door 18. Center housing 25. Lower housing 12. Door linkage 13. Fresh air door 14. Evaporator 19. Heater Core 20. Pipe 26. Vent assembly 30. Blower motor 31. Bracket 32. Bracket 33. Water valve 27. Bracket 34, Clip 21. Gasket 28. Fan 35. Vacuum mOtor I for doors 1 1 and 1E 17. Gasket EXPLODED VIEW C 1F A/C-HEATER ASSEMBLY _ Air Conditioning CONTROL PANEL REMOVAL AND INSTALLATION Disconnect battery ground cable. Remove radio. Remove two knobs (1 and 4) from leversc Remove fascia panel {2). Remove and disconnect clock. or remove clock opening cover plate [3). l. Knob 2. Fascia panel 3, Clock Opening cover plate 4. Knob Remove screw (1) holding control panel (2) to support (3). 1. Screw 2. Control panel 3. Support Remove four screws (1 and 3) holding support; (2) to instru— ment panel. Maneuver support out of instrument panel. leaving control panel in position. 1. Screws 2. Support 3. Screws 501.03 Page 50-14 At top side of control panel, disconnect electrical connectors l1 and 3} and vacuum hose connector (2). At bottom side of control panel. remove screw and clamp holding cable and disconnect cable from lever. Remove control panel. Install in reverse order. 1. Electrical connectors 2. Vacuum hose connector 3. Electrical connectors 1. Wires 7. Gasket 13. Lever 2. Socket 8. Switch panel 14. Pin 15. Clip 3.Bulb 9_Knob 4. Cover 10. Screw 16. Pad 5. Fascia panel 1 1 . Switch 17. Support 6. Push buttons 12. Knob EXPLODED VIEW OF CONTROL PANEL '* Air Conditioning HEATER CORE REMOVAL AND INSTALLATION Disconnect battery ground cable. Drain cooling system. Unscrew gearshift knob (1). Remove five screws (2 and 4) holding lower console (3). Tilt and of console up until it clears gearshift lever and lay it to one side. 1. Gearshift knob 2. Screws 3. Lower console 4. Screw Remove three screws (1] and two retaining plates (2) holding center vent duct (3) to housing. Remove center vent duct. 1. Screws 2. Retaining plate 3. Center vent duct Working in passenger's side footwell, remove access panel covering expansion valve. Lower fuse/relay panel and set to one side. Working in both footwells. remove four clips (1) holding lower housing (2) to center housing (3). Lower assembly down to floor. 1. Clips 2. Lower housing 3. Center housing 501.03 Page 50-15 Page 50-16 Place container on floor to catch coolant. Loosen two hose clamps (2) and disconnect hoses from heater core (1]. Remove heater core from lower housing (3). Install in reverse order. 1. Heater core 2. Hose clamps 3. Lower housing A/C-H EATER UNIT REMOVAL AND INSTALLATION NOTE: AXC—heater unit must be removed to remove evaporator, blower assembly and water valve. Disconnect battery ground cable. Drain cooling system. Purge A/C system. Refer to procedures in this section. Unscrew gearshift knob (1}. Remove five screws {2 and 4) holding lower console (3). Tilt end of console up until it clears gearshift lever and disconnect all electrical connectors. Remove Iower consoie. 1. Gearshift knob 2. Screws 3. Lower console 4. Screw Remove three screws (1) and two retaining plates (2) holding center vent duct (3} to housing. Remove center vent duct. 1. Screws 2. Retaining plate 3. Center vent duct Air Conditioning Working in passenger's side footwell, remove access panel covering expansion valve. Lower fuse/relay panel and set to one side. With container on floor to catch coolant, loosen clamp (1) and disconnect heater core outlet hose (2). Loosen fittings (4) and disconnect high and low pressure lines (5}. Loosen clamp (6) and disconnect drain hose (7). Disconnect blower motor electrical connector. Disconnect electrical leads (3) from frost prevent switch. 1. Clamp 2. Outlet hose 5. Pressure lines 3. Electrical leads 6. Clamp 4_ Fitting 7. Drain hose Working at lirewall side of unit, remove screw (3) and clamp holding water valve cable (1 ) to bracket. Loosen screw (4) holding end of cable to valve and disconnect cable end. Loosen clamp (2) and disconnect inlet hose (5). 1.Watervaivecable 2.Clamp 3.5crew 4_Screw 5.Inlethose Working in driver's side footwell, disconnect vacuum hose (1) from vacuum motor (2). From each side of unit. remove two nuts(3) holding unit to body at top. Fold carpet and padding away from tunnel. Maneuver A/C-heater unit out through passenger's side footwell. l.Vacuum hose 2. Vacuum motor 3.Nuts 501.03 Page 50-18 DISASSEMBLY AND REASSEMBLY ‘J Loosen clamp holding hose (3) to heater core and disconnect hose. Remove two screws (1) holding water valve to bracket (2) and remove valve. Remove clip 15) holding temperature sensing tube and frost prevent switch {4} to pipe. Loosen fitting (7) and remove expansion valve (6). 1.5crews 2. Bracket 3.Hose 5. Expansion valve 7. Fitting 4_Frostpreventswitch 5. Clip Remove clip (5) holding vacuum motor rod (5) to door linkage and disconnect rod from linkage. Remove four clips (1) holding upper housing (2) to center housinn). Lift upper housing off of center housing. 1.Clips 2.Upperhousing 5.l 6.Ciip 3.Centerhousing 4.Vacuummmor Remove four screws (1 and 4) retaining evaporator (2) in upper housingt3). Remove evaporator from housing. 1.5crew 2.Evaporator 3. Upper housing 4. Screw . \IB 33.1mm '5 .4ni9 ,x‘ H. Air Conditioning 501.03 Page 50-19 Remove connector casing (1) from blower motor wires (2). noting position of wires for reassembly. Remove four clips (3) holding center housing (5) to lower housing (4). Lift center housing off of lower housing. l.Connectorcasing 2.Wires 3.Clips 4.Lowerhousing 5. Center housing Lift heater core (1 ) out of lOWer housing (4). Remove screw (3) holding blower assembly (2) in housing and remove blower assembly. Reassemble in reverse order of disassemblv. Use new "0" ring on expansion valve. l.Heatercore 2.Blower assembly 3. Screw 4. Lower housing CONDENSER REMOVAL AND INSTALLATION NOTE: Condenser and radiator are removed as an assembly. Remove twelve screws (2) holding grille (1) to body and remove grille. Remove four bolts (3 and 5) and washers holding center section of spoiler (4) to body and remove spoiler. 1.Gri|le 2.5crews 3.Bolts 4.Spoiler 5.Bolts Page 50-20 Drain cooling system. Purge air conditioning system. Refer to procedures in this section. Disconnect fittings (1) connecting lines (10) to condenser pipes. Loosen clamps [4 and 6) and disconnect hoses (3 and 7) from pipes. Disconnect electrical connectors (5) to electric fans. Remove two nuts (2] holding support bracket (9) to body and lower bracket complete with radiator (8) and condenser. Remove four nuts holding condenser to radiator and separate condenser from radiator. Install in reverse order. 1.Fittings 7. Hose 2.Nut 3.Hose 8.Fladiatcr 5.Connector 4.C|amp 9.5upport bracket 6.Clamp 10.A/Clines CONDENSER FAN REMOVAL AND INSTALLATION Working from under vehicle, disconnect electrical connector“ ). Remove four nuts (2 and 4) and washers holding condenser fan assembly [3) to radiator and remove fan assembly. Install in reverse order. 1,Electricalconnector 2.Nut 3.Fanassembty 4,Nut RECEIVER/DRYER REMOVAL AND INSTALLATION Remove protection panel from right-hand side of front luggage compartment. Purge system. Refer to procedures in this section. Disconnect fittings [1 and 4) for condenser and expansion valvelines. Remove two bolts (2) holding receiver/dryer (3) to body and remove receiver/ dryer. Replace receiver/dryer if clogged or moisture saturated. Install in reverse order. 1.Fitting 2,Bolt 3. Receiver/dryer 4. Fitting Air Conditioning THERMAL SWITCHES REMOVAL AND INSTALLATION NOTE: There are three thermal switches: condenser fan control switch (2), high pressure control switch (3) and frost prevent switch. The condenser fan and high pressure switches are on the high pressure line next to the receiver/dryer. The frost prevent switch is on the suction line at the evaporator, as shown in the following illustration. Remove protective panel from right-hand side of front luggage compartment. Disconnect electrical connectors for switches. Unwrap insula— tion. Unclip and remove retaining strap clips (4). Remove switches. For installation. make sure pipe and switch faces are clean of dirt or corrosion. Place switches on pipe and secure with clips. Wrap switches and pipe with insulation. Connect wires. 1 . Receiver/dryer 2. Condenser tan control switch 3. High pressure control switch 4. Clips EXPANSION VALVE REMOVAL AND INSTALLATION Disconnect battery ground cable. Working in passenger's side footwell. rem0ve access panel covering expansion valve. Lower fuse/ relay panel and set to one side. Purge system. Refer to procedures in this section. Remove temperature sensing tube from clamp (4) on evaporator outlet line (3). Disconnect high pressure line (2) from expansion valve (1). Loosen fitting (5) holding expansion valve to evaporator inlet line and remove valve. Install in reverse order. Use new "0" ring. 1. Expansion valve 2. High pressure line 3. Evaporator outlet line 4. Clamp 5. Fitting 6. Frost prevent switch FROST PR EVENT VALVE REMOVAL AND INSTALLATION Purge system. Refer to procedures in this section. Remove electrical lead (2) from frost prevent valve (3). Disconnect two fittingsH ) from ends of valve. Remove two nuts (5) holding bracket (4) to body and remove valve complete with bracket. Install in reverse order. l.Fitting 2.Electrical lead 3. Frostpreventvalve 4. Bracket 5.Nut 501.03 Page 5021 Page 50-22 LOW PRESSURE SWITCH REMOVAL AND INSTALLATION On vehicles with fuel injection. remove air cleaner. Refer to 102.04. Purge system. Refer to procedures in this section. Disconnect low pressure switch electrical connector (3). Unscrew low pressure switch (1 I from union (2). Install in reverse order. 1.Lowpressure switch ‘2. Union 3. Electrical connector FAST IDLE ELECTROVALVE REMOVAL AND INSTALLATION (Vehicles With Carburetor) Disconnect electrical connectors and vacuum hoses (1 and 3) from electrovalve (4). Remove two nuts holding electrovalve to bracket (2) and remove electrovalve. Install in reverse order. ‘l.Vacuurn hose 2. Bracket 3.Vacuum hose 4. Fast idle electrovalve =I EMOVAL AND INSTALLATION Vehicles With Fuel Injection) Disconnect electrical connectorsll ) and vacuum hoses (3 and 5) .rom electrovalve(2). Remove two bolts holding electrovalve to bracket (4) and remove slectrovalve. nstall in reverse order. LEIectrical connectors 2. Fast idleelectrovalve L Bracket 5. Vacuum hose 3.Vacuum hose Air Conditioning VACUUM RESERVOIR REMOVAL AND INSTALLATION From behind passenger's seat. remove spare tire cover and spare tire. Disconnect two vacuum hoses l‘l ) from reservoir (3). Remove nut [2! holding resevoir to bracket and remove reser— voir. Install in reverse order. 1.Vacuum hoses 2.Nut 3.Vacuum reservoir COMPRESSOR REMOVAL AND INSTALLATION Remove access panel from inside rear luggage compartment. Purge system. Refer to procedures in this section. Disconnect compressor clutch wire (1) at connector. Disconnect inlet and outlet lines (2) from compressor. Remove nut, through bolt (3) and washers holding bracket (4). 1.Wire 2. Compressor lines 3. Bolt 4. Bracket Raise and support rear of vehicle. Remove three bolts holding shield under compressor and remove shield. Remove nut, through bolt (2) and washers holding bracket. [1). Lower Compressor out of vehicle with bracket attached. Install in reverse order. To adjust belt. refer to 101.15. 1. Bracket 2. Bolt 501.03 Page 50-23 Page 50-24 COMPRESSOR CLUTCH REMOVAL AND INSTALLATION Remove compressor as outlined above. Using Sankyo wrench 32409 and 3/4" wrench remove not (3). Using Sankyo puller. remove clutch plate (4). Remove external and internal snap rings with snap ring pliers. Using Sankyo puller 32418 remove pully assembly (6). Remove three screws (5) to remove clutch coil (1) from compressor. Installation is reverse of removal. 1. Clutch coil 2. Compressor 6. Polly assembly)r 3. 3/4" out 4. Clutch plate 5. Screw X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL 55 BODY 70 ELECTRICAL - 55 PARTS CATALOG. SERVICE MANUAL 8: SERVICE TIME SCHEDULE CODE Page 55 551.01 552.01 553.01 554.01 555.01 55510 555.15 Specifications ....................................... Electronic Ignition .................................... Starting System ..................................... Charging System .................................... Lighting Equipment .................................. Signaling ............................................ Instrument Cluster ................................... Accessories .......................................... 55-1 55-7 55-13 55-17 55-23 55-27 55-29 55-31 55 Electrical Page 55-1 SPECIFICATIONS IGNITION Firing order ....................................... Distributor Type .............................................. Static advance: — Vehicles with carburetor ...................... 1 -3 -4 - 2 Bosch — 0-237 . . . 5° -— Vehicles with fuel injection ................... Centrifugal advance: — Vehicles with carburetor ..... _................. -—— Vehicles with fuel injection ................... Total advance (static and centrifugal): — Vehicles with carburetor ...................... — Vehicles with fuel injection ................... 28° to 32° at 5500 rpm 26° to 30° at 3500 rpm Vacuum advance: — Vehicles with carburetor with air pump ............................. without air pump .......................... — Vehicles with fuel injection ................... 16° to 18° at 12 in. Hg 26" to 30" at 12 in. Hg 12° to 16° at 11 in. Hg Air gap ........................................... Rotor arm resistance ............................. Pickup coil resistance ............................. Electronic Control Module Type .............................................. Current limiter output ............................ Input voltage ..................................... Coil Type .............................................. Primary winding resistance at 68°F (20°C) ........ Secondary winding resistance at 68°F (20°C) ..... Ballast resistor resistance ........................ 10° 23° to 27°.at 5500 rpm 16° to 20° at 3500 rpm 0.011 to 0.019 in. (0.3 to 0.5 mm} 6000 ohms 890 to 1285 ohms Bosch — 0-277-100-029 4.5 to 6 amps 6 to 18 volts Bosch — 0-221-122-012 1.1 to 1.7 ohms 6,000 to 10,000 ohms 0.85 to 0.95 ohms Spark Plugs Thread diameter and pitch, metric ................ Vehicles With Carburetor Type ...................... AC ............................ Bosch ............................ Champion ............................ Marelli Gap ........................................... Vehicles With Fuel Injection Type .......................................... Gap ........................................... NormaI 42XLS W175T30 N9Y CW7LP M 14 x 1.25 Resistor R42XLS W175TR3O RNSY CW7LPR 0.023 to 0.027 in. 0.027 to 0.031 in. (0.6 to 0.7 mm)~ (0.7 to 0.8 mm) Champion RNSY 0.027 to 0.031 in. (0.7 to 0.8 mm) Page 55-2 STARTER MOTORS Type and male ......... Boschy— Marelli 0001212210 E 9509/12 Voltage ..........—..—. . . 12 V 12 V Rated output .......... 0.8 kW 0.9 kW Direction of rotation, — pinion end ............ clockwise clockwise Poles ................. 4 4 Field winding .......... series Pinion engagement . . . . .—. with flywheel Control ............... — with flywneel “h solenoid solenoid Internal diameter of expanded shoes ........ 60.85 to 61.02 mm Internal diameter of armature .............. Mechanical Data Brush spring pressure {new brushes) ........ Armature end float . . . . Depth for commutator recutting ........... series 59.95 to 60.00 mm 1.15 to 1.30 kg 1.15 to 1.35 kg 0.10 to 0.15 mm 0.15 to 0.45 mm 0.8 mm 0.5 to 0.7 mm Data for Bench Testing Running test (‘1: — Current ........... — Speed ............ — Voltage ........... 200 A 1900 i 100 rpm 10 V — Torque developed . . . 0.55 kgm Lock test 1‘): — Current ........... 320 to 410 A 440 to 460 A — Torque developed . . . 1.25 kgm 2 1.4 kgm test P): — Current ........... —Voltage ........... — Speed ............ 35 to 55 A 11.5V 6000 to 8000 rpm — Voltage ........... Light running torque 8.5 V 7.5 i 0.1 V 35 i 5 A 11.4to11.7V 6000 t 500 rpm Solenoid .Winding resistance at 20°C: Pull-in ........... Hold-in .......... Travel of contact plate ............. Magnetic plunger travel ............. Lubrication Pinion splines ........ Contact surface of plnlon sleeve ....... ('1 A: 20" c 0.37 t 0.01 52 1.25 i 0.05 52 3.25 to 3.95 mm 12.58 to 15.48 mm Olifiat VS+ Artic (SAE 10 W) Grassofiat MR 3 Electrical 55 Page 55-3 CHARGING SYSTEM Alternator Make and Type ................................. Bosch K1 -14 V65 A 21 Marelli A 125-14 V-55 A Voltage ........................................ 12 V 12 V Maximum output (constant) .................... 65 A 55 A Cut-in speed, balanced thermally ............... 1100 t 50 rpm 900 i 50 rpm Current flow at 7000 rpm and balanced thermally ......................... 2 65 A .>_ 55 A 3.36 i 0.3 $2 3.1 t 0.1 Q Direction of rotation (drive side) ................. Clockwise Clockwise Engine/alternator driving ratio ................. 1 to 1.75 1 to 1.75 Field winding resistance across slip rings (1) ................................. Rectifier diodes ................................. Voltage Regulator Make and Type ................................. Built-in diode plate (all) Bosch Electronic, integral FIMM ”RTI' 1 13 C" Electronic, integral Alternator speed for adjustments ............... 6000 rpm 6000 rpm Current for thermal balance .................... 20 to 22 A 20 to 22 A Regulating voltage (1) ........................... 13.8 to 14.2 V 13.8 to 14.2 V with alternator [2) with alternator Battery Voltage ........................................ 12 V Capacity (at 20-hour discharge rate) ............ 60 AH (11 At 25°C. {2} Some vehicles are equipped with a non-integral regulator. Page 55-4 LIGHTING Location SAE Standard FIAT Std. Part No. Headlights(high and low beams) ..................... "Sealed Beam” headlight unit 6012 Front lamps: — Turn signal and parking ........................... 1034 (3/32 cp) 1/141446/90 (12 V - 5/21 W) Rear lamps: — Turn signal, back-up and stop ..................... 1073 (32 cp) — Tail ............................................... 1073 (32 cp) — License plate ..................................... 67 (4 cp) Side marker lamps .................................... 158 (2 cp) 1/41458/90 Courtesy light ........................................ — 1 /08630/90 (12 V - 5 W) — 1(1/‘211f393/38 Fiber Optic cable lamp ................................. Instrument cluster lights .............................. ".EX GAS SENSOR” indicator ........................ Turn signal indicator .................................. High beams indicator ................................. Battery charge indicator .............................. Low oil pressure indicator ............................ Fuel reserve indicator ................................. Parking and tail lamps indicator ....................... Hazard warning signal indicator ...................... Low brake fluid level/hand brake ON indicator ........ Fasten belts indicator. ................................ ’ Rear window defogger ............................... Heater control panel light ............................. Cigarette lighter light ................................. Ideogram illumination light ........................... Air conditioner ideogram light ........................ — 1/41460/90 (12 V - 21 W) 1/41460/90 (12 V - 21 W) 1/41459/90 (12 V - 5 W) 1/41437/90 (12 V - 1.2 W) Electri ial $5— Page 55-5/5 FU ES AND RELAYS FUSES Eight 8-Amp, six 16-Amp and two 3-Amp fuses are located in fuse/relay panel under glove compartment. In addition, one 8—Amp and two 16-Amp fuses are located in separate in—line holders. Panel Fuses Stop lights Stop light switch A/C blower relay coil Rightfront marker light (8 Amps) A/C control relay coil Heater fan motor Heater fan switch Rear window defogger switch Right front park light Left taillight Right license light Left rear marker light Lights-on indicator Digital clock Instrument cluster lights Dash panel lights Turn lights Turn indicator Hazard indicator \ A (8 Amps) WlPER DELA‘ \_ TIMER \/ l (16 Amps) Right headlight motor L Left headlight motor Rear window defogger relay coil (16 Amps) (8' Amps) Windshield wiper/washer switch 'Windshield washer pump Wiper motor Back-up switch Back-up light Gulp valve thermoswitch Gulp valve electrovalve solenoid Seatbelt timer Seatbelt relay coil Fasten seatbelt indicator Brake indicator Digital clock (display on) Oil pressure warning indicator Exhaust gas sensor indicator C (8 Amps) D M (16 Amps) N (16 Amps) Rear window defogger Turn/ haza rd flasher Coolant fan Horns O Condenser fan motor P A/C blower motor (16 Amps) (16 Amps) Left headlight high beam High beam indicator Q (3 Amps) Right headlight high beam (3 Amps) R Headlight closing relay coils Headlight opening relay coils (8 Amps) E (8 Amps) F (8 Amps) G (8 Amps) Left headlight low beam ln-Line Fuses 8 Amps Right tail right 9 Left license light Right rear marker light Lights-on indicator FUSE/RELAY PANEL Cigar lighter Power antenna motor l l Digital clock (power) l Courtesy light . l Seatbelt chime Right headlight low beam Left front marker light Left front ark li ht Fuel injectors fan motor Carburetor fan motor 16 Amps Power wmdow motors 16 Amps Auxiliary air regulator Fuel pump UF'PROTECTED—CfRCUfiS Alternator, starter, ignition, charge indicator, radiator fan relay winding, radio, parking light switch and headlight control relay windings, instrument cluster lights, fuel injection relay winding, power window relay winding. 551.01 Electronic Ignition Page 55-7 DESCRIPTION With ignition switch closed, battery voltage is supplied to electronic control module and through a ballast resistor to primary side of ignition coil. The resistor is used as a current limiter. Voltage is regulated by the control module to supply a regulated current to primary side of ignition coil. When the distributor turns, a trigger generates an impulse on the pickup assembly. This impulse is sensed by the control module. and turns the coil primary on and off. Each time the coil primary is turned off, a high voltage is induced in the coil secondary. The high voltage is distributed through the distributor rotor cap, to spark plugs. R ESISTOR IGNITION SWITCH Er. *‘ BATTERY , SPARK PLUG + 15 1 O : I I 0 ° CONTROL MODULE 0 : COIL | | | BREAKERLESS DISTRIBUTOR i____.______ .. TO FUEL INJECTION CONTROL UNIT SERVICE Before performing any service observe the following: 00 NOT 0 Energize ignition unless coil support base is properly grounded. 0 Crank engine with high voltage wire disconnected from coil. 0 Disconnect high voltage wire from coil when engine is running. - Start or crank engine when instrument panel is disconnected. 0 Ground primary circuit or use diagnostic equipment to ground primary circuit. - Test for current or voltage by flashing terminals with each other or to ground. I Disconnect battery cables when engine is running. The electronic voltage regulator will be damaged. DO 0 When required, the distributor pickup assembly may be disconnected when engine is running, or when cranking for compression testing. Page 55-8 PRIMARY lNPUT CHECK iGNITION SWITCH COIL Connect voltmeter from coil +8 terminal to ground. —"' ___ .. ' HE With ignition switch on, check for 12 volts (battery). if not, check for faulty battery, ignition switch, wiring, or connections. 15 “EN 0 GROUND CHECK [ With ignition switch off, connect an Ohmmeter from control module support mount to battery ground terminal. 9 O O o m 0 0 IGNITION SWITCH + 7 31d 15 31 18 16 0 '3 CONTROL MODULE Reconnect one Ohmmeter lead to coil high voltage terminal. Check for 6K to 10K ohms. Replace coil if not within specifications. Disconnect one end of resistor, then connect Ohmmeter across resistor. Check for 0.85 to 0.95 ohms. Replace resistor if not within specifications. . '-‘ "‘1— L Also check that control module casing is clean, and that mounting hardware is clean and tight. Check for 1.1 to 1.? ohms. __L BATTERY If not, check support, mounting, and battery ground connections. Disconnect primary leads from coil, then connect Ohmmeter to coil. O E Check for less than 0.2 ohms. COIL RESISTANCE CHECK BATTERY *oooo -) 1.1 T0 1.7 OHMS Ge V 0.29 OR LESS 6000 TO 10,000 OHMS 0.85 m 0.95 oums 551.01 Electronic Ignition Page 55-9 PICKUP ASSEMBLY CHECK lNFlNITY {'I Disconnect pickup assembly from control module. 390 TO ‘285 OHMS Connect ohmmeter to pickup assembly connector (terminals 7 and 31d). Check for 890 to 1285 ohms. Reconnect one ohmmeter lead to distributor body. Check for infinity ohms. : comTHbLMODULE CONNECTOR .LL 1: ".1_ 1L_".. . r .m. Replace pickup assembly if not within specifications. l Using a nonmagnetic feeler gauge check gap between stator pole and trigger. Adjust as required. .smron POLE O “‘1 o o: .TRIGGER O I 0.3 T0 0.5 mm / (001110 0.019 ml GAP 1. ___ _ a \GAP CONTROL MODULE CHECK Reconnect primary leads to coil, pickup assembly to control module, and resistor lead. 5mm -—l _ Disconnect high voltage wire from distributor. Do not disconnect from coil. E I I ‘GNITION SWITCH SPARK o While holding (use insulated holder) high voltage wire about 5 mm from ground, crank engine and check for spark. BATTERY Replace control module if no spark appears. 7 ROTATE DISTRIBUTOR SHAFT ELIE 0 O O ‘3 ° Check all parts for cracks. wear. or breaks that may affect system operation. Check cap for corroded terminals. —SHIELD TRlGGER mowur . ASSEMBLY VACUUM CAPSULE ---r $REL . -_ I 15 O SYSTEM PARTS CHECK Clean or replace cap as required. 31 CHECKING AND SETTING IGNITION TIMING Check ignition timing with a timing light. Connect timing light power leads to battery or to hot side of coil. Either connection will not affect ignition system. When using an inductive timing light. connect inductive pickup to number 1 spark plug wire at a point where it can be separated from other spark plug wires. High voltage wire must not be disconnected from coil while engine is running or being cranked. Crankshaft timing mark (4) on crankshaft pulley indexes with timing pointer. With rpm at less than 900. timing should be 5° BTDC for vehicles with carburetor, 10" BTDC for vehicles with fuel injection. To adjust timing. loosen nut. then turn distributor as required to obtain correct timing. Tighten nut. 1 TDC 2. 5" BTDC 3 10" BTDC 4. Crankshaft pulley mark DISTRIBUTOR REMOVAL AND INSTALLATION Crank engine until crankshaft pulley timing mark indexes with timing pointer. Remove distributor cap from distributor and lay to one side. Disconnect vacuum hose (2) from vacuum diaphragm (4). Disconnect electrical connector for distributor electrical lead {1 l at side of distributor l3). CAUTION: Upon installation, make certain that raised notch on electrical connector is correctly indexed with slot in distributor. Noting rotor position for installation, remove nut, washer and plate. Remove distributor and gasket. Install in reverse order. Set timing. 1. Electrical lead 2. Vacuum hose 4. Vacuum diaphragm 3. Distributor Electronic Ignition 551.01 Page 55-11 DISASSEMBLY AND REASSEMBLY Unclip cap (21). Remove rotor (20) and cover (19). Remove screws (1 and 3) to remove vacuum diaphragm (2). Remove lock ring (18). lockwasher (16), rotor (15) and lock ring (14). Remove screw (9) to remove connector (24). Remove screws (5. 7, and 23) to remove coil (13) and pickup assembly (12). Remove screw (1 1) to separate pickup assembly. Remove clip (6 and 22) only if damaged. Reassembiy is reverse of disassembly. 1,Screw 2. Vacuum diaphragm 3. Screw 4. Support 5. Screw 6. Spring clip 7. Screw 8. Gasket 9. Screw 10. Spring clip 1 1. Screw 12. Pickup assembly 13. Coil 14. Lock ring 15. Rotor 16. Lockwashers 17. Pin 18. Lock ring 19. Cover 20. Rotor 21 . Cap 22. Spring clip 23. Screw 24. Connector 25. Body INSPECTION Check distributor cap (21 ) for cracks. breaks, or corroded terminals. For light corrosion. clean terminals, otherwise replace. Check rotor (20) for cracks. breaks. or c0rrosion. Replace if damaged. Check rotor(15)for bent for broken tabs. Replace if damaged. Check coil (1 3) for damaged wires. Check for 890 to 1285 ohms resistance. Replace if damaged. Check pickup assembly (1 2) for damaged parts. Replace if damaged. Check vacuum diaphragm (2) for leakage. Replace if damaged. Check body (25) for worn or sticky shaft. Replace if da maged. Page 55-12 ELECTRONIC CONTROL MODULE REMOVAL AND INSTALLATION Remove two screws holding cover at right side of engine com— partment. Disconnect electrical connector (1) from control module (2). Remove two nuts {3) holding control module to body and re— move control module. Install in reverse order. 1. Electrical connector 2, Electronic control module 3. Nut Starting System STARTER REMOVAL AND INSTALLATION Disconnect battery gr0und cable. Disconnect electrical leads to starter (4). Remove three bolts (3), lockwashers (2), and washers (1) to remove starter. 1.Washer 2. Lockwesher 3. Bolt 4. Starter DISASSEMBLY AND REASSEMBLY (MARELLl) Remove nut (4), lockwasher (3), and two washers (2). Disconnect terminal on housing assembly (5) from stud on starter solenoid (1 1. Remove nut (10). lockwasher (11), and washer (12) to remove starter solenoid (1) and spring (14). Remove stud (15) only if damaged. Remove two nuts (7) and bolts (9). Carefully separate support (6) from housing assembly (5) until brushes can be removed from brush holder. Separate housing assembly (5) from support (13). Remove washer (8). 1. Starter solenoid 2. Washers 3. Lockwasher 4. Nut 5. Housing assembiy 6. Support 7. Nut 8. Washer 9. Bolt 10. Nut 11. Lockwasher 12. Washer 13. Support 14. Spring 1 5. Stud Remove plug (13). Remove cotter pin (11) and pin (2). Separate armature (4) with attached parts (5 through 9), fork (3) and cup (1) from support (12). Remove washers (8 and 9). Press on clutch (5) to remove clip (7). Remove ring (6) and clutch (5) from armature (4). Remove bushing (10) from support (12) only it damaged. 1. Cup 2. Pin 3. Fork 8. Washers 9. Washer 13. Plug 4. Armature 10. Bushing 5. Clutch 6. Ring 11. Cotter pin 7. Clip 12. Support 552.01 Page 55-13 Page 55-14 If damaged, remove bushing (7) by removing screw (9) and cover [8). 1 Remove brush holder (4) only if damaged. To remove coil assembly (2), remove four screws (11) and stator cores ( 1). Carefully slide coil assembly (2) from housing (10). Assembly is reverse of disassembly. if a new coil assembly is installed, preheat to about 120°F (49°C). This will aid fitting in housing. Lubricate inner spline at clutch with 10 W oil. 1. Stator core 2. Coil assembly 3. Spring 4. Brush holder 5. Insulator 6. Support 7. Bushing 8. Cover 9. Screw 10. Housing 11, Screw DISASSEMBLY AND REASSEMBLY (BOSCH) Remove nut (9) and washer (8). Disconnect terminal on housing assembly (4) from stud on starter solenoid (7). Remove three screws (6) to remove starter solenoid (7). Remove two screws (1) and washers (2). Carefully separate cover (3) until brushes can be removed from brush holder. Separate housing assembly (4) from support (5). 1. Screw 2. Washer 13. Cover 4. Housing 7. Starter solenoid 8. Washer 9. Nut 5. Support 6. Screw Remove screw (14) and nut (16). Separate fork (15) and armature (1) with attached parts (2 through 5) from support (11). Squeeze bushing (2) and pinion (5) together to remove lock ball (4). Separate pinion (5), spring (3) and bushing (2) from armature {1). Remove cover (6), spring (7). cup (8), washer (9) and bushing (10) only if damaged. Remove plug (13) and cover (12). 1.Armature 7. Spring 13. Plug 2. Bushing 8. Cup 3. Spring 4. Lock ball 5. Pinion 6. Cover 9. Washer 10. Bushing 11. Support 12. Cover 14. Screw 15. Fork 16. Nut 10 552.01 Starting System Page 5545/15 if damaged, remove bushing (5) by removing screw (1),cover (2), ring (3} and washers (4). Remove brush holder (8) only if damaged. To remove coil assembly (9), remove four screws (11) and stator cores (12). Carefully slide coil assembly (9) from hous- ing (10). Assemble in reverse order of disassembly. If a new coil is installed, preheat to about 120°F (49°C). This will aid fitting in housing. Lubricate inner spline of pinion with 10 W oil. 1. Screw 2. Cover 3. Ring 4. Washers 5. Bushing 6. Cover 7. Spring 8. Brush holder 9. Coil assemn 10. Housing 11 . Serew 12. Stator core H g 12 é?-“ “g 2 1 W9 54 3 1 Charging System 553.01 Page 55-17 ALTERNATOR REMOVAL AND INSTALLATION Disconnect battery ground cable. From inside rear luggage compartment. remove engine compartment access panel. Remove three nuts to remove rear shield. On Bosch alternator. remove cooling duct. Mark to identify. then disconnect electrical leads. Remove bolt and nut (2). Remove nut (3), lockwasher, washer and bolt to remove alternator (1). Install in reverse order. Adjust belt tension. Refer to 101.15. 1. Alternator 2. Nut 3. Nut 4. Integral voltage regulator DISASSEMBLY AND REASSEMBLY (MARELLI) Disconnect electrical plug and remove two screws to remove voltage regulator (15) (if equipped with integral voltage regulator). Remove screw and washer to remove brush holder (13). Remove nut. lockwasher, pulley (1), fan (2), spacer (3), key (6), and spacer (4). Remove three long bolts, lockwashers, and washers, then carefully separate front frame (5) from rear frame (1 1). Remove rotor assembly (7) from rear frame by pulling rotor out. Remove nut, washer, nut. lockwasher, bolt and washer to remove cover (14). Remove rectifier assembly (12) by first disconnecting three stator wires. Carefully separate Stator assembly (8) from rear frame. Remove screw to remove condenser (10). Remove screw. washer. and insulator (16). Reassemble in reverse order of disassembly. 1. Pulley 5. Frame 2. Fan 6. Key 10. Condenser 9. Seal 13. Brush holder 14. Protective cover 3. Spacer 7. Rotor 11. Frame 15. Voltage regulator“ 4. Spacer B. Stator 12. Rectifier 16. Insulator *Some vehicles with Marelli alternator are equipped with a non—integral voltage regulator. ALTERNATOR MAR ELLI A125-14V—55A Page 55-18 DISASSEMBLY AND REASSEMBLY (BOSCH) Disconnect electrical plug and remove screw and lockwasher to remove condenser (7). Remove two screws to remove voltage regulator/brush assembly (8 and 9), Remove nut to remove pulley (1). fan (2), spacers. and key(13). Remove four short screws on front frame (3) to free bearing retainer (14). Remove four long screws to separate from frame from rear frame (6). Remove rotor assembly (12) from rear frame by pulling rotor out. Remove stator assembly (4) and rectifier assembly (5) as a unit by removing three screws. Remove three stator wires from rectifier to separate rectifier. Reassemble in reverse order of disassembly. 1. Pulley 6. Frame 1 1. Bearing 2. Fan 7. Condenser 12. Rotor 3. Frame 4. Stator 5. Rectifier 8. Voltage regulator 13. Key 9. Brush assembly 14. Bearing retainer 10. 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Hold one test lead on one slip ring and other test lead on other slip ring. Heading should be 3.0 to 3.7 ohms. If not, rotor is open. Replace rotor. 1. Slip rings Stator Short to Ground Test Remove stator leads (1) from rectifier board. Set ohmmeter to x1000 scale. Touch one test lead to stator core (2) bare metal and other test lead to any stator lead. Reading should be infinite (no needle movement). If any needle movement is shown, stator is grounded. Replace stator. 1. Stator lead 2. Stator core Charging System 553.01 Page 55-21/22 Stator Continuity Test Set ohmmeter to x1 scale. Touch one test lead to any stator lead (1). Touch other test lead to any other stator lead. Note reading. Repeat at all pairs of test leads. Equal readings should be obtained at each pair of stator leads. A reading of infinity indicates poor connection at neutral junction. Repair connection or replace stator. 1. Stator lead Diode Test Remove stator leads from rectifier board. Set ohmmeter to x1 scale. Touch one test lead to a diode junction ( 1). Touch other test lead to heat sink (2). Note reading. Reverse test lead positions and note reading. Repeat for remaining diodes. One high and one low reading should be obtained for each diode. lf proper readings are not obtained, replace diode plate. 1. Diode junction 2. Heat sink Lighting Equipment 554.01 Page 55-23 HEADLIGHTS REMOVAL AND INSTALLATION Remove three screws (1 and 4) holding trim molding (5) to body and remove molding. Loosen three screws holding ring (2). Turn ring counter— clockwise and remove ring. Disconnect plug from headlight (3). Remove headlight. Install in reverse order. 1.3crews 2,Ring 3. Headlight 4. Screws 5. Trim molding ADJUSTMENT All headlight adjustments should be made with the car unloaded at 16 ft. (5 m) from the screen. When using headlight alignment equipment, refer to instructions provided. Turn headlights on low beam. Adjust horizontal alignment by turning screw (1). 1. Horizontal adjustment screw Adjust vertical alignment by turning screw (1). 1. Vertical adjustment screw HEADLIGHT MOTOR REMOVAL AND INSTALLATION Remove bolt [1) holding arm (2) to motor shaft. Remove three bolts [3) and washers holding motor (5). Disconnect electrical connector. Remove motor. Install in reverse order. 1. Bolt 2. Arm 3. Bolts 4. Knob 5. Motor 6. Turnbuckle FRONT PARKING/DIRECTIONAL/ HAZARD LIGHT REMOVAL AND INSTALLATION Remove twa screws holding lens and remove lens. Remove two nuts and washers from studs (1). Remove light assembly (2) from bracket (4). Remove two screws (3) holding reflector in housing and pull reflector out of housing. 1. Stud 2. Light assembly 3. Screw 4. Bracket Disconnect electrical leads (1 and 3) from back of reflector (2). Pull wires out of housing. Install in reverse order. 1.’Electrical leads 2. Reflector 3. Electrical lead Lighting Equipment BULB REPLACEMENT Remove two screws (3) and remove lens (2). Remove bulb [1) by twisting out. Install in reverse order. ‘I. Bulb 2. Lens 3. Screws TAIL LIGHT ASSEMBLY REMOVAL AND INSTALLATION Working inside trunk. remove four nuts and washers from studsm. Pull tail light assembly (2) out of body and disconnect eight electrical leads (3). Install in reverse order. 1. Studs 2. Tail light assembly 3. Electrical leads BULB REPLACEMENT Remove screws and lens (2) covering defective bulb (1). Remove bulb by twisting out. Install in reverse order. 1. Bulbs 2. Lens 3. Reflector . , 554.01 Page 55-25 LICENSE PLATE LIGHT REMOVAL AND INSTALLATION Working inside rear luggage compartment, disconnect electrical connectortl ). Remove nut (21 holding ground wire (3)10 body. Remove two screws (4) holding license plate light to body and remove light Install in reverse order. 1. Electrical connector 2. Nut 3. Wire 4. Screws BULB REPLACEMENT Remove screw (2) holding lens (3) to housing (1). Remove bulb {4} by twisting out. Install in reverse order. 1. Housing 2. Screw 3. Lens 4. Bulb Signaling WIPER/DIRECTIONAL/LIGHT SWITCH REMOVAL AND INSTALLATION Disconnect battery ground cable. Center steering wheel and front wheels. Pry horn button off steering wheel (3). Remove two horn button springs (4). Remove nut (1) holding wheel (3) to shaft (2). Mark steering wheel and steering shaft for installation refer— ence. Pull wheel off shaft. 1. Nut 2. Steering shaft 3. Steering wheel 4. Horn button springs Remove four screws [2 and 3) to remove upper and lower steering column covers (1 ). 1.8teering column covers 2.5crews 3. Screw Loosen bolt (2) holding switch assembly (1) to shaft housing (3). Slide switch assembly off steering column. Disconnect electrical connectors and remove switch assembly. Install in reverse order. 1.Switch 2.Bolt 3.5hafthousing 555.01 Page 55-27 Page 55-28 HORNS REMOVAL AND INSTALLATION From front luggage compartment, remove headlight access panel. Working inside headlight compartment. disconnect electrical connector from horn (3). Remove bolt {1) holding horn bracket (2) to body and remove horn (3} complete with bracket. Repeat procedure on opposite side to remove remaining horn. Install in reverse order. 1. Bolt 2. Bracket 3. Horn \/ "’ Instrument Cluster 555.10 Page 55-29/30 REMOVAL AND INSTALLATION Disconnect battery ground cable. Working in front luggage compartment. remove four screws and one bolt holding left grille and remove grille. Uncouple speedometer cable (1) by sliding sleeve (4) on coupler (3) toward front of vehicle. Remove grommet (2) from firewall. 1. Cable 2. Grommet 3. Coupler 4. Sleeve Remove five Allen bolts (1) holding instrument- cluster (2) to support (3). Pull instrument cluster out of panel far enough to gain access to rear of cluster. NOTE: it may be necessary to guide cable coupler through firewall hole. 1. Allen bolts 2. lnstrument cluster 3. Support Unplug three electrical connectors (1, 2 and 3) from instru— ment cluster. On vehicles with fuel injection. cut wire (4). Remove instrument cluster. To install. reverse removal procedure. On vehicles with fuel injection, splice together wire cut during removal. 1. Connector 2. Connector 3. Connector 4. Wire Accessories 555.15 Page 55-31 WINDSHIELD WIPER MOTOR REMOVAL AND INSTALLATION NOTE: Wipers should be in "park" position. Disconnect wiper motor connector (7). Remove two nuts (8) and both halves of retaining plate (10). Push connector through hole in cowl. Remove left wiper arm (1 1). Remove out (1 ), Spacer and rubber washer from wiper arm shaft. Remove nut (4) holding motor arm (9) to shaft and remove motor arm. Remove two bolts (6) and washers holding bracket (2). Remove bolts (3) and washers holding wiper motor(5) to bracket. Lift bracket until motor can be maneuvered out of vehicle. Install in reverse order. 1. Nut 2. Bracket 3. Bolts 7. Electrical connector 1 1 .Wiper arm 4. Nut 8. Nuts 5. Wiper motor 9. Arm 6. Bolts 10. Retaining plate WIPER ARM ADJUSTMENT With wiper arms in "park" position, check arm height at wiper blade. Check that dimension "A" is 2.4 to 3.3 in. (60 to 85 mm) and dimension “8" is 2.6 to 3.3 in. (65 to 85 mm). If necessary. remove wiper arms and reposition them to correct park position. WINDSHIELD WASHER RESERVOIR REMOVAL AND INSTALLATION Disconnect hose (3) from motor (5) and plug opening to prevent leakage. Disconnect electrical connector (4) from motor. Remove nut (1) holding reservoir (2) and remove reservoir. Install in reverse order. 1. Nut 2. Reservoir 3. Hose 4. Connector 5. Motor Page 55—32 HEATED REAR WINDOW REPAIR When repairing an open metallic conductor attached to rear window, it is not necessary to remove glass. The repair can be accomplished with a special kit made for this purpose or a silver paint with metallic content. Clean area around break‘ Mix paintthoroughly. Mask off each side of the break. Carefully apply paint to break with a camel hair brush as shown. Allow to dry for about 4 to 5 hours. A source of low tempera; ture heat (hair dryer, infrared lamp) will shorten drying time. CAUTION: Do not turn on rear window heater until repair is completely dry. X1/9 1979 1979 -- 1982 1982 X1/9 SERVICE SERVICE MANUAL MANUAL GENERAL INFORMATION INFORMATION GENERAL MAINTENANCE MAINTENANCE TUNE UP UP TUNE 00 00 ENGINE ENGINE 10 10 CLUTCH CLUTCH 18 18 TRANSMISSION TRANSMISSION DIFFERENTIAL DIFFERENTIAL AXLE AXLE 21/27 21/27 BRAKES BRAKES 33 33 STEERING SYSTEM SYSTEM STEERING 41 41 SUSPENSION AND AND WHEELS WHEELS SUSPENSION 44 44 ACCESSORIES ACCESSORIES 50 50 ELECTRICAL ELECTRICAL 55 55 BODY 70 BODY - 70 PARTS CATALOG. SERVICE MANUAL & SERVICE TIME SCHEDULE CODE 70 701.01 General Information .................................. Engine Compartment Lid ............................. 701.02 Instrument Panel ..................................... 701.11/.17 Internal and External Bodywork ....................... 701.25 Hard Top ............................................ 701 .27/.30/.31 Doors-Door Glass-Lock Mechanism ................... 701.54 Rear Window ........................................ 701.60 Luggage Compartment Lids ........................... 703.06/.07 Front and Rear Bumpers ............................ 706 .01 Seats ................................................ Page 70-1 70-3 70-5 70-7 70-1 1 70-13 70-19 70-21 70-25 70-27 70 Body Page 70-1 /2 GENERAL INFORMATION Two-door unitized body. Instruments and switches on driver's side. Heat and air con- Front doors hinged at front. Side window with two safety glass panes, i.e. fixed quarter window and drop window controlled by regulator. lets. one at each end and two in center panel. Doors have outside key handles and inside locking devices. Outer door handles have Spring-loaded releaSe grips. Rear window is fixed safety glass. Luggage compartments in front and rear. Front compartment unlatched by latch in driver‘s footwell. Rear compartment key lock located in left door column. Tool kit and jack located in rear compartment. Seats are adjustable bucket-type with tiltable back for access to rear of seats. Spare wheel housed behind passenger‘s seat. trols are in center of instrument panel. Four adjustable out— Rear view mirrors inside and outside. Sun visors are padded and adjustable. Carpeting in passenger compartment. Rubber mats in luggage compartment. Engine compartment lid has key lock located in driver‘s door column. Air Iouvers in both sides for letting air into engine compart— ment. Ignition key lock with anti—theft device. Removable hard top. Front and rear energy absorbing bumpers made of aluminum. Engine Compartment Lid 701.01 Page 70-3 ENGINE COMPARTMENT LID REMOVAL INSTALLATION AND ADJUSTMENT Unhook prop (2) from bushing (1). CAUTION: Prop is under high spring tension. Remove four nuts (4) and washers holding lid (3) to hinges {5). Remove lid. When installing lid. check position. Shift lid on hinges to obtain proper alignment. Tighten bolt holding lid to hinges. l. Bushing 2. Prep 3. Lid 4. Nuts 5, Hinge 1 . Cover 8. Cover 15. Screw 23. Cable 2. Plastic clip -9. Bolt 16. Access panel 24. Gasket 3. Pin 4. Air duct “Hal '"iem‘?" WY) 5- Striker 5- Screw 7- Washer 10_Lockwasher 11.Washer 12, Lid 13. Pad 14, Support (fuel injection only) 17. Bolt 18. Grille 25. Duct 26. Air intake 19. Screw 27. Bolt 21 . Plate 29. Clip 20. Washer 22. Latch 28. Bracket 31. Plate 32. Hinge 33. Bolt 34. Bracket 35. Prop 36. Bushing 30. Lock assembly EXPLODED VIEW OF ENGINE COMPARTMENT LID COMPONENTS AND AIR DUCTS ENGINE COMPARTMENT LID LATCH REMOVAL, INSTALLATION AND ADJUSTMENT Disconnect cable (3) from latch (1). Remove two bolts (2) and washers holding latch to body. Remove latch. When installing. position latch for proper operation. Tighten two bolts and reconnect cable. 1. Latch 2. Bolts 3. Cable Instrument Panel 701.02 Page 70-5 INSTRUMENT PANEL REMOVAL AND INSTALLATION Disconnect battery ground cable. Remove radio. Remove instrument cluster. Refer to 555.10. Remove heater or air conditioning control panel fascia panel. Remove and disconnect clock. or remove clock opening cover plate. Remove screw (3) holding control panel (2) to support (6). Remove four Screws (4 and 5) holding support to instrument panel (1). Maneuver support out of instrument panel. 1. Instrument panel 5. Screw 2. Control panel 3. Screw 4. Screws 6. Support Disconnect electrical connectors from light switch (2) and cigarette lighter. Remove two screws holding glove box liner and remove liner. Lower luse/ relay panel. Working through openings and under instrument panel, remove seven bolts [1 and 3) holding instrument panel to cowl. Carefully remove instrument panel from vehicle. Install in reverse order. 1. Bolts 2. Light switch 3. Bolt Page 70-6 1 .Spring 2. Pad 3. Bracket 4. Bolt 9. Clip 10. Instrument panel 1 1 . Glove box liner 12. Screw 'l 7. Support 18. Clip 19. Bracket 13. Glove box door 14. Latch 7. Bracket 20. Upper steering column cover 21 . Lower steering column cover 22. Screw 15. Clock opening cover 8. Bushing 23. Instrument cluster support 15. Radio opening cover 5. Lockwasher 6. Washer EXPLODED VIEW OF INSTRUMENT PANEL 701.11/.17 Internal and Exterlnal Bodywork FRONT LUGGAGE COMPARTMENT TOP VIEW ENGINE'COMPARTMENT 515/16" Q (151) \ Page 70—7/8 TOP VIEW BOTTOM VIEW as DRIVER'S SIDE \ PINCHWELD 377/8‘ 497/3" (1 267) \. /V\ 43%" (1 1 1 1) eon/(6'7 (1545) 36‘5/15" (938) 16%" (422) 501/2” (1283) 28‘/a" (714) 44%4" (1137)( (813) 127/11" (327) 359/115" (903 ) 701/8” (1781) 521/4" (1327) (902) MEASUREMENTS All measurements are given in inches and millimeters. Measurement Points SIDE VIEW Bolts, nuts and plugs are measured from the center of the unit and are shown on the illustration as a solid dot-+— Holes are measured from the closest edge to the other point of the measurement. Holes are shown as outlines only. It The symbol Q next to a hole indicates that the measure— ment is taken from the center of that hole. Top and Bottom View Measurements Datum Measurements Datum measurements provide a fixed reference point for all vertical measurements. Measurements along the datum line are not point-to»point. The measurements must always be made parallel to the datum line. 63/3" (162) 8%" (210) 17" (432) 73/8" (187) 15" 4%" (121) (292) (3 2) (495) Dimensions provided courtesy of KLM Inc. for the exclusive use of Fiat Motors of North America. @1981 KLM AUTOMOTIVE PUBLISHING INC. 14 1n 41/16" (103) 19/2" \\\«~ (381) ~11w" w. All dimensions are point-to—point, closest distance between the points of measurement. UNDERBODY DIMENSIONS 375/16" :3 7\ 215/16" (541) / PINCHWELD 351/2" J O 16‘i’ (419 (962 / 24" (610) I 371/2” (953) 121/2" (318) 21va" (540) (948) o HVEH FRONT 6013/18" (1 545) Internal and External Bodywork 1. Crossrail 701.11/.17 Page 70-9 2. Wall 5. Joining element 6. Cover 9. Battery seat 10. Framing 3. Nut 4. Lockwasher 7. Bracket 8. Framing 11. Side panel 1. Air intake wall 2. Air intake case 3. Reiniorcement 4. Framing 5. Windshield framing 6. Joining element 7. Framing B. Joining element 9. Reinforcement 10. Framing BODY SHELL INNER COMPONENTS 12. Wall 11. Reinforcement 12, Reinforcement 13. Reinforcement 14. Framing 15. Joining element 1. Boxed panel 2. Wall 4. Side panel 5. Wall 3. Joining element 6. Joining element 7. Side panel 8. Wheel well 9. Reinforcement 10. Side panel BODY SHELL INNER COMPONENTS 19 1. Panel 2. Panel 3. Panel 4. Channel 5. Hood channel 6. Panel 7. Windshield panel 8. Panel 9. Panel 10. Panel 11. Panel 12. Panel 16. Panel 17, Panel 13. Panel 18. Seal 14. Panel 15. Hood channel 19. Joining element 20. Joining element BODY SHELL OUTER COMPONENTS 1B 21. Panel 22. Door opening panel 23. Panel Hard Top 701.25 Page 70-11/12 ADJUSTMENT Adjust hard top for proper alignment by loosening four screws [1] holding striker plate (2). Shift plate as necessary for proper adjustment. 1. Screws 2. Striker plate 1. Hard top 8. Weatherstrip 14. Support 2. Lug 9. Molding 15. Molding 3. Striker plate 10, Weatherstrip 16. Weatherstrip 4. Cover 11. Coupling 17. Weatherstrip 5. End plate 6. Channel 12. Latch 13. Striker plate 18. Channel 19. Weatherstrip 7. Weatherstrip EXPLODED VIEW OF HARD TOP COMPONENTS Doors-Door Glass-Lock Mechanism 701 .27/.3G/.31 Page 70-13 DOOR PANEL REMOVAL AND INSTALLATION Pry out plug [1) in top of arm rest (2). Remove three screws holding arm rest to door and remove arm rest. Unscrew lock button (3). Pry back cover (6) and remove clip on window crank. Remove window crank (7). Remove door handle trim ring (5) by pushing toward rear of vehicle and pulling out. Carefully pry door panel (4) off door. Install in reverse order. 1. Plug 6. Cover 2. Arm rest 3. Lock button 4. Door panel 5, Trim ring 7. Window crank ((1%n 27 26 25 1 . Latch rod 8. Tie rod efi 15. Latch 2. Clip 3. Nut 4. Washer 9. Handle assembly 10. Lock cylinder 1 1 . Spring 16. Washer 17. $crew 18. Screw 5. Bracket 6. Lock button ‘1'. Lock rod 12. Pin 13. Pawl 14. Screw 19. Lockwasher 20. Outer skin 21.000r EXPLODED VIEW OF DOOR 22. Door panel 26 Lockwasher 28. Bolt 29. Hinge 30. Hinge pin 31. Trim rlng 32. Door handle 33. Clip Page 70-14 DOOR REMOVAL AND INSTALLATION Remove door panel. Remove electrical leads (5) by removing clip (1) and, on vehicles with power windows. disconnecting leads from motor. Pull electrical leads out through hole in door. Disconnect door check (4) by squeezing rods together. Scribe marks for hinge location. Remove six screws [2 and 7) holding hinges (3 and 6) to door jamb and remove door. Install in reverse order. 1. Clip 2. Screws 3. Hinge 6. Hinge 7. Screws 4. Door check 5. Electrical leads DOOR LATCH REMOVAL AND INSTALLATION Remove door panel. Disconnect lock rod (2) from plastic clip (3) and remove rod. Disconnect adjustable head (1) from handle assembly. 1. Adjustable head 2, Lock rod 3. Clip Remove three screws (1 and 3) holding latch (2) to door. Tilt latch until latch rod (4) can be disconnected from latch. Maneuver latch out of door. install in reverse order. Adjust door handle. 1. Screw 2. Latch 3. Screw 4, Latch rod _ Doors-Door Glass-Lock Mechanism HANDLE AND LOCK CYIJNDER REMOVAL AND INSTALLATION Disconnect adjustable head (2) from handle assembly (3), Remove three nuts (1) holding handle assembly to door and remove handle assembly. Install in reverse order. Adjust handle. 1. Nuts 2. Adjustable head 3. Handle assembly ADJUSTMENT Disconnect adjustable head (2) from handle assembly (1 ). Turn head on tie rod (3) until proper length is obtained. 1. Handle assembly 2. Adjustable head 3. Tie rod STRIKER PLATE ADJUSTMENT Loosen two screws (1) and shift plate (2) as necessary. 1. Screws 2. Striker plate 701 .27/.3a/.31 Page 70-15 1. Doorsill molding 2. Weatherstrip 3_ Bolt 4. Washer 5. Boot 6. Channel 1'. Glass 3. Weatherstrip 9. Pillar 10. Pad 11. Weatherstrip 12. Clip 13. Plate 14. Screw 15. Pad 16. Glass 17. 18. 19. 20. 21. 22. 23. 24. G uide Plate Screw Weatherstrip Cover Boot Weatherstrip Channel 25. 26. 27, 28. 29. 30. 31. 32. Washer Lockwasher Bolt Weatherstrip Pad N ut Washer Pulley EXPLODED VIEW OF WINDOW ASSEMBLY WINDOW REGULATOR REMOVAL AND INSTALLATION Remove door panel. Lower window. Loosen nut [31 on adjustable pulley and relieve tension on control cable (1). Unhook control cable from five pulleys (2). 1. Control cable 2. Pulley 3. Nut 33. 34. 35. 36. 37. 38. 39. Washer Bolt Lockwasher N u! Cover Handle Window regulator _ Doors-Door Glass-Lock Mechanism Pull window up part way and remove two screws (2) and plate [31 holding control cable (1) to right side of window (4). Repeat above procedure to remove cable from left side of window. Lower window. 1. Control cable 2. Screws 3. Plate 4. Window Remove three nuts (1 and 3) and washers holding regulator (2) to door. Remove regulator from door complete with control cable. Install in reverse order. Adjust regulator. 1. Nuts 2. Regulator 3. Nut ADJUSTMENT Loosen four screws (1) through two plates holding control cable (2) at left and right side of window. Lower window to full down position. Set regulator handle in “wide open" position. Tighten screws securely. After adjustment, glass must run full length of its travel. Control cable must wind and unwind properly on regulator pulley. ‘l. Screws 2. Control cable 701 .27/.30/.31 Page 70-17 Page 70-18 To adjust tension of control cable (1), loosen nut (2) on adjustable pulley. Move pulley in slot (3) to set tension. Tighten nut. 1. Control cable 2. Nut 3. Slot Rear Window 701.54 Page 70-1 9 REMOVAL AND INSTALLATION Remove engine compartment lid. Refer to 701.01. Remove gas cap (1). Remove four screws (3 and 4) and washers holding two covers (2 and 5) to body and remove covers. 1. Gas cap 2. Cover 3. Screws 4. Screws 5. Cover Disconnect one rear window heater wire from each side of window. Remove four bolts (3) and washers holding prop (2) to body and remove prop. Remove four nuts and washers holding hinges (1 and 4) to body and remove hinges. Remove six bolts (6 and 7) and washers holding weatherstrip (5) to body and remove weatherstrip. 1. Hinge 6. Bolt 2. Prop 3. Bolts 4. Hinge 5. Weatherstrip 7. Bolt Pull iubber seal .(2) around window towards center of window (1). Slide seal out from under window at edge. Pull window down. Remove top rubber seal. Remove window. To install, place rubber seal on top of window. Place window in frame (3) and push it up into place. Slide rubber seal (2) under window. Make sure window is in center of seal and seal overlaps frame. Reverse removal procedure to complete installation. 1. Rear window 2. Rubber seal 3. Frame Page 70-20 1. Frame 2. Rubber seal 3. Weatherstrip 4. Bolt 5‘ Lockwasher 6. Washer 7‘ Window EXPLODED VIEW OF REAR WINDOW COMPONENTS 701.60 Luggage Compartment Lids Page 70—21 FRONT LUGGAGE LID REMOVAL, INSTALLATION AND ADJUSTMENT Remove four bolts (1) and washers holding lid (3) to hinges (2). Remove nut (5) and washers holding support rod (4) to lid. Remove lid. When installing lid, tighten hinge bolts enough to permit lid to be shifted. Close lid and check for preper alignment. Shift lid as necessary. After lid is positioned properly, tighten bolts. Install support rod. 1. Bolts 2. Hinge 3. Luggage lid 4. Support rod 5. Nut 29 28 27 1. Spring washer 2. Rod 8. Washer 9. Washer 15. Washer 16. Handle assembly 22. Lockwasher 23, Nut 29. Washer 30_ Washer 4. Lockwasher 10. Bolt 1 1. Nut 17. Bracket 18. Cable 24. Bolt 25. Lockwasher 31. Bolt 32. Hinge 5. Nut 6. Bolt 12. Washer 13. Nut 19. Rubber seal 20. Latch 26. Washer 27. Nut 34. Hinge 7. Bracket 14. Washer 21 . Washer 28. Lockwasher 35. Lid 3. Washer EXPLODED VIEW OF FRONT LUGGAGE LID COMPONENTS 33. Nut Page 70-22 FRONT LUGGAGE LID LATCH REMOVAL, INSTALLATION AND ADJUSTMENT To provide slack in cable for latch removal, remove two cap nuts (ll and washers holding handle assembly (2) to body. Separate handle assembly from body. 1. Cap nuts 2. Handle assembly Remove four screws [1) and bolt holding grille (2) on right side of vehicle. Remove two bolts (3 and 5] and washers holding latch (4) to cowl. Maneuver latch out through grille opening. ‘I. Screws 2. Grille 3. Bolt 4. Latch 5. Bolt Loosen bolt (2) attaching cable (4) to latch (3) and disconnect cable. Remove two bolts holding latch to bracket (1) and remove latch. When installing, tighten bolts enough to allow lock to be shifted. Check lock operation and shift lock as needed. Tighten two bolts. Reverse removal procedure to complete installation. 1. Bracket 2. Bolt 3. Latch 4. Cable Luggage Compartment Lids HEAR LUGGAGE LID REMOVAL. INSTALLATION AND ADJUSTMENT Remove four bolts (1 and 6) holding lid (5) to hinges (2 and 7). Unhook prep (3) from bracket (4) and remove lid. Remove prop. cotter pin, washers and bushing. When installing lid. check position. Shift lid on hinges to obtain proper alignment. Tighten bolts holding lid to hinges. 1. Bolts 2. Hinge 3. Prop 1. Striker plate 2.14:1 4. Bracket 5. Lid 6. Bolts 7. Bolt 8. Lockwasher 3. Hinge 9. Washer 4. Washer '1. Hinge 13. Washer 14. Bolt 15. Cable 19. Screw 20. Lockwasher 21. Screw 25. Fork 26. Screw 27. Washer 16. Rubber ring 22. Lock cylinder 28. Weatherstrip 5. Lockwasher 10. Latch 11. Spring 17. Washer 23. Lock assembly 29. Bushing 6. Bolt 12. Lockwasher 18. Lockwasher 24. Washer 30. Prop 31. Pin EXPLODED VIEW OF REAR LUGGAGE COMPARTMENT LID COMPONENTS Page 70-24 HEAR LUGGAGE LID LATCH REMOVAL, INSTALLATION AND ADJUSTMENT Remove two bolts (2) and four washers holding latch (1) to body. Disconnect cable {4) from latch. Disconnect emergency cable [Bl from latch. Remove latch. When installing latch, position it for proper operation. Tighten two bolts. NOTE: Release pull for emergency cable is in engine com— partment. 1. Latch 2. Bolts 3. Emergency cable 4. Cable REAR COMPARTMENT LOCK ASSEMBLY REMOVAL AND INSTALLATION Disconnect cables from engine compartment lid latch and rear luggage lid latch. Disconnect cables (2) from levers l1 and 3). Remove screw [5) holding lock assembly (4) in door frame. Remove lock assembly. Install in reverse order. 1. Lever 2. Cable 3. Lever 4. Lock assembly 5. Screw Front and Rear Bumpers FRONT BUMPER REMOVAL AND INSTALLATION Remove four nuts (3) and washers holding parking/hazard lights (5) to brackets (4). Separate lights from brackets. Remove four bolts (1) and washers holding front bumper to shock absorbers (2). Remove bumper. Install in reverse order. 1. Bolt 2. Shock absorber 3. Nut 4. Bracket 5. Light assembly REAR BUMPER REMOVAL AND INSTALLATION Remove four bolts (3) and washers holding bumper (2) to shock absorbers (1). Remove bumper. Install in reverse order. 1. Shock absorber 2. Bumper 3. Bolts 703.06/.07 Page 70-25/26 Seats 706.01 Page 70-27f28 REMOVAL AND INSTALLATION Disconnect spring (1) from bracket (2) under seat (4). Flaise lever. Slide seat off floor tracks (3). Install in reverse order. 1. Spring 2. Bracket 3. Track 4. Seat ~.._.‘I L/