alfa romeo 33: Руководства по ремонту и обслуживанию

DIREZIONE ASSISTENZA

CONTENTS

GENERAL VIEWS . . , . . . . . . . . . . . . . .OO-2

Dimensions and weights. . . . . . . . . . . OO-2

MODEL VARIATION . . . . . . . . . . . . . . . OO-3

IDENTIFICATION DATA . . . . . . . . . . . .OO-5

LIFTING POINTS AND... .’G TOWING . . . . . . . . . . . . . . . . u., . . . . . .OO-6

.-.Pantograph jack . . . . . . . . . . . . . . . . . 00-6

Garage jack and safety stands. . . . . . . 00-7

Towing. . . . . . . . . . . . . . . . . . . . . . . , OO-7

SPECIAL SERVICE TOOLS., . . . . . . . . .OO-8

INSTRUCTIONS FOR PRE-DELIVERY

INSPECTION AND PERIODICAL

MAINTENANCE COUPONS. . . . ; . . . . . . OO-8

Pre-delivery . . . . . . . . . . . . . . u . . . . . 00-8

Checking level . . . . . . . . . . . . . . . . . . 00-8

Functional tests . . . . ; . . . . . . . . . . . . . 00-8

Cleaning and finishing inspection. . _ _ 00-8

Maintenance. . . , . . . . _ ........... 00-10

MAINTENANCE SCHEDULE. . . . . . . . . . 00-l 1... :,--FLUIDS AND LUBRICANTS CHART . . 00-19

*. RECCOMMENDED FUEL AND

LUBRICANTS . . . . . . . . . . . . . . . . . . . . -00-20

Fuel..........................OO-2 0

Fluids and lubricants . . . . . . . . . . . . . 00-21

APPROXIMATE REFILL CAPACITIES. 00-24

ENGINE MAINTENANCE . . . . . . . . . . .OO-24

Basic mechanical system . . . . . . . . . . 00-24

Ignition and fuel system. . . . . . . . . . . 00-28

Checking CO% . . . . . . . . . . . . . . . . . . OO-29

TROUBLE DIAGNOSIS AND

CORRECTIONS . . . . . . . . . . . . . . . . . . . .OO-32

CHASSIS AND BODY MA!NTENANCE. 00-39

Checking fuel and exhaust system . _ . 00-39

Clutch . . . . . . . . . . . . . . . . . . . . . . . . OO-39

Gearbox-differential . . . . . . . . . . . . . . 00-39

Assembly drive shaft . . . . . . . . . . . . . 00-39

Front axle and front suspension. . . . . 00-39Rear axle and rear suspension. . . . . . . 00-40

Checking suspension heights . . . . . . . 00-40Wheel alignment. . . . . . . . . . . . . . . . . 00-42

Brake system . . . . . . . . . . . . . . . . . . . OO-43

Steering system . . . . . . . . . . . . . . . . . 00-45

Body . . . . . . . . . . . . . . . . . . . . . . . ..OO-4 5

SERVICE DATA AND

SPECIFICATIONS. . . . . . . . . . . . . . . . . . OO-45

Engine maintenance . . . . . . . . . . . . . . .OO-45

Chassis and body maintenance. . . . . . 00-47.SPECIAL SERVICE TOOLS . . . . . . . . . :OO-48

May 1983

COMPLETE CAR

GENERAL VIEWS

DIMENSIONS AND WEIGHTS .; -.1

Model 1200 1350 1500-identification number 905.00 905.02 905.04 905.05

405.03 905.06 - 905.07

Wheelbase P m m ( i n ) 2 4 5 5 (96.651

TrackFront

Rear

Ca

CPm m (in)

1392 (54.8) -... IT.:

1 3 5 9 ( 5 3 . 5 )

Overall length

OverhangFront

Rear

LLI m m (in) 4015 (158.07)Sa 800 (31.5)

SPmm (in)

760 (29.921

Overall width La m m (in) 1612 (63.46)

Height (unladen)

Ground clearance

Min. steering radius

Kerb weight

Max. allowed aross weiaht

H m m (in1 1305 (51.38)

m m (in) 121 (4.76)

mm (in) 4700 (185.04)

kg (lb) 890 (1962.1)

ks (lb) 1 3 1 5 (2899)

Payload

Max. allowed axle gross weightFront

Rear

kg (lb)

kg (lb)

425 (936.91725 (1598.31725 (1598.31

Max. towing gross weight

Seating capacity

kg (lb) 1000 (2204.6)

Front 2Rear ‘\ ‘\ 3

May 1 9 8 3

COMPLETE CAR

MODEL VARIATION(Except Switzerland, Sweden, Australia)

Model 1200 I 13501500

WADRIFOGLIO1500

Body 5 -door saloon 5 - door saloon

Left Right Left-r

RightDrive qight RightLeft Left

905.04 905.07

- on certification

Identification No. 905.03 905.06905.02 905.OE

905 A2

906 A20

-

- on identification

label

- on identification

label905 A 905 Al

905 Al 0

905 A2

905A20

Type approval No.

Serial NO.

- on intermediate

bulkhead label905 A00

from

05.001 .OOl

- on intermediate from

bulkhead label 05.001 .OO’

from

0 5 . 0 0 1 .OOl

305.04from

000.000.1

165170 SR 13

5Jx 13H2Or

5 ‘/ml x 13 CH

305.02from

000.000.1Type and serial No.

Tire dimensions 165170 SR 13 165170 SR 13

5Jx13H2or

5 ‘/2J x 13 CHRim dimensions 5J x 13 H2

00-3 May 1983

COMPLETE CAR

IDENTIFICATION DATA

IDENTIFICATION LABELS(Except Switzerland, Sweden, Australia)

5 - Door Saloon 1200 - .I350 - 1500

VEHICLE IDENTIFICATION(AND SERVICE) DATA

VEHICLE IDENTIFICATIONCODES

A) Chassis numbering

z A I? 9 0 5 A00 0 5 . 0 0 2 . 4 5 8(I) (3) (2)

(1) Manufacturer identification let-ters.

Certification and identification label(Identification No. and Type approval No.)Intermediate bulkhead label-(Type approvalNo. and serial No.)Cylinder block label (Engine No.)Lubrication data label (see “Fluids and Lubricants”of each grouplllubrication data)

Paint label (This label indicates the productused for the first paintl(Paint)

(2) Serial number: progressivelyassigned by Production.(3) “Type approval number”: notfor service identification use; forservice purposes, use the “typenumber” which iS stamped onidentification label along with the“type approval number”.The following is an example of suchlabel.

(4) Identification number: to be

used as vehicle service identificationnumber. This number consists of fivefigure numbers, divided as follows:4a) Basic type number: it is assignedto all vehicles having a commondesign concept (Ex.: 905: Saloon).4b) Type variant number: it identi-fies, within the basic type, thosevehicles that differ because of somevariant that alters their features (Ex.:905.02 5-door Saloon).

00-S May 1983

COMPLETE CAR

II I ALFA ROMEO AUTO SPAI II

B) Engine numberingIt consists of two sets of figures,namely:

305.00 00045 12(I) (2)

(I) Type number: ir is assigned tos all engines having common gen-

eral technical characteristics(Ex.: 305.02: 1350 engine withtwin carburetor).

(2) Ser ia l number : p rogress ive lyassigned by production.

LIFTING POINTS AND TOWING

PANTOGRAPH JACK

WARNING:a. Never get under the vehicle

while it is supported only by theiack. Always use safety stands tosupport frame when you have towork under the vehicle.

*,-+, - ?’ b. Place wheel chocks at both frontand back of the wheels diagonal-ly opposite the jack’s position.

Fit pantograph jack, supplied withthe vehicle, to safety points shown infigure.

May 1983 00-B

COMPLETE CAR

GARAGE JACK AND SAFETY STANDS

WARNING:a. When raising vehicle with garage

jack, be sure to support it withsafety stands.

b. When jacking up the rear (front)of the vehicle, place chocks infront ( in back) of the front(rear) wheels.

C A U T I O N :When raising the vehicle, alwaysplace a wooden block under vehicle’slifting points.Position garage jack and safety stands‘in a safe manner under the pointsshown in the figure.

TOWING

Closely follow Motor Vehicle Fiegu-lations regard ing veh ic le towing.

CAUTION:Use proper towing equipment toavoid possible damage to thevehicle.Before towing, make sure thatfront and rear axes as well assteering system are in goodworking condition; contrarywiseuse a dolly.If vehicle must be towed with itsrear wheels raised, front wheelsmust be placed on a towingdolly.

d. Set ignition key to “GAR” anddo not withdraw it from switch;otherwise antitheft device couldbecome engaged.

e. Release parking brake and setgearshaft lever to “neutral” be-fore starting to tow the vehicle.

f. Do not apply lateral forces totowing hook. Keep towing baror similar devices always inline with the vehicle.

g. Remember that when vehicle isbeing towed, there is no vacuumin servobrake; consequently,when braking, greater pressuremust be applied onto brakepedal.

00-7 May 1983

COMPLETE CAR

SPECIAL SERVICE TOOLSSpecial service tools play a veryimportant role in a vehicle’s majnte-nance since they are essential toensure accurate, reliable and quickservice. To this effect, it must beremembered that times taken rele-vant to the various maintenanceoperations are computed assumingthat said special tools are being used.A l l special; se rv ice too ls , made

expressly on the manufacturer’sdesign, needed for overhauling, main-tenance and repair of models arelisted and illustrated in this manual.The identification number is deter-mined by the relevant ordering partnumber and consists of *a letterfollowed by a five figure numberaccording to the following schedule:

A.O.OOOO Special Service Toolc.0.0000 Testeru.0.0000 Reamer

Order of the listed tools by theauthorized workshop, must be per-formed according to the usualsystems alretidy followed by eachService - net.

INSTRUCTIONS FOR PRE-DELIVERY INSPECTIONAND PERIODICAL MAINTENANCE COUPONS

In this chapter are listed anddescribed all pre-delivery and main-tenance operations required byAI-FA 33 models.As far as technical specificationsregarding each operation are con-cerned, refer to each sect ion’srelevant “Service Data and Specifica-tions” chapter.

PRE-DEL IVERY

Pi-e-delivery inspection of a newvehicle, prior to customer delivery,consists in carrying out all checkingoperations and tests hereafterdescribed in order to detect and thuseliminate any damage or malfunc-tion.It goes without saying, however, thatwhen Dealer personnel picks-up thevehicle should perform a visual checkin order to:- make sure that vehicle is in

normal driving condition, espe-cially as regards level of fluidsand controls in general

- detect any dents or scratchesonbody or other damage to thevehicle’s interior (upholstery)

- make sure nothing is missing,especially factory supplied ac-cessories, spare tire and any

r parts that are to be fitted onvehicle only prior to customerdelivery.

If checking operations show thattopping up -as foreseen by this text -

May 1983

is required, proceed accordingly;such operation will be considered aspart of pre-delivery inspection. Incase damages or malfunctions otherthan those herein described areencountered, they will have to betaken care of repair or adjust accord-ing to current technical and adminis-trative procedures. As each operationis being carried out, the relevant cardmust be filled out and then filedtogether with the sold vehicle’s otherdocuments; also the pre-deliverycard included in the InstructionBook supplied to the customer mustbe duly filled out as demostration ofstrictly execution of pre-deliverychecks.

C H E C K I N G L E V E L

Coolant- When engine is cold, check level

in expansion reservoir. If re-quired, top up to specified max.level.

Engine oil- Check if level is up to MAX.

mark on dipstick (carry out thisoperation after having parkedthe vehicle on an even surfaceand after the engine has been offfor a few minutes). If required,top up with specified oil.

Gearbox and Differential oil- Remove filler cap and check if

00-a ,

oil level reaches the filler loweredge. If required, top up withspecified oil and fit cap back.

Brake and clutch fluid- Check if level in the reservoir is

up to max. mark. If required,t o p up w i th spec i f i ed f lu idremembering that tins must besealed and opened only whenready to use..Be sure to perform this opera-t ion w i th u tmost ca re andcleanliness.

Battery electrolyte- Check and make sure electrolyte

covers the plate upper edge by 5mm (0,2 in); contrarywise, topup with distilled water.

Windshield washer fluid- Check if relevant reservoir is full;

if required, top up with specifiedsolution.

Tire pressure- Check tire pressure and, if

required, restore to specifiedvalues. Use higher p.s.i. for sparetire.

F U N C T I O N A L T E S T S

Engine starting and idling- Check if engine starts properly.

When engine is warm, checkspecified idle-rpm.

COMPLETE CAR

Engine controls- Check and make sure starterc o n t r o l k n o b w o r k s f r e e l y ,

without sticking; further checkthat when this knob is pushedin, respective device is not at allengaged on carburetor.

- Check accelerator pedal andmake sure it does not stick; alsocheck that when pedal is pusheddown all the way, throttle valveis fully open.

Brake, clutch and gearbox controls- With engine running, push brake

pedal and check if ” after theinitial stroke - it comes withoutelasticity.Also check if parking brakecontrol lever works properly.

- With engine running, push clutchpedal down and make sure thatall gearbox speeds engage easily,without sticking and noiselessly.

Tightening wheel screws- Use a spanner and check if wheel

screws, are properly tightened.Also check if screws, are incompliance with vehicle and rimtype, as shown in the Spare PartsCatalogue.

Dashboard instruments- While starting up the engine,

check if all electrically con-trolled instruments work proper-ly (needles are moving): rpmindicator, oil pressure gauge,water temperature gauge, fuellevel indicator, and clock.

System circuits tightness- Visually check circuits of follow-

ing systems for leaks or evidencethereof: fuel, brake, clutch, andengine cooling.

- Check engine, gearbox and dif-ferential for evidence of oil

leaks.

Engine cooling electric fan- Connect and short-circuit wires

of radiator thermal contact andcheck if fan starts and worksproperly.Also make sure that wires areproperly and securely connectedto thermal contact.

Heating system- Check proper working condition

of levers controlling heater andoutlets for admission of air intothe vehicle (open and close).

- Check i f e l ec t r i c f an worksproperly at different speeds andif relevant warning light on theboard lights up.

Lights, signal, electrical accessoryequipment- With ignition key set to “M A R ”

check if lights outside and insidethe vehicle, as well as relevantwarning lights, go on: frontand rear parking lights, numberplate lights, direction indicatorsand emergency flasher, stoplights, high and low beamheadlights, headlights flasher,reverse gear lights, rear fog lightsinside ceiling lamp (throughmanual as well as door switch),instrument cluster light.

- Check proper working conditionof following warning lights:alternator, fuel reserve, oil pres-sure, brake fluid level, parkingbrake on, starter on, defrosteron, cooling water temperature.

- Check proper operation of hornsand cigarette lighter.

Windshield and rear window wiperand washer- Af te r hav ing ins ta l l ed w iper

blades, check if windshield wiperworks properly at both speeds aswell as it is set to intermittentoperation.

- Operate the windshield washerand check if sprayer jets arenormal and properly directedtoward the windshield’s highersection.

Locks, hinges, windows- Check proper working condition

of all door locks (close, lock,open from inside and outside).Check in the same manner alsolocks of engine and back door.

- Check door and bonnet hingesfor smooth noiseless operation.

- Check if windows can be openedand closed all the way withoutsticking and noiselessly.

Doors and bonnets- V isua l l y check a l l wea ther -

stripping for tight fit and makesure they are not damaged, outof shape or dirty.

-y See if doors and bonnets arealigned and centered with rele-vant openings.

Seats, seat belt and ac!essory equip-ment- After having removed relevant

protecting covers, inspect seatschecking if they slide freely ontracks without st icking andnoiselessly. Also check properworking condition of seat andhead-rest adjusting devices.

- Check if seat belts and relevantretractors are in good workingcondition.

- C h e c k inside and outsiderear-view mirrors making surethey swing easily and stay firmlyin place when set; also check

s n a p switch on mirror forday/night driving.

- Check maneuverability of sun-visors, ashtrays, glove compart-ment and any other accessory.

CLEANING AND

FINISHINGINSPECTION

Exterior cleaning- If required, dewax the vehicle

using suitable products andprocedures; wash the vehicle’sexterior with a solution ofwater and shampoo, rinse itthoroughly and dry it.Finish up cleaning by removingany stubborn spots by means ofsuitable compounds.

Paint- Visually and thoroughly check

all painted surfaces and removeaccidental or manufacturingflaws, if any.

Exterior/Interior mouldings and fit-

tings- Visually check all vehicle’s out-

0 0 - 9 May 1983

COMPLETE CAR

side parts: bumpers, mouldings,grills, headlight rims, letters andemblems making sure they aresecurely fitted, and *have n ospots or dents.Verify all upholsteries (roof,carpets, panels etc ..) removingpossible stains or scratches.

Factory issued accessory equipment- Check if following items are in

their proper place in the vehicle:tool kit, spare tire, jack, Instruc-tion Book and Service Book.

MAINTENANCE

Maintenance operations consist inchecking and restoring proper work-ing condition of some parts of thevehicle which are most likely tobecome worn or out-of-adjustment asa consequence of the vehicle’snormal use.A list of various operations to beperformed at different intervals, asshown in the chart that follows, isincluded in the coupons of theService Book which accompanieseach vehicle.

Coupons will have to be stamped bythe Service Organisation Agency toshow that specified maintenanceoperations have been carried out.Just as for pre-delivery inspection,should topping UP or change of fluidsand lubricants - as described in thetext - become necessary, they will beconsidered as part of maintenanceoperat ions. .In case damages ormalfunctions other than those listedare encountered, they will be takencare of repair of adjust according tocurrent technical and administrativeprocedures.

May 1983 0 0 - 1 0

COMPLETE. CAR

MAINTENANCE SCHEDULE(Except Switzerland, Sweden, Australia)

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COMPLETE CAR

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May 1983 0 0 - 1 2

COMPLETE CAR

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COMPLETE CAR

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0 0 - 1 5 May 1983

COMPLETE CAR

MAINTENANCE SCHEDULE(Australia version)

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00-I 7 May 1983

COMPLETE CAR

FLUIDS AND LUBRICANTS CHART

May 1983

COMPLETE CAR

RECOMMENDED FUEL AND -LUBRICANTS

FUELTo ensure proper engine operation,use petrol with a 2 98 Octane Rating(R.M.) and a G 11 sensit iv i ty (I).

(1) Difference between Research Method

Oct%ne Rating and Motor Method Octane

Rating.

COMPLETE CAR

FLUIDS AND LUBRICANTS

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00-2 1 May 1983

COMPLETE CAR

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May 1983

i COMPLETE CAR

APPROXIMATE REFILL CAPACITIES

A P P R O X I M A T E REFILL CA P A C I T I E S I kg (lb) I 1 (Imp gal 1

FUEL TANK 50 (11)

FUEL RESERVE - 6.5 (I ,431

COOLANT - 7.3 (I ,611

ENGINE OIL SUMP

GEARBOX-DIFFERENTIAL OIL

With filter

Without filter

3.6 (7.94)

3.15 (6.94)

2.3 + 2.4 (5.1 + 5.3) --CONCENTRATE ANTI FREEZE QUANTITY

IO”2 (14°F) 1.8 (0.40)-

DEPENDING ON TEMPERATURE E - 20°C (-4’F) 2.6 (0.57)

- 35°C (-31°F) 3.65 (0.80)

ANTIFREEZE QUANTITY READY FOR USE - - 20°C (4’F) I - I 7.3 (1.61)

CAM SHAFT SUPPORT SUMPS 01 L Kg 0.250 (lb 0.55) FOR EACH

SUPPORT (REFILL TO BE C A R R I E D OUT I N C A S E O F DISASSEMBLIESONLY-COMPLETELY DRY SUPPORTS

0.5 (1.1)

ENGINE MAINTENANCE

BASIC MECHANICALSYSTEM

CHECK AND POSSIBLEADJUSTMENT OF VALVECLEARANCE

Following operations must be per-formed while engine is cold.

1. Disassemble spark plugs, removecamshaf t suppor t cover and , bymeans of a syringe, suck oil fromtank.2. Using the feeler gauge C.6.0168check clearance between cam restingradius and cup crown making sure itis within specified value.

Valve clearance (cold engine)Intake

0.35 + 0.40 mm (0.014 + 0.016 in)Exhaust

0.45 + 0.50 mm (0.018 + 0.020 in)

In case clearance is not within theprescribed values, carry out adjust-ment operating as follows:1. Rotate crankshaft till piston is inits compression stroke (valve closed).

2 . Inser t the key A . 5 0 1 9 3 i n t oproper hole on camshaft,3. Further rotate crankshaft so thatcamshaft hole is in l ine with theadjusting screw on the cup.4. Suitably rotate the cup involvedin the adjusting operation as well asthe one next to it so that relevantcavities will face each other.5 . I n t r o d u c e t o o l A . 2 . 0 2 7 8 f o rretaining of valve cups in order toprevent ro ta t ion o f cups dur ingclearance adjustment (tool does notprevent axial sliding).

May 1983 0 0 - 2 4

COMPLETE CAR

6. Interpose tool C.6.0168 betweentapper bucket upper part and camminimum radius and, by means ofwrench A.5.0193, operate until theprescribed clearance is obtained..7 . For better security check clear-ance after having removed previouslyinserted cup locking pin.8. Repeat the procedure for eachvalve of the two heads.9. At the end of operation, restorethe tank oil level and reassemblecover and spark plugs.

CHECKING, REPLACINGAND ADJUSTING DRIVEBELTS

Alternator and water pumpcontrol belt

Inspect belt for cracks or damage.Replace it if necessary. Push on beltlongest section, located betweenengine pulley and alternator pulley,applying an 79 N (8 kg; 3.63 lb) loadand verify relevant deflection whichshould be of 15 mm (0.59 in);contrarywise proceed to adjust belttension as follows.

7. Loosen bolts 81 and 0 aswell as screws 3 t h a t s e c u r ealternator support bracket to theengine’s front cover.2. Move the alternator so as toeither stretch or slacken the belt andthen tighter&gain bolt 0.3. Check again belt tension andthen tighten all previously loosenedbolts.

1 Bolt2 Bolt

3 Screw

Replacing timing belts withengine on car

REMOVAL

1. Disconnect electric fan wiring,loosen relevant screws 0 andremove fan from radiator throughlower channel 0.

1 Screww2

2 Channel

2. Remove spark plugs, alternatorand water pump control belt.3. Remove camshaft belts plasticcovers.4. Remove camshaft support cov-ers.5. Remove t iming plastic coverlocated on cylinder block rear cover,and rotate crankshaft till piston inno. 1 cylinder is set in top deadcenter on its combustion -stroke.Such correct position is achievedwhen the T-shaped referencemark @ on flywheel is in line withthe mark on rear cover 10.

1 Mark on rear cover2 T - shaped reference mark

6. Loosen idler pulleys locknuts 10 and then press idlerpul leys @ so as to overcometension load on belts. Tightennuts 0 while in this position.

1 Lock nur 2 Idler pulley

7. Now remote first the right handcogged belt and then the left handbelt from camshaft and crakshaftpulleys.

ASSEMBLY

CAUTION:Check again engine timing proceed-ing as per step Sabove.

1. Rotate camshafts till referencemarks stamped on same are in linewith those stamped on relevantsupport.

00-25 M a y 1 9 8 3

COMPLETE CAR

2 . Key camshaft control belts. ontocrankshaft and camshaft pulleysstarting with the one of the left handcylinder head.(1) Belt keying must take placewhile belt pulling section (oppositethe idler pulleys) is fully stretched.(2) Loosen idler pulleys lock nuts allthe way and then tighten them again.(3) Let driving shaft rotate in thefunctioning direction so as to allowbelt to set on pulleys.(4) Set, one by one, the camshaftsto the neutral position, then unloos-en nuts securing backstand, press afew times on them and secure nuts to

the prescribed torque.(5) Rotate crankshaft a few times inits working direction so that beltsmay take up their final position.

Rotate camshafts till they are inneutral position: loosen idler pulleyslock nuts pressing idler pulleys a fewtimes, and then tighten relevant nutsaccording to specified torque.Rotate crankshaft a few times in itsworking direction thus allowing beltsto settle on pulleys, and then repeatabove described tension checkingoperation while positioning cam-

shafts one at the time - with cups

disengaged.

@ : Tightening torqueIdler pulley lock nut(cold engine)

37+46 N-m(3 .8 + 4.7 k g - m27.49 + 33.98 ft-lb)

3. Check again engine timing.4. Fit back camshaft support cov-ers, alternator and water pumpcontrol belt, electric fan and sparkplugs.5. Start engine and warm it up tonormal running temperature, thenremove again camshaft support cov-ers. Working on one cylinder head at

the time, proceed as follows: bringrelevant camshaft in neutral position,loosen and then tighten again idlerpulley lock nut thus giving the belt inits final tension load.

@ : Tightening torqueIdler pulley lock nut(warm engine)

29+35 N-m( 3 + 3.6 k g - m2 1 . 3 8 f 2 5 . 8 ft.lb)

.

.

2 .

A milky oil indicates the pres-ence of cooling water.Identify the cause and takecorrective measures.An oil with extremely lowviscosity indicates dilution withpetrol.

Using an oil filter wrench,remove oil filter.

6. Fit back camshaft support cov-ers and timing belts covers.

CHANGING ENGINE OILANQ REPLACING OILFILTER

1. With engine warm, remove oilfiller cap and oil pan drain plugletting oil drain completely into asuitable container (wait at least 15minutes).

3. When engine oil is completelydrained, clean oil pan drain plug andscrew it back into place.4. Moisten the gasket of the newoil filter and then install the filtertightening it all the way.5 . Refill engine with specified newoil referring to LUBRICANTS &hart.Check oil level with dipstick.

ENGINE OIL QUANTITY

1 kg 1 (lb)

Camshaft support sumps (*I 0.25 (0.55)

Engine oil sump 3 . 6 0 ( 7 . 9 4 )Sump capacity 3 . 1 5 (6.94)Filter capacity 0 . 4 5 (1 .OO)

(*I Refill to be carried out, far each sump.in case of disassembly only.

M a y 1 9 8 3 00-26

COMPLETE CAR

6. Fit oil filler cap back and startthe engine letting it idle for about 2minutes.7. Now check following items forany oil leaks: filter, pan, seal rings,oil pressure transmitter, gaskets ofcylinder block and cylider headcovers, and cylinder head gaskets. Ifnecessary, tighten or replace itemsthat are not oil tight.8. Turn the engine off and wait afew minutes.9. Take out dipstick and clean it;fit dipstick back, take it out againand check oil level making sure itreaches the MAX reference mark.

1 Coolant drain plugs

3. Fill cooling system with recom-mended anti-incrustator followingrelevant instructions for use.

Recommended anti-incrustator:NALCO 1006INTERPROIND Jal AutoStand. No. 3681-69955

4. Remove again drain plugs fromcylinder block bottom and letanti-incrutiator drain completely.5. Thoroughly flush the systemwith running water.6. Fit drain plugs back to cylinderblock and fill the radiator.

System refill

CAUTION:When checking oil level, park the caron a level surFace.

After having drained the coolingsystem, refill it with the kind andquantity of coolant as shown inthe following chart.

COOLING SYSTEM

System flushing

This operation should be performedonly if plain water is used as enginecoolant in summertime.

1. While engine is cold, removeradiator filler cap.

2. Loosen and remove drainplugs 0, located on bottom ofcylinder block, let coolant draincompletely and then fit plugs backon cylinder block bottom andtighten them.

Sunimertime

Drinkable water I 7.3

( Imp Ga l ) (1 .61)

Minimum out- Cside temperature (S

Concentrated anti-freeze Std. No.3 6 8 I - 6 9 9 5 6 I

(Imp Gal )

Diluting drinkablewater

(Imp Gal !

Ready-to-use anti-freeze Std. No.3 6 8 1 - 6 9 9 5 8 I

(Imp Gal 1

- IO(14)

1.8(0.40

5.5Il.211

-20(- 4)

2.6(0.57)

4.7(I .03)

7.3(1.61)

3.65(0.80)

3.65(0.80)

Refill radiator through relevant filleraccording to following instructions:

1. Refill the system till max. levelmark in expansion reservoir isreached.2. Start the engine and warm it upto normal running temperature thusallowing the thermostat to open andto expel any air that was left over inthe system.3. When engine is cold, top upcooling system till max. level mark inexpansion reservoir is reached.4. Fit filler cap back and.tighten it.

Checking the system’

1. Check coolant level in radiatormaking sure it is within MAX andMIN level marks.2. Check hoses and unions for leaksmaking sure they are not in any waydamaged.3. Check filler cap making surerelevant spring, gasket and valves arein good working condition.4. Test the electric fan as follows:(1) Disconnect thermostat wires andshort-circuit them.(2) Turn ignition key and check ifelectric fan-starts up.5. Check radiator as per instruc-tions contained in Group 07 - Radia-tor.6. If top-up requires an abnormallylarge amount of coolant, check entirecooling system for leaks and elimi-nate them.

Radiator cap pressure test

1. Fit union @ onto tester andthen insert it on expansion reservoircap.2. Apply pressure to the cap andcheck tester to make sure that whenspecified pressure reading is reached,

‘the relief valve opens up.

Radiator filler cap relief pressure:68.6 kPa (0.69 bar;

0 . 7 kg/cm’; 9.96 p.s;i.l

00-27 M a y 1 9 8 3

COMPLETE CAR

1 Tester2 Union

3 Filler cap

Cooling system pressure test

1. Remove expansion reservoir cap.2. Tighten tester onto expansionreservoir filler.3. Apply pressure to the coolingsystem and check tester to make surethat pressure remains within spec-ified value.

Cooling system testing pressure:107.9 kPa (I.08 bar;

1.1 kg/cm’; 15.65 p.s.i.1

May 1983

CHECKING CYLINDER or between cyl inder l iners and

COMPRESSION p i s t o n s .

When diagnostic poor engine perfor-mance because power is not up tonormal, it is advisable to test cylindercompression using relevant tester(MOTOMETER) and according tofollowing procedure:1. Start rhe engine and warm it upto norma l running temperature.2. Remove spark plugs.3. Disconnect distributor’s highvoltage cable.

REPLACING AIR CLEANERCARTRIDGE

I. Unfasten air cleaner cover retain-ing spring clips 0.2. Lift cover 0 and removecartridge.3. Thoroughly clean cartridge byblowing low pressure compressed airfrom within.If necessary, replace cartridge.

4. Apply compression tester ontothe seat of one spark plug.

5. _ Crank the engine briefly keepingthe accelerator pedal fully pressed sothat carburetor throttle valve is fullyopen.6. Verify that compression pressureis above min. value (make sure thereare no leaks from tester’s union).

1 Cover2 Air cleaner cover retaining spring clip

Min. compression pressure1030 kPa (IO.3 bar;

10.5 kg/cm2 ; 149.34 p.s.i.1

IGNITION AND FUELSYSTEM

7. Repeat the test to check com-pression in other cylinders, beingcareful to reset the tester eachtime. Compare the readings andmake sure that max. di f ferencebetween the various cylinder pressuremeasurements does not exceed speci-fied value.

CHECKING AND REPLACINGSPARK PLUGS

Max. compression differencebetween cylinders98 kPa (0.98 bar;

1 kg/cm’; 14.22 p.s.i.1

If picked up values are not withinspecified ones, look for the trouble’scause in poor tightness of the valves

1. Disconnect spark plug wires withrelevant protecting boots.2. Remove spark plugs with sparkplug wrench.3. Clean electrodes and check insu-lation for cracks and chips.If electrodes are excessively worn,replace the spark plugs.Spark plug type: LODGE 25 HL4. When replacing spark plugs, coatplug thread with specified grease andthen fit them in relevant seat tighten-ing them according to specifiedtorque.

0 0 - 2 8

COMPLETE CAR

Spark plug thread:ISECO Grease: Molykote A - Std.No.4500-18304

@ : Tightening torqueSpark plugs25+34 N-m(2.5+ 3.5 kg-m18.08 + 25.31 ft.lb)

5. Connect spark plug wires and fitback relevant protecting boots ac-cording to following sequence: I - 3 -2 - 4.

CHECKING THEDISTRIBUTOR

Visual check1. Remove distributor cap androtor @ and check them for cracksor chips.

2. Make sure that distributor capcarbon is securely kept in place in itsseat by the relevant spring and that itmoves freely thus ensuring properconstant adherence to distributorrotor.3. Apply a coating of engine oil tofelt inside rotor control shaft and acoating of specified grease to cam.

CHECKING CO%

CHECKING IGNITIONWIRING

ignition coil.

CHECKING AND ADJUSTINGIGNITION TIMING,IDLE-RPM AND COY..

I. Connect stroboscopic flash lampfeed clamps to the battery and thepickup to the high voltage cable ofcylinder no. 1.2. Connect an electronic tachome-ter to the engine by fitting feedclamps to the ignition coil’s feedingand the pickup to the coil’s highvoltage cable.

1. Visually check ignition wiringfor cracks, burns and loose terminals.2. Measure resistance of high volt-age cable by connecting an ohmme-ter between the cable’s terminal and .the corresponding electrode on the P

oo-‘2 9 May 1983

COMPLETE CAR

3. Remove the small plastic covet

located on the engine rear cover.

1 Advance hose2 Ignition timing check hole

4. Start the engine and warm it up

to norma l running temperature.5. Using the stroboscopic flashlamp, check if - with engine runningat g 900 r.p.m. - the mark on theengine rear cover is in line with thefixed advance notch on flywheel.

Fixed advance8% 1”

6. Disconnect the vacuum advancehose from distributor and verify thatwhen engine at 4500 r.p.m. the markon the engine rear cover is in linewith the max. advance notch onflywheel.

Max. advance36”+ 1”

7. If specified alignment does nottake place, loosen the distributorretaining bolt and rotate distributoreither clockwise to retard or anti-clockwise to advance.

8. Tighten the distributor retainingbolt and check f ixed and max.advance to make sure they arewithin specified values.9. Fit the small plastic cover backonto engine rear cover.10. Fit vacuum advance hose backonto distributor.If above described adjustment doesnot succeed in correcting max.advance, overhaul or replace thedistributor.

CHECKING AND ADJUSTINGIDLE-RPM AND CO%

Preliminary inspection:a.b.

C.

d.

Clean or replace air cleaner.Inspect ignition system makingsure following parts are in goodworking condition: spark plugs,cables, distributor cap, rotorarm, (refer to: Group 05 - Igni-tion System).Check ignition timing.Check adjustment of acceleratarcontrol (see: Group 04 - Accel-erator Control).

CAUTION:If during engine tune up there is noextra cooling fan available, keepchecking indicator pump and thewater temperature gauge on dash-board and immediately suspendtesting if temperature goes up,meaning that engine is overheating.

Check idle-rpm and overall CO% asfollows:1. Insert CO-tester probe @ intothe tail pipe 0.2. Connect an electronic tachome-ter to the engine.

1 Tail pipe 2 CO-tester probe

May 1983 00-30

COMPLETE CAR

3. Start the workshop’s gas ex-hauster.4. Srart the engine and warm it upto normal running temperature.5. Now check if engine rpm iswithin specified value.

Idle-rpm900 + 1000 r.p.m.

850 + 950 r.p.m. ( l )

(“1 (for Switzerland, Sweden,Australia)

. .

6. If not within specified value,adjust idle-r-pm just by turningrelevant idle-adjusting screw @which makes it possible to changerpm without changing CO percentage(Carbon monoxide).7. Verify that CO percentagepicked up by tester corresponds tospecified value and that engineruns smoothly.

Ajlowed CO %< 3.5 % total

If not within specified value or incase of engine tune up after engineoverhauling or after having cleanedor replaced the carburetor, anadjustment involving also mixturemetering screw @) and throttlevalve screw @) is required. In thisinstance, proceed as follows:(1) Remove seals from mixturemetering screw 0 and from throt-tle valve screw 0.(2) Tighten idling screw @ all thew a y .( 3 ) N o w act on throttle valvescrew 30 and on mixture meteringscrew @ till following conditions arepresent:

Rpm8 5 0

8 0 0 (*)C O %

0.5 + 1% total

(“) for Switzerland, Sweden,Australia

(4) Loosen idling adjustingscrew @ till a 900 + 1000 rpm(850 + 950 rpm for Switzerland,

Sweden, Australia) idling speed isreached.(5) Act on mixture meteringscrew @ till the smoothest possibleengine running is obtained, whilekeeping CO% within the prescribedvalves.

CO%< 3.5% total

0 . 7 + 2 . 4 % (*)

(“) for Switzerland, Sweden, Aus-tralia

(6) Fit back into place mixturemetering and throttle valve screwseals,(7) ff further optimizing of idle-rpmis desired, just act on.relevant idlingadjusting screw 0.

1 Idling mixture metering screw2 Idling adjusting screw3 Throttle valve adjusting screw

EMISSION CONTROLSYSTEMRecycling of exhaust gas and oilvapors, generating in the cylinderblock and then burned in the cylin-ders, is achieved through a series ofblow-by hoses.At any rpm, the vacuum created inthe carburetor is sufficient to conveygas and vapors into intake duct andfrom here into cylinders for finalcombustion.When engine is idling or running at

00-3 1

medium rpm, the vapors going up theoil filler go through the flame traplocated in the hose @ connectingoil filler to air cleaner; from herethen they go through the min. rpmblow-by hose @ and, downstreamfrom throttle valve, are distributedonto intake manifold @ _Since when the accelerator ‘is fullydepressed the vacuum generated bythe engine is not sufficient to com-pletely suck exhaust gases solelythrough the min. rpm hose, gases arealso conveyed inside air cleaner,upstream from carburetor, by meansof the max. rpm blow-by hose 0.

CHECKING HOSES ANDUNIONS1. Inspect hoses and unions tomake sure they are not in any waydamaged and that are no leaks.2. Disconnect all hoses and cleanthem blowing a jet of compressed airthrough them.Replace any damaged hose.3. Remove flame trap located inmain blow-by hose near the oil filler;wash it with suitable cleaner, blow itwith compressed air and, then fitit into place.

Air cleanerMax. rpm blow-by hoseMain blow-by hoseOil filterMin. rpm blow-by hoseCarburetorIntake manifoldCvlinder block

May 1 9 8 3

COMPLETE CAR /

CLEANING CARBURETORJETSIf necessary, clean carburetor jetsand blow-by hoses as fol lows:a. Remove air cleaner, carburetor

cover, and then remove main jets

b.as well as idle jets.Clean jets with compressed air(do not use any metal tool) andthen fit them back onto carbure-tor; also fit cover and air cleaner.

REPLACING FUEL FILTER

Loosen hose clamps and remove thefilter. Install a new filter payingspecial attention to the fuel flowingdirection as indicated on filter body.Tighten hose clamps.

TROUBLE DIAGNOSIS AND CORRECTIONS

l Dead battery

l Faulty battery

l Oxidized battery terminals

l Loose wiring connections instarting circuit

l Faulty starter switch

l Faulty starter

Condition Probable cause

CANNOT CRANK ENGINEOR SLOW CRANKING

(Starting circuit trouble-shooting procedure)

Turn on starter while lights are on (set switch to “ON”).If lights go off or dim considerably:

a. Check battery’b. Clean battery terminals

If lights stay bright and starter does not work:

a. Check wiring connection between battery and starterb. Check starter switchc. Check starter

ENGINE CRANKS NORMALLY BUT WILL NOT START

Corrective action

Recharge and check recharge system

Replace

Clean terminals

Correct

Replace

Repair or replace

In most cases the trouble lies either in the ignition system or in the fuel system.

- Trouble in ignition system- Trouble in fuel system- Valves do not work properly- Low compression

(Trouble-shooting procedure)First of all check spark plugs as follows:Disconnect high voltage cable from one spark plug and hold it about 10 mm (0.39 in) from any engine metal partand let the starter run.

CAUTIONAbove test must be performed with uttermost care.

May 1983 00-32

ENGINE MAIN MECHANICAL UNIT

.DRlVE UNIT REMOVAL AND INSTALLATION

REMOVAL

Drive unit supports

DETAIL A

040 c4s(4.1 + 529.6 f 36.2)

DETAIL C

Drive unit central supportCentral supporr to body fixing boltRear support pinRear support to body fixing screwsGearbox casingEngine unitEngine front support to crossmember fixing screwEngine front support

DETAIL 6

(kg.mftlb)

Detail A Central supportDetail 6 Rear supportDetail C Front support

M a y 1 9 8 3 0 1 - 2


Engine compartment - Electrlc w i r e s dlsconnectlons

Ignition inductor cableignition distributorCooling temperature transmitter cableCoil high voltage cableTachometer and coil low voltage cablesAlternator and alternator warning light supply cableHead lamps cablesElectric fan thermal switch cablesFoglamps cables

1011121314151617

Horn cablesElectric fan supply cableWindshield and rear window washers pump cablesWater temperature thermal contact cableOil pressure manual contact cableStarter supply cablesEnergization cableEarth cable on engine cover

01-3 May 1983


Engine compartment - Plplng release

1 Fuel pipe2 Clutch oil supply pipe3 Expansion tank plug4 Air bleeder into crankcase5 Sleeve for water return from radiator6 Sleeve for water delivery to radiator7 Servobrake vacuum pipe6 Hot water to heater supply pipe9 Heater warer return pipe

May 1983 0 1 - 4


During engine removal from car, it isnecessary to remove engine andgearbox - differential as singleunit.Put the vehicle on the auto lift andengage first gear.

~~tY~~~~~ngine~ jGreat care is required when dealing

1. Operating from passenger com-partment inside withdraw knob ofgearbox lever, then remove thetwo lever bellows.2. Remove the hood (refer to:Group 56 - Hoods).3. Working from inside the enginecompartment, disconnect the batteryearth cab le.4. Disassemble the air filter asfollo\lvs:(1) Disconnect the corrugated airintake pipes from the air filter bytaking off the fixing clamps.(2) Disconnect the blow-by pipes.Then remove the filter (Refer to:Group 04 Air Filter - Removal).5. Disconnect accelerator andstarter controls as follows:(1) Extract the retaining ring 0,slip the return spring @ off itsclamps and take off the slottedadjuster @ from the throttlecontrol lever.(2) Release accelerator cable to-gether with bracket @ unscrewingthe two securing screws located onintake manifold.(3) Disconnect hose and sheath ofstarter control of operating on sheathsecuring screw @ and on startercontrol lever screw 0.

1 Bracket 4 Spring2 screw 5 Retaining ring3 Screw 6 Adjuster

6. With reference to the figure onpage 01-3 disconnect the followingelectric cables, preferably as indi-cated : -.

.

.

.

l

.

.

l

.

.

.

l

.

.

l

.

.

earth cable @I, from theengine rear coverhigh voltage cable @, from thecoillow voltage and tachometercables @ from coilalternator and warning lightsupply cable @, from thealternatorwater temperature thermal con-tact cable @, from the thermalcontact on the right hand headelectric fan supply cable 0 ,from the fanwindshield and rear windowwashers pump cables @ fromthe pumpstarter motor supply I@ andenergization @ cables fromthe starter motoroil pressure switch cable @ ,from manual contact on the rearcoverelectric fan thermal contactcable @, from the thermalcontact on radiatorfog lamp supply cables @,from fog lamp connectorshead lamp supply cables 0,from the headlampshorn supply cables @I , fromthe hornswater temperature transmittercable @ , from the transmitteron the intake manifoldelectronic ignition inductorcable a from distributorremove ignition distributorcap 2 together with spark plug0cablesoil level sensor cable, from levelrod (for models fitted withcheck control, only)

CAUTION:Unfix the electrical cables from theirclamps, separate them from the driveunit so as not to impede its removal.

7. Unscrew and remove the coolantexpansion tank plug.8. Raise the car and from beneathremove the right hand drain plug 3and then the left hand drain plug 84under the cylinder block and drainoff the coolant; screw the plugs again

after draining.9. Depending on what is to bedone, drain the oil from the oil sumpby removing the plug @ and, ifnecessary, drain the oil from thegearbox by removing the drainplug 0. Screw the plugs again afterdraining.

1 Gearbox oil drain plug2 Engine oil drain plug3 Right head coolant drain plug4 Left head coolant drain Plug

10. Lower the vehicle and withreference to figure of page 01-4,disconnect the following pipes andcouplings, preferably as indicated:

hot water to heater deliverypipe @, from the supply mani-foldwater from heater returnpipe @, from the water pumpintakedelivery pipe @ to block fromthe water pump intakewater delivery coupling @, toradiatorradiator water return coupl-ing 0, from the water pumpintakefuel inlet line 0, from supplypumpclutch oil delivery hose 0,from pipe union (properly plugthe hose)servobrake vacuum intakepipe 0, from the suction mani-fold.

11. Loosen bolt 0 securing enginecentral support @ to body.

M a y 1 9 8 3 01-6

E N G I N E M A I N M E C H A N I C A L U N I T

INSTALLATION

1 Central support2 Central support securing bolt3 Rear support4 Pin5 Rear support securing screw

CAUTION:Drive unit assembly must be per-formed in such a way that thegearbox rear support and the enginefront support are not respectivelyupwards and longitudinal ly pre-loaded.

Referring to preceding illustration,follow as indicated.1. Raise the drive unit with thecolumn lifter used for disassemblyuntil the centre support axis @ is atabout the halfway point of thebody slot and tighten the relevantbolt-@, -+’Connect the left strut to the enginesupport cross member and fasten thecross member in position to the bodywith the screws @.

2. Fasten the front support @ inposition to the cross member tighten-ing the correct screws.

6 Bolt securing gearbox rear support7 Exhaust pipe8 Engine cross member securing screw9 Engine support cross member

10 Front elastic support

3. Remove the lifter and unloosethe lower bolt @ securing thegearbox to the rear support.4. Put the rod @ in the rearsupport 0, positioning it on itsbody clamping points and screw upthe screws 50.5. Screw up the drive shafts todifferential shafts joint screws in oilwith the prescribed torque.

0: Tightening torqueDrive shafts to differentialshafts connection screws

33 f 36 N-m(3.4 + 3.7 kg-m24.58 + 26.75 ft-lb)

6. Assemble the exhaust pipe 0.7. Clamp the lower bolt @ secur-ing the rear support to the gearbox.8. With reference to the following

illustration put the side rod @ inthe support @ on the right siderail @ then tighten, first,screw @, second, screw 0.

1 Right cylinder 4 Side rodhead 5 Screw

2 Right side rail 6 Screw3 Support

M a y 1 9 8 3 01-8


9. Complete the unit assemblecarrying out the disassembly opera-tions in reverse order, with particularattention to the following steps.(I) By means of a spanner, tightento the prescribed indicative torque,the union connecting hose to clutchcontrol pipe.

0: Tightening indicative torquerelevant to hose union to pipe.

15 + 19 N.m(1.5 + 1.9 kg-m10.84 + 13.78 ft.lb)

(2) Check The engine oil levelc&responds to the MAX mark on thedipstick, and the gearbox oil levelreaches the lower edge of the fillerhole. If necessary, top up with the

prescribed oil:

Engine oilAGIP Sint 2000 lOW50I P S u p e r M o t o r O i l lOW50

Gearbox oil differential:AGIP Fl Rotra HP SAE SOW90IP Pontiax HD SOW90

(3) Bleed the clutch hydraul icsystem (See Unit 12 - Hydraul icSystem Bleeding) and if necessarytop up the oil level to the MAX markon the tank with the prescribed fluid(AGIP Fl Brake Fluid Super HD orIP Auto Fluid FR).(4) Top up the coolant with theprescribed liquid.

SummerPotable water

WinterAntifreeze (See Unit 07 -General Directives)

(5) Adjust the accelerator cable (SeeUnit 04 Accelerator Wire Adjust-merit).(6) With the engine at running heat,check its idling. For any tuning uprequired, see Unit 00 EngineMaintenance - Ignition and FeedSystem.

SEPARATION AND ASSEMBLY OF THE UNITS

SEPARATION ASSEMBLY

With the drive unit on the rotatorystand fitted with suitable supportingequipment, separate the engine unitfrom the gearbox unit for the pur-pose of replacement or overhaul ofthe two units and of the clutch, asfollows:1. Unscrew and take off the nutsand washers @ from the startermotor 0 securing screws 0and remove the starter motor fromthe engine unit.

2 . Remove the lower cover @protecting the engine flywheel afterdisassembling the screws and wash-ers 20 securing the lower cover tothe engine rear cover and to thegearbox.3. Unscrew and remove the remain-ing nuts and washers @ and com-plete the separation of the two units.

Withdraw the thrust beating from itssupport on the gearbox so as not to

1. Lubricate the direct drive shaftworking seat with the prescribedgrease (Grease Molykote paste G).2. Perform assembly operations inthe reverse order to the separation,tightening connecting nuts and boltsto the prescribed torque.

0: Tightening torqueNuts and bolts connecting thetwo units

39 + 48 N-m(4 + 4.9 kg-m28.92 + 35.43 ft.lb)

1 Nut and washer 3 Starter motor 1 Lower cover 3 Nut and washer2 Screw 2 Screw and washer

0 1 - Q May 1983


ENGINE DISASSEMBLY@xl

M a y 1 9 8 3


(6.7 + 7.448.4 + 53.5)

5.8 f 7.2)

1 Main bearings2 Woodroff key3 Thrust half-ring4 Oil pump gear5 Bush6 Seal ring7 Rear cover8 Oil plug9 Flywheel

10 Washer11 Lock ring12 Fin

13 Compression rings14 Oil scraper ring15 Oil pump16 Oil sump17 Engine oil drain plug18 Main bearing caps19 Piston20 Connecting rod21 Connecting rod bearings22 Connecting rod cap23 Crankshaft

@ N.m(kwmfr-lb)

M a y 1 9 8 3 01-12


PRELIMINARIESI. R e m o v e d r i v e u n i t f r o m c a raccording to procedures: Drive UnitRemoval and Installation.

2. Remove gearbox unit and clutchu n i t f r o m engine according to

procedures: Separation and As-sembly of the units.

ENGINE UNIT1. Sequentially remove followingparts:- Oil f i l ter @ u s i n g p r o p e r

spanner- Dipstick 0.- Pressure switch @ for mini-

mum oil pressure check-- Thermal contact @ for water

temperature check from rightcylinder head.

1 Oil filter 3 Dipstick2 Pressure switch 4 Thermal contact

2. Remove sparking plugs usingproper box spanner.

3. Remove distributor assembly.(1) Disconnect vacuum advancepipe 0 from carburettor.(2) Loosen distributor securingnut 0 and withdraw distributorfrom rear cover.

1 Vacuum advance pipe2 Distributor securing nut

4. Remove alternator.(1) Loosen securing bolts @ fixingalternator @ and remove drivingbelt.(2) Complete bolts 0 removal andtake out alternator @ _(3) Unscrews screws @ and re-move bracket @.

1 Bolts 3 Screws2 Alternator 4 Bracket

5. Remove pipings.(1) Loosen screws of clamps andremove fuel supply pipe 0.(2) Loosen screws @ of watersystem coupling @ clamp @ andremove coupling.

1 Fuel pipe2 Clamp

3 Coupling

6. Unscrew and remove screws @fix ing un ion 0 to block, thenremove the union.

1 Pipe union 2 Screws

7. Remove carburettor(1) Unscrew the four nuts withsecuring washers carburettor to in-take manifold.(2) Remove the accelerator cablereturn spring securing bracket, carbu-rettor, relevant gaskets and spacer.

8. Remove thermostat(1) Unscrew screws 0, removecover @ and thermostat.(2) Unscrew nuts 2 and remove

8thermostat housing 1 from intakemanifold @.

1 Thermostathousing

2 Nuts

3 Screws4 Intake manifold5 Cover

01-13 May 7983


9. Remove intake manifold(1) Unscrew nuts 0, remove en-gine lifting bracket @ and mani-fold 0.(2) Remove water temperaturetransmitter from intake manifold.

(2) Unscrew right belt stretcher @securing nut and press on jockeypulley @ to overcome belts tensionload; lock nut by fixing belt stretcherin the “loose belt” position.

1 Intake manifold 3 Nuts2 Bracket

10. Remove fuel pump assembly(1) Unscrew nuts with washers se-curing fuel pump to block rear cov-er 4 .0(2) Remove pump 0, spacer 28and pump control push rod 1 .

1 Push rod2 Spacer

3 Pump4 Cover

11. Remove camshaft drivingtoothed belts.(I) Loosen securing screws andremove two camshaft driving frontbelts guards.

1 Jockey pulley 2 Belt stretcher

(3) Withdraw belt from pulley oncamshaft and on driving shaft,respectively.(4) Repeat procedure for left headcamshaft driving belt.

12. Unscrew screws securing pulleysto camshafts preventing their rota-tion by toothed spanner A.5.0195,then remove pulleys.

13. Unscrew securing nut and re-move right belt stretcher @ andspring @ _

1 Belt stretcher 2 Spring1 Belt stretcher 2 Spring

14. Remove camshaft driving beltsrear covers.14. Remove camshaft driving beltsrear covers.15. Remove water pump assembly.15. Remove water pump assembly.(1) Unscrew screws 1 with wash- . .(I) Unscrew screws 1 with wash- . .

88ers securing pulley 2 to waterers securing pulley 2 to waterpump hub and* remove pump drivingpump hub and* remove pump drivingpulley.pulley.

1 Screws 2 Pulley

(2) Unscrew screws @ securingwater pump @ to block andremove pump with gasket.16. Unscrew nut @ and removeright jockey pulley.

1 Nut2 screws

3 Water pump

May 1983 01-14


17. Lock flywheel by tool A.2.0378.18. Unscrew screws 0 and @,remove guard @and engine frontsupport 40.

1 Screw 3 Screw2 Guard 4 Front support

19. Remove pulleys from crank-shaft.(1) Unscrew nut 0.(2) Sequentially remove washer @and spacer 0, water pump a.ndalternator driving pulley @, righthead camshaft drive toothed pul-

ley 0, spacer @, left head cam-shaft drive toothed pulley @ andpilot belt washer @.

I N u t2 Washer3 Spacer4 Pulley

5 Toothed pulley6 Spacer7 Toothed pulley8 Washer

20. Remove flywheel locking tool,previously fitted.21. Remove cylinder heads.(1) Unscrew screws @ fixing COV-ers 2 to camshaft supports; remove0covers with relevant gaskets.

1 Screws 2 Cover

(2) Suck oil from camshaft supportstanks with a suitable syringe.(3) Unscrew screws @ and @securing cylinder heads to block;remove heads with relevant gaskets.

1 Screws 2 Screws

22. Remove oil sump.(1) Unscrew screws with wash-ers 10 securing oil sump to block.(2) Remove oil sump and relevantseal gasket.(3) If required remove sealant markson sump and block.

1 Screws 2 Oil sump

23. Remove oil sump assembly.(1) Unscrew screws with wash-ers 10 securing oi l pump @ toblock rear cover.

1 Screws 2 Oil pump

01-15

(2) Withdraw upward pump fromblock.

24. Remove block front cover.(I) Unscrew screws @ and nutswith washers @ securing cover @and remove cover with relevantgasket.(2) Remove front oi l retainingring @ from cover by lever with ascrewdriver.Replace ring at assembly.

1 Screws2 Nuts

3 Block front cover4 Oil retaining ring

25. Remove pistons and connectingrods.(1) Fit to flywheel a tool whichallows crankshaft rotation.

(2) Turn crankshaft to permit accessto screws securing connecting rodcaps.(3) Unscrew and remove screws @and connecting rod caps 0.

May 1983


CYLINDER HEADS1. Secure head to support standA.2.0195 connected to forkA.2.0226 previously clamped in avice,2. Unscrew screws 2 securing

8c a m s h a f t r e a r c o v e r 3 t o sup-port 0; remove cover with sealgasket.3. Loosen and remove screws 40with washers fixing camshaft supportto cylinder head; remove supportwith relevant gasket.

A.2.0:7$$7=

1 Support2 Screws

3 Cover4 Screws

1 Camshaft 2 cups

5. Withdraw front oil retaining ringfrom its seat on camshaft supportusing a screwdriver.

6. F i t too ls A .3 .0321, A.3.0324a n d A.3.010316, used for valvesremoval, to head.7. If not already done, insert valvesreta in ing y o k e 0 into cylinderhead support tool A.2.0195.

4. Remove cups @ from housingon support, then camshaft @ with-drawing from rear side. 1 Yoke

8. Acting on lever A.3.0324 com-press springs and withdraw valvestem totters using a screwdriver.9. Sequentially remove upper caps,outer and inner springs, boots fromintake valves, washers and lowercups.10. Repeat removal procedure foreach valve.

11. Withdraw yoke from head sup-port tool and take out valves fromhead lower side.

CRANKSHAFT

1 . Clamp cranksahft in vice.2. Secure puller A.3.0402 to shaftand withdraw rear guide bushingfrom crankshaft.

n yA.3.0402

3. Withdraw oil pump and distribu-tor control gear by using proper plateand press.

0147 M a y 1 9 8 3

ENGINE MAIN MECHAN1CA.L UNIT

grinding, in order to ensure exactguide/seat perpendicularity as well

as proper valve working position.

VALVE SEATS

1. Check valve seats for any scores,cracks or burrs and make sure theyare properly fitted in their respectiverecess on the cylinder head.2. If necessary, mount the head ontool A.2.0226 and regrind the valveseats using the proper tool.This operation may be performed aslong as there is sufficient grindingallowance that will permit eliminat-ing the existing flaws while keepingthe specified profile; contrarywise,valve seats will have to be replaced.For relevant procedure see para-graph: “Valve Seat Replacement”.

(1) Regrind valve contact face till allevidence of wear has been removedand following taper is obtained :

p = 90” t 90” 30’

o f d i m e n s i o n “ a ” o n t h e “ 0 ”reference diameter.

0 Reference diameter:Intake = 37.3 mm (1.4685 in)

Exhaust = 31.9 mm (1.2559 in)“a” dimension at max. regrinding

limit:2.9 mm (0.1142 in)

(2) Machine the valve seat upperface still the 6 reference diameterposition obtained through the pre-vious operation is reached, attainingthe specified CL taper.

Taper of valve seat upper facea=120°

(3) Machine the seat inner face tilldimension “b” of the valve contactface is restored, attaining the speci-fied y taper.

Height of inner face:Intake: b = 1.07 + 1.37 mm

(0.0421 + 0.0539 in)Exhaust: b = 1.26 + 1.56 mm

(0.0496 + 0.0614 i n )

Taper of valve seat lower face:Intake: y = 50”

Exhaust: y = 30”

01 Valve seat 3 Profile after max.2 Original profile regrrdrng

(4) Having completed all machining,lap valve seats with proper tool.

For seat lapping use the properlapping compound (SIPALAREXONS Carbosilicium for valves -Std. no. 4100-31502).

Valve seat replacement

1. Remove worn valve seats usingthe proper tool.2. With a set of new valve seatsverify that dimensions shown in thefollowing table are complied with:

Valve seat

outerdiametermm (in)

Diameterof valveSeat recessmm (in)

Valve

i. = intake valvee. = exhaustvalve

Engine

12(N) 1 3 5 0 1 5 0 0

38.875 + 38.9

(1.5305 + 1.5315)

33.375 + 33.4

(1.3140~1.3150)

38.8 + 38.825

II .5276 + 1.5285)

33.3 + 33.325

(1.3110+1.3120)

3. Oven preheat the head at 140°C(284°F).4. Fit new valve seats using theproper tool.

Checking valve tightness

When replacing guides, after regrind-ing and lapping of seats, it is advis-able to test valve tightness - withvalves and sparkplugs duly mounted -according to the following pro-cedure:1. Mount the head on toolA.2.0226 and A.2.0195 previouslysecured in a vice.2. Fi l l the combustion chambercavity with gasoline.3. Let some low-pressure air intothe intake ducts and check forpresence of air bubbles in the gaso-line.

4. Follow the same procedure andcheck tightness of the exhaust valvesby letting low pressure air into theexhaust valve ducts.5. Should there be some leaks,ascertain that valves are properlyfitted in their seats and then repeatabove tightness tests; if the resultsare negative, valve seats will needrelappin,g as indicated in paragraph:Checks and Inspections - CylinderHeads and Valves - ‘Valve Seats.

01-19 M a y 1 9 8 3


SPRINGS

Visually check the springs for cracksand make sure they are not out-of-square if the evidenced flaws suggestit, check the technical data of theinner and outer springs and then witha dynamometer verify that theirlenght under load falls within thevalues shown in the following table:

Load N

(kg ; lb)

Length

under

load

mm (in)

425.32 + 452.76

(43.4 + 46.2 :

95.68 + 101.85)

194.53 + 208.25

(19.85+21.25;

43.76 + 46.85)I I

I I0.1i.

25.25 (0.9941)

23.25 (0.9153)

0. = outer spring

i. = inner spring

CUPSCheck that the outer surface of thecups as well as the upper surface onwhich cams work, show no scores, noevidence of pitting or Abnormal wear.Further verify that- calking of- the

cup’s nut is intact and that the cuphas retained its original punchingp o s i t i o n .

CAUTION:Do not remove the valve clearanceadjusting screw from the cup.

VALVESCheck and make sure that valves donot show any scores, burns orevidence of sticking with theircorresponding cylinder head seats(forming a step); if they do, replacethem.

CAMSHAFT SUPPORT1. Visually check the seats ofcamshaft cups and journals for scoresand for any evidence of pitting orabnormal wear.(1) Reset reamer to testing di-mension.

(2) Measure the diameter of cam-shaft bearings.

Diameter of camshaft bearingsFront = 35.015 + 35.040 mm

(1.3785 + 1.3795 in)Centre = 46.500 + 46.525 mm

(I.8307 + 1.6317 in)Rear = 47.000 + 47.025 mm

(1.8504 + 1.8514 in)

(3) Following the same procedure,measure the diameter of the four cupseats and determine the relevantfitting play.

Diameter of cup seats36.00 + 36.025 m m(1.4173 + 1.4183 in)

Max. cup-to-seat play0.1 mm (0.0039 in)

CAMSHAFT1. Carefully examine working sur-faces of cams and of camshaftjournals making sure that thereare no scores, no evidence of seizure,

S overheating or abnormal wear.2. With a micrometer measure thediameter of camshaft journals.

May 1983 0 l-20


MAINAND CONNECTINGROD BEARINGSThoroughly clean the main andconnecting rod bearings and visuallycheck them for scores as well as forany evidence of seizure.In case of excess wear, replace allbearings. When fitting connecting rodbearings to the crankshaft, be sure touse matching parts, i.e. belonging tothe same size class; for this purposethey are identified by same colourdots on the side of the half-bearingand on the relevant crank pin of theshaft. Applicable dimensions andtolerances are shown in: Service Dataand Specifications “Connecting rodbearings” and “Main bearings”charts.

PISTONS ANDCONNECTING RODS1. Visually check pistons and con-necting rods for cracks, scores andevidence of excess wear.2. Measure the play between therings and their seats in the piston.For relevant dimensions and toler-ances see: Service Data and Speci-fications - “Pistons” and “PistonRings” charts.

3. Check piston diameter with a

micrometer. For relevant dimensionsand tolerances see: Service Data andSpecifications - “Piston” chart.

4 . I n case the connec t ing rodpiston assembly has been disassem-bled, check the piston pin seatson the connecting rod small end aswell as on the piston pin bosses forexcess wear.5. Should parts not be replaced andtherefore used again, remember thatworking surfaces - especially that ofthe piston pin seat on the piston -must be totally free of any scores,even the slightest one.

The piston pin must always bereplaced.

FLYWHEEL1. Verify that teeth of gear are notin any way chipped or- show anyevidence of pitting; contrarywise,replace the flywheel.2. Check the clutch driven platecontact surface on the flywheel forany scores, chips or evidence ofoverheating. Before doing so, how-ever, make sure that the contactsurface has not been previouslyground and that the amount ofmaterial. available for removal isgoing to be sufficient for eliminationof the existing flaws.For this purpose, verify that dimen-sion “b” shown in the chart is greaterthan the min. specified limit and thatthe removable stock wi l l a l lowsurfacing as required.

Min. limit of dimension “b”20.95 mm (0.8248 in)

Surface grinding must be performedin accordance with the roughness,flatness and. parallelism tolerancesshown in the above chart.

CYLINDER BLOCK1. Visually check cylinder blockfor cracks or excess wear of slidingsurfaces.2. Check cylinder walls surfaces forroughness.

Max. allowed roughness of cylinder‘wall surface

0.5 + 1 pm (20,10*” + 39.10m6 in)

3. See to which size class thecylinder walls refer to and thenproceed to check them by measuringthem. CylintJer walls are selectedaccording to their inner diameter andare divided into five different classes:A, B, C, D, and E. The class iden-tifying letters are stamped on thecylinder block upper surface next toeach wall location.

May 1983 01-22


Dimensions relevant to each class areshown in: Service Data and Speci-fications “Cylinder block” chart.

(1) Reset the reamer by means of amicrometer.

(2) Measure the diameter at therecommeded depth and then deter-mine taper and out-of-round ofcylinders walls.

Cylinder wall max. taper:A - B = 0.02 mm (0.00079 in)

Cylinder wall max. out-of-round:X - Y = 0.02 mm (0.00079 in)

(3) Compare actual values D withnominal ones C of each size class andthen determine the cylinders wallsmax. wear.

Cylinder wall max. wear:C - D = 0.04 mm (0.00157 in)

4. If the dimensions thus estab-lished are not within tolerance,cylinders walls must be reboredkeeping in mind that three differentoversize pistons are available as spareparts; this means that the diameter ofwalls will have to be in accordancewith the tolerances shown in: ServiceData and Specifications “Cylinderblock” chart.(1) Mount main bearing caps on thecylinder block and tighten screws asspecified in: “Engine assembly -Engine unit”.Then proceed to bore cylinder wallsso as to stay within the tolerancesshown in: Service Data and Speci-fications - “Cylinder block” chart.

Lapping must be performed so thattool marks cross each other at anangle of 9CP + 1203

(2) If wear does not exceed thespecified limit but pistons and springrings need replacing because of someflaws or damage, cylinders wallswill need at least to be lapped; in thiscase measure the diameter of thewails in order to identify the newsize class to which they belongand that will have to be kept in mindduring piston fit operations, regar-dless of the letter stamped on thecylinder block. Should lapping causea size class change, cylinder wall willno longer be identifiable through theletter stamped on the cylinder blockwhich, therefore, must be erased inorder to avoid mistakes during futureoperations_

PISTON - CYLINDERWALL FIT

1. When original parts are involved,they will be selected by matchingeach cylinder wall identificationletter that is stamped on cylinderblock upper surface to the pistonthat has the same letter stamped onits head or a coloured dot painted onthe inside of its crown, according tothe following schedule:

Engine

1200

1350

1500

Wall 8identifying

letter

Pistonidentifyingletter and

colour

A - b lue

B - p ink

C - green

D - yellow

E - w h i t e

If the letter stamped on the cylinderblock has been previously erased,matching will take place according tothe identification letter stamped onthe piston that needs replacing; inthis instance, it is advisable to make adouble check and measure thecylinder wall diameter.

2. When oversize walls are used,they will be matched to the relevantcompletely assembled pistons,namely with compression rings andoil scraper ring, which are available asspare parts according to the follow-ing oversize scale: G.2 - 0.4 - 0.6 mm(0.0078 - 0.0157 - 0.0236 in).

0 1 - 2 3 May 1983


Cylinder wall to piston playStandard 0.03 + 0.05 mm

(0.0012+ 0.0020 in)Oversize 0.03 + 0.06 mm

(0.0012 + 0.0024 in)

2. Apply engine oil to piston pin,to the connecting rod small end, andto the piston pin supports.3. Fit the connecting rod‘small endbetween the piston pin supportsensuring that holes are perfectlyaligned in order to allow properpiston pin fit.4. Fit the piston pin @ into thepiston @ and connecting rod 0,and then lock it with two springrings 0.a. PoSition pistons so that the

arrow stamped on their cr0w.npoints in the direction of enginerotation, namely: upward forthe right head pistons and”downward for the left headpistons.

b. Fit connecting rods in thepistons so that the position ofmatching identification numbersand arrows corresponds to thatshown in the below Figure.

Connecting rodPiston pinSpring ringLeft head piston (No. 2 and 4)Right head piston (No. 1 and 3)

With the help of a suitablespecial pliers, fit piston rings in thepiston seat making sure that themarking stamped on the flat surfaceof the rings faces upwards.

MARKING

-

CRANKSHAFT1. Fit rear bushing and oil pumpdrive gear on the crankshaft.(1) Fit the crankshaft rear bush-ing 0 by means of tool A.3.0450.(2) Heat the oil pump and distribu-tor drive gear to 150°C (302°F).(3) Shrink the gear @ on thecrankshaft positioning it so that theaxis of the flywheel centering doweland the front surface of one ofthe gear’s form the specified angle.

Positioning of crankshaft rear gear 2. Fit main bearing caps on cylin-a = 22°+2~o der block,

1 Bush 2 Pump drive gear

a

ENGINE UNIT1. Fit crankshaft on cylinder block.(1) Fit main bearings on relevantmain bearings supports and lubricate

them with oil. Select bearings accord-ing to the diameter of crankshaftjournals.

(2) Fit thrust half-rings on therelevant seat obtained in the thirdmain bearings support.Make sure that these half-rings arefitted with oil channels facing thecrankshaft shoulders.

(3) Place crankshaft on main bearingsupports.

(1) Fit main bearings to mainbearing caps and lubricate them withoil.

(2) Fit main bearing caps: front @(see markings), centre @, andrear 0, fitted with relevant bear-ings, on cylinder block supports.Coat supports with engine oil andtighten oiled screws without fullylocking them.(3) Tighten screws securing the mainbearing caps to the relevant cylinderblock supports in two or three

01-25 May 1983


successive steps, according to speci-fied torque and sequence (from Ato F).

0: Tightening torqueCaps to cylinder supports se-curing screws:

6 6 + 73 N - m(6.7 + 7.4 k g - m

46.4 + 53.5 ft-lb)

(4) Subsequentially tighten screwssecuring the main bearing caps to thecyl inder block in two or threesuccessive steps, according to speci-fied torque and sequence (from Ato F).

0: Tightening torqueCaps to cylinder block sup-ports securing screws

40+49 N-m(4.1 + 5 kgam29.6 + 36.2 ft.lb)

Having completed tightening of allscrews, apply engine oil ‘to t h esupports and rotate the crankshaftby hand.

3 . Check c ranksha f t end p lay .(1) Attach a centesimal dial gaugewith magnetic base to the cylinder

block having the gauge’s indicatingfinger touch the crankshaft parallel-wise to the shaft’s axis.(2) Using a screwdriver, move thecrankshaft along its axis and checkthe gauge’s reading to ensure that“g” end play is within specifiedvalues.

Crankshaft end play0.35 mm (0.0137 in)

(3) If the shaft has not been pre-viously reground and therefore thevalue established as per step above isgreater than the specified value, it ispossible to regrind the shoulders ofthe rear journal till its “c” iength issuch that it will allow fitting of theoversize thrust half-rings available asspare parts.

Rear journal “c” length2 8 . 7 6 4 + 2 8 . 8 0 4 m m .(1.1324 + 1.1340 in)

4. Fit seal ring in the main oilgallery of the cylinder block rearcover.

5. Fi t rear cover, with relevantgasket, on the cyl inder block.Tighten all cover retaining screwsaccording to specified torque.

@ : Tightening torqueRear cover retaining screws

19+24N-m(1.9 + 2.4 kg -m13.7 + 17.4 ft.lb)

6. Fit crankshaft oil seal ring usingtool A-3.0337.a. Apply engine oil to the ring’s

sealing lip, its external surface aswell as to i ts working seat.

M a y 1 9 8 3 01-26


10. Fit front cover, with propergasket, to cylinder block and tightenscrews and nuts according to speci-fied torque.

0: Tightening torque 1 Nut 5 Toothed pulleyFront cover to cylinder block 2 Washer 6 Spacer

retaining screws: 3 Spacer 7 Toothed pulley

19 + 24 N-m 4 Pulley 8 Washer

(1.9 + 2.4 kg-m13.7 + 17.4 ft.lb)

11. Fit the engine front support @and the pulley’s lower guard @ tothe cover.

(2) After having suitably lockedflywheel rotation, tighten pulleyretaining nut according to specifiedtorque.

1 Pulley’s guard 2 Front support

12. Fit crankshaft oil seal front ringusing tool A.3.8338. Before doing so,apply a coating of engine oil to thering’s sealing lip and work surface.

13. Fit crankshaft front pulleys.(1) Key the below mentioned partsaccording to the indicated sequence:the belt guide washer @, the lefthead camshaft drive toothed pul-ley 0, the spacer @, the righthead camshaft drive toothed pul-ley 0, the water pump and alterna-tor drive pulley @, the spacer 0,and the washer 0.

Tightening torquePulleys to cylinder block re-taining nut:

118 + 144 N-m(12 + 14.7 kg-m

86.8 + 106.3 ft.lb)

14. Fit the water pump.(1) Fit new gasket @ on pump.(2) Fit pump 0, without pulley,on cylinder block.(3) Fit screws @ with washers andtighten them to specified torquevalue.

0: Tightening torqueScrews securing water pump

1 9 +24 Nam(I .9 + 2.4 kg-m13.7 + 17.4 ft.lb)

1 Gasket2 Pump

3 Screw

15. Fit cylinder heads.(I) Turn crankshaft till the piston inNo. 1 cylinder is set at Top DeadCenter in the compression stroke;this correct positioning is furtherensured by the ‘7” notch 0 on theflywheel matching with the refer-ence 20 o n The r e a r c o v e r 0.

1 Notch2 Reference

3 Cylinder blockrear cover

(2) Align the references shown onthe camshaft rear journal and on thesupport rear side panel.

May 1983 01-28


(3) Fit cylinder heads, with relevantgaskets, on the cyl inder block.

By extremely careful during thisassembly operation in order to avoidthat opened valves, projecting abovethe head surface, might strike theFylinder block surface and thus bedamaged.

(4) Position and then tighten the sixcylinder heads retaining screws @in two or three successive steps,according to the specified torque andsequence (from A to F).(5) Tighten screws @ securing thecamshaft support to the cylinderheads.

0: Tightening torqueHead to cylinder block re-taining screws:

‘81 + 87 Narn(8.3 + 8.9 kg-m60 + 64.4 ftdlb)

1 Head retaining screw2 Camshaft support retaining screw

In case of in-car tightening, useextension spanner A.5.0198 in accor-dance with the following tighteningtorques:- for torque spanner with 300 mm

(11.811 in) lever arm:57t62 N-m(5.8 + 6.3 kg-m41.9 + 45.6 Wb)

for torque spanner with 400 mm(15.748 in) lever arm62+67 N.m(6.3 + 6.8 k&m45.6 + 49.2 ft.lb)

16. Fit camshaft belts rear covers.17. Fit belt tensioner assemblies onthe cylinder block pins according tothe following sequence: sup-ports 50, spring @, washers @and washers 0. Lock belt jockeypulley assemblies with relevantnuts 0 after having pre-loaded beltjockey pulley in order to allow forbelt passage.

1 Nut2 Washer3 Washer

4 Spring5 Support

18. Fit camshaft driving belts.(1) Fit camshaft drive pulleys andtighten the retaining screw to speci-fied torque being careful, at the sametime, to stop pulley rotation bymeans of toothed spanner A.5.0195.

0: Tightening torquec Camshaft pulley retaining

screw:63 + 70 Nam(6.4 + 7.1 kg-m

46.3 + 51.3 f&lb)

(2) Veri fy that the crankshaft’sangular position corresponds to theTop Dead Center of cylinder No.1,as previously mentioned for headsassembly.(3) Rotate camshaft by means oftoothed spanner A.5.0195 till t h ereference stamped on the support’srear side panel is aligned with the onestamped on the shaft’s rear journal.(4) Key camshaft drive belts on thecrankshaft inner pulleys and on thepulleys of both camshafts. Beltkeying must take place with thebelt pulling section, opposite thejockey pulleys, fully stretched.(5) Check that “5” clearance be-tween the camlhaft belt and theprofile of the engine front supportis not below the specified min. value;if it is, modify the profile of thesupport till it meets the specifiedvalue.

“S” min. clearance between camshaftbelt and engine from mounting

9 mm (0,3543 in)

Y-

(6) Completely loosen the beltjockey pulley lock nuts and thentighten them again.(7) Turn the crankshaft a few timesin its working direction so that thebelts may take up their final po-sition.(8) Act on the camshaft till cams aredisengaged; loosen the belt jockeypulley lock nut and then retighten itaccording to specified torque.

01-29 M a y 1983


0: Tightening torqueBelt jockey pulley lock nut(with cold engine)

37 f 46 N.m(3.8 4 4.7 kgm27.5 + 34 ftalb)

19. Fit oil pump.(1) Turn crankshaft till piston No. 1is at Top Dead Center in the com-pression stroke, as mentioned forheads reassembly.(2) Turn the pump drive shaft sothat the next rotation, which Willfollow mating of the pump drive gearwith that on the crankshaft, willposition the distributor couplingaccording to the specified p angle.Apply a coating of engine oil to thedrive shaft.

Distributor coupling positioningp = 22”

1 Distributor coupling

(3) Fit the oil sump pump on rearcover and tighten screws 0 accord-ing to specified torque.

a: Tightening torqueOil sump to rear cover re-taining screws

IQ+24 Nhrn(1.9 + 2.4 kg-m13.7 + 17.4 ft+lb)

(4) Tighten retaining screws @between pump body and support

according to specified torque.

May 1983

0: Tightening torquePump body to support re-taining screws:

8-I-10 N-m(0.8 f 1 kgmm5.8 + 7.2 ftblb)

1 Pump to rear cover retaining screws2 Pump body to support retaining screw

(5) Reassemble oil sump with prop-er gasket @ and tighten all re-taining screws. Before doing SO,

evenly apply the specified cement tothe gasket (Cement Std. No.3522-00040 DOW CORNINGSilastik 732 RTV).Before applying the sealant, removeall traces of old sealant and of oilfrom all surfaces.

1 Oil sump 2 Gasket

20. Fit distributor on rear cover.(I) Turn the distributor’s shaft sothat the rotor arm @ is positioned

on the reference mark stamped onthe distributor’s body.The rotor arm 0 should pointtoward the No. 1 cylinder. Thisposition corresponds to ignition inNo. 1 cylinder and to correct cou-pling of the oil pump and distributorshafts.(2) If necessary, correct misalign-ment of the rotor arm with thereference mark stamped on thedistributor’s body by rotating thelatter and then tightening the locknut @ securing the distributor tothe cylinder block rear cover.

01-30

12

Rotor arm 3 Distributor shaftDistributor lock -couplingnut

21. Adjust clearance of intake andexhaust valves while engine is cold.The relevant procedure is describedin Group 00 - Engine Maintenance.

Valve clearance (cold engine):Intake

0.35 4 0.40 mm(0.0138 + 0.0157 in)

Exhaust0.45 + 0.50 mm

(0.0177 + 0.0197 in)

22. Fill chambers of camshaft sup-ports with engine oil.

Oil quantity required for fill-up0.250 kg (0.5511 lb)

in each chamber

23. Fit support covers @ withrelevant gaskets 0.

1 Cover 2 Gaskets


34. Assemble carburetor with spacerand the interposed gaskets on intakemanifold studs.

0: Tightening torqueCarburetor nuts

19+24 N.m(1.9 + 2.4 kg-m13.7 + 17.4 ft.lb)

35. Perform following connections.- Fuel supply pipe @ from fuel

pump to carburettor.- Vacuum advance pipe @ from

carburettor and advance con-troller located on distributor.

1 Advance pipe 2 Fuel supply pipe

36. Fit oil filter by manually tigh-tening it and insert dipstick.37. By means of adapter A.5.0115f i t spark plugs t ightening themaccording to specified torque.

@I: Tightening torqueSpark plugs:

2 5 G34 N-m(2.5 + 3.5 kg-m18.1 + 25.3 ft.lb)

38. Secure cap to distributor bodywith relevant springs, then connectignition cables between spark plugsand distributor cap, securing them torelevant clamps.Cables connection must take placeaccording to the ignition sequence ofcylinders.

39. Fit alternator and control belt.(1) Secure bracket @ to enginefront-. cover and tightening therelevant screws 30(2) Position alternator on enginesupport and tighten b o l t s 0without fully locking them.

(3) Key alternator and water pumpdrive belt on relevant pulleys.(4) Adjust belt tension according tospecified value and then lockbolts 0. For adjusting procedurerefer to Group 00 - Engine Main-

(

tenance.

L o a d : 7 8 . 4 0 N (8 k g )Arrow: 15 mm (0.5905 in)

1 Bolts2 Alternator

3 screws4 Bracket

40. Fill the engine with specifiedengine oil (AGIP Sint 2000 lOW50o r IP S u p e r M o t o r O i l lOW50).

Oil quantity required for fill-up3.6 kg (7.93 lb)

May 1983 01-32


ENGINE LUBRICATION SYSTEM

DESCRIPT.ION

1 Bypass valve 4 Oil sump2 Oil filter 5 Gear pump

-

? I. I-4Oil pump -1 Oil filter cartridge

FM

iI I Oi l s t rainer I

--, .I& ,I Block oil galleries I

N O T E

Oil passagi

- Return

)- BYpass passage

II I Connecting rodhalf-bearings

01-33

cartridge 6 Pressure relief3 Camshaft bear- valve

ing housing

The engine is pressure lubricated bymeans of a gear pump. The pump ismounted on the rear cover of theengine and is actuated by a shaftwhich is driven by a gear fitted to thecrankshaft.The maximum oil pressure is ad-justed by means of a proper valvefitted on the pump.Oil is completely filtered in thesuction head by a strainer then by afilter with cartridge placed on the oilpassage and provided with a bypasssafety valve, should the cartridgebecome clogged.The oil filter, on the engine rearcover, has unions for the recircula-tion of the oil vapours at minimumand high running.The insuff ic ient oi l pressure isindicated on the combination meterby means of a warning light con-nected to a manual contact insertedon the main oil gallery of the block.

OIL PUMPOIL PRESSURE CHECK

1. Start engine and heat oil to 90°C(194°F).2. Remove oil pressure checkingmanual contact.3. Fit gauge to manual. contacthole.4. Start engine and record oilpressure as shown on gauge.

May 1983


Engine Oil pressmeEngine speed kPa (bar,

r.p.m. kg/cm2 , psi)

117.7 f274.6(1.18 f2.75,

1200 800 1.2+2.8,17.07 c-9.82)

1350

411 .E + 568.7

1500 (4.12+5.69,

4.2 +5.8 ,

I 1 59.74 G82.49)

5. Remove gauge and refit manualcontact.

If the oil pressure value is not withinthe limits shown in table, the oilpump is to be checked.

REMOVALRemove fuel pump from cover (see:Engine Disassembly - Engine Unit).1. Drain engine oil and remove oilsump. If required, tap with a woodenmallet on attachment side of sump toblock.2. Unscrew screws @ and with-draw pump from its seat.

DISASSEMBLY ANDASSEMBLY1. Unscrew screws @ securingpump body to pump support.2. Withdraw driven gear avalve @ , spring @I and w a s h -er @I.3. Reassemble pump carrying outthe above procedure but in thereverse sequence. Slightly tightenscrews @ without locking fullyhome.4. Manually rotate driving. shaftchecking for ,crawling and regular

@-1 Upper support 7 Screw2 Driving gear 8 Strainer3 Driven gear 9 Pump body4 Washer 10 Washer5 Washer 11 Spring6 Screw 12 Valve

CHECKS AND INSPECTIONS1. Check gears for wear, ensurethat--teeth are free from cutting orchipping or that wear is regular andnot excessive on all the face length.2. Check driven gear pin forindications of seituring and cutting.3. Carry out same check as abovefor the pressure regulator valve,additionally ensuring that it slides in

its seat on pump body withoutcrawling. If the spring of the pressureregulator valve is supposed to haveyielded, also considering the troubleshown, replace valve.4. Check that driving gear iscorredtly positioned on driving shaftof oil pump and that crankshaftdriving gear has the pin regularlyfitted. .5. Finally check working surfacesof shaft and rear cover, of drivingcam of fuel push rod, and the at-tachment point to the distributor forcutting and signs of seizure.

INSTALLATION1. Lubricate driving shaft with en-gine oil as per step 4.2. Refit oil pump carrying outprocedure detailed in: Engine As-

sembly Engine Unit.3. Tighten screws @ securingpump to engine rear cover thenscrews @ fastening pump bodyto pump support to the specifiedtorque value.

0: Tightening torqueScrews securing pump to en-gine rear cover

19+24 N-m(1.9 + 2.4 kg-m13.7 + 17.4 ft.lb)

Screws fastening pump body topump support

Se-10 N-m(0.8 + 1 kg-m5.8 + 7.2 ft.lb)

1 Screw fastening pump to pump support2 Screw securing pump

4. Fill engine with th.e specified en-gine oil (AGIP Sint 2000 lOW50 orIP Super Motor Oil lOW50).

OIL FILTERREPLACEMENT

1. Drain hot oil of engine fromsump.2. Remove filter using proper tool.

3. Fit a new filter of the prescribedtype. Manually screw in the filter.4. Fill engine with prescribed en-gine oil. After fitting new filter, letengine run for a few minutes andcheck for oil leakages.

M a y 1 9 8 3 01-34

-ENGINE MAIN MECHANICAL UNIT

INSPECTION AND ADJUSTMENT

CAMSHAFT SYSTEM

RIGHT SUPPORT L E F T S U P P O R T

U n i t : m m (in)

t 306.00 1200 I 305.02 1350 I 305.04 1500

Camshaf t 5 3 1 . 3 6 4 5 3 1 . 3 6 4 5 3 1 . 3 6 4

I I

Tappet clearance

Value of the angle of t iming

marks on camshaft supports

I make

Exhaust

R i g h t s u p p o r t

Left support

0 . 3 5 f 0 . 4 0 ( 0 . 0 1 3 8 + 0 . 0 1 5 7 )

0.45+0.50 ( 0 . 0 1 7 7 + 0 . 0 1 9 7 1

2 3 ”

2 3 ”

All values are with cold engine

CHECKING VALVE OPENING AND CLOSING ANGLES

U n i t : m m ( i n )

Engine

1 2 0 0 1 3 5 0 1 5 0 0

3 0 5 . 0 0 3 0 5 . 0 2 3 0 5 . 0 4

Valve clearance for checking m m (in) 0 . 7 ( 0 . 0 2 7 6 )

”E O p e n i n g B T D C a 1zL

C l o s i n g A B D C b 48O

Valve clearance far checking m m (in) 0 . 7 (0.0276)5r” O p e n i n g B T D C c 456lz

C l o s i n g ABDC d P

(I 1 Crankshaft rotat ion ACW seen from f lywheel side.

M a y 1 9 8 3 01-36


CYLINDER BLOCK

Unit: mm (in)

inspection data

C y l i n d e r b o r e “ a ”

Standard

Oversize

1200Engine

1358 1 5 0 0

Class A

Class B

Class C

Class D

Class E

8 0 . 0 0 t 8 0 . 0 1 ( 3 . 1 4 9 6 +3.1500) 8 4 . 0 0 t 8 4 . 0 1 ( 3 . 3 0 7 1 - 3 . 3 0 7 5 )

8 0 . 0 1 e80.02 (3.1500+3.1504) 8 4 . 0 1 + 8 4 . 0 2 ( 3 . 3 0 7 5 f 3 . 3 0 7 9 1

8 0 . 0 2 - 8 0 . 0 3 ( 3 . 1 5 0 4 + 3 . 1 5 0 8 ) 8 4 . 0 2 G - 8 4 . 0 3 ( 3 . 3 0 7 9 4 3 . 3 0 8 3 )

80.03+80.04 (3.1508-3.1512) 8 4 . 0 3 + 8 4 . 0 4 ( 3 . 3 0 8 3 f 3 . 3 0 8 7 )

80.04+80.05 (3.1512+3.15163 8 4 . 0 4 + 8 4 . 0 5 ( 3 . 3 0 8 7 f 3 . 3 0 9 1 )

1st 8 0 . 2 0 +-80.21 ( 3 . 1 5 7 5 +3.15791 8 4 . 2 0 + 84.21 ( 3 . 3 1 5 0 f 3 . 3 1 5 4 )

2 n d 80.40+80.41 (3.1654+3.1658) 8 4 . 4 0 + 8 4 . 4 1 ( 3 . 3 2 2 9 f 3 . 3 2 3 3 )

3 rd 80.60+80.61 (3.1733+3.1737) 8 4 . 6 0 + 8 4 . 6 1 ( 3 . 3 3 0 7 f 3 . 3 3 1 I)

Out-of-square between cyl inder bore centrel ine0 . 0 5 ( 0 . 0 0 1 9 7 )

and centrel ine of main bearings

Taper and out-of-round l imitS tandard

M a x

0 . 0 1 ( 0 . 0 0 0 4 1

0 . 0 2 ( 0 . 0 0 0 8 )

Cyl inder bore surface roughnessI

o.5.10-3+l~10-3 ( 0 . 0 1 9 7 ~ 1 o-3 + 0 .0394~10”)

Cyl inder bore gr inding angle 9 0 ” + 1200

Main bearing diameter “b”

F r o n t

R e a r6 3 . 6 6 3 G 6 3 . 6 7 3 ( 2 . 5 0 6 4 + 2 . 5 0 6 8 )

Cent ra l 6 3 . 6 7 3 - 6 3 . 6 8 3 ( 2 . 5 0 6 8 + 2 . 5 0 7 2 )

Width of rear main bearing support “c” 2 3 . 6 8 + 2 3 . 7 3 ( 0 . 9 3 2 3 + 0.9343)

01-37 IWay 7983


PISTONS, COMPRESSION RINGS AND PINS

Pistons

u

-a

m

Ia

Unit: mm (in)

Piston diameter

“ a ” (I)

Inspection data

Standard

Oversize

First compression ring groove height “c”

Class A (Blua)

Class B (Pink)

Class C (Green)

Class 0 (Yellow)

Class E (White)

Engir

1200 1350

79.96 +79.97 (3.1480 + 3.1484)

79.97 f79.98 (3.1484+3.1488)

79.98+79.99 (3.1488-3.1492)79.99 + 80.00 (3.1492 e-3.14961

80.00 G-80.01 (3.1496 +3.1500)

1st 80.15+80.17-(3.1X5+3.1563)

2nd 80.35-80.37 (3.1634+3.1642)3rd 80.55-80.57 (3.1713-3.1720)

Second compression ring groove height “d”

Oil scraper ring groove height “c”

Pin seat bore “b”

1.525+1.5450.0600+0.0608)

1.775 + 1.795

0.0699+0.0707~

4.015 G-4.0350.1581 +0.1589)

1.525 + 1.550

0.0600+0.0610)(2)

1.525e1.5450.0600+0.0608)

(3)

1.775+1.8000.0699 + 0.0709)

(2)

1.775 + 1.795

0.0699-0.0707)(3)

4.015+4.w0(0.1581 -0.1590)

(2)

4.015 e4.035(0.1581+ 0.1589:

(3)

1500

83.96 f 83.97 (3.3055 + 3.3059)

83.97 f 83.98 (3.3059 + 3.3063)

83.98 -83.99 (3.3063 + 3.3067)

83.99 + 84.00 (3.3067 + 3.3071)84.00-84.01 (3.3071 f3.3075)

84.15F84.17 (3.3130 t3.3138)84.35f84.37 (3.3209f3.3217)84.55G64.57 (3.3287 -3.3296)

1.525 + 1.545 (0.0600 + 0.0608)

1.775 + I.796 (0.0699 + 0.0707)

4.015 e-4.035 (0.1581 +0.1589)

21.002+21.006 (0.8269+0.8270)

(1) To be measured to right angle to the piston pin at 17 mm (0.6693 in) from piston skirt

(2) Borg0 Piston

(3) Mondial Piston

May 1983 m-38


CONNECTING ROD AND CONNECTING ROD BEARINGSConnecting rod

Unit: mm (in)

lnspecrion data

Small end bush bore diameter “a”

Big end bore diamater “b”

Engine

1200 I1350 I 1500

21.007 + 21.015 (0.8270 f 0.8274)

52.696 + 53.708 (2.0746 + 2.1145)

Connecting rod bearings Unit: mm (in)

Inspection data

a--e Standard

Connecting rod

bearing thickness

“a”

I 4th

Engine

12ctcl I 1350 I SO0

Blue 1.831 + 1.835

T

Blue 1.830 + 1.836

(0.0721 +0.0722) (0.0720 + 0.0722)

Red 1.827 + 1.831

(0.0719+0.0721)

Red 1.8?6 + 1.832

(0.0719 + 0.0721)

1.966 + 1.962 (0.0770 + 0.0772)

2.083 + 2.089 (0.0820 + 0.0822)

2.210+2.216 (0.0870+0.0872)

2 . 3 3 7 + 2 . 3 4 3 ( 0 . 0 9 2 0 + 0 . 0 9 2 2 )

M a y 1983 0 i-40


FLYWHEEL

Unit: mm (in)

Inspection data

Regriding dimensions (I)

ab

c

1200Engine1350 1500

24.0 + 24.2 (0.9449 + 0.9528)

G 0.2 (0.0079)

> 20.95 (0.8248)

Parallelism of the driven plate contact face compared

with flywheel-to-crankshaft support face (as read at

a 100 mm radius)

0.08 (0.0031)

Maximum out-of-flat of driven plate contact face 0.02 (0.0008,

Surface roughness of driven plate contact face 2.1 o-3 (0.0787~10”)

(1) The depot of regrinding, dimension “b”, must be the same both on clutch driven plate contact face and on the face of the

register for the clutch cover, so that dimension “a” kept constant. Dimension “c” must not be lower than the specified limit.

01-41 May 1983


Unit: mm (in)

Inspection dataEngine

1200I

1350I

1500

Max. misalignment between the centrelines of the two

pairs of crankpins and the journals centrelineI

0.25 (0.0098,

Max. out-of-square between thrust ring face and

main journals I0.03 (0.00121

Rear crankshaft bush diameter “b”I

16.065 + 16.080 (0.6325 + 0.6331)

Fitment of rear crankshaft gear “U”

(distributor/oil pump drive)22’ + 26O

(.I ) Re-cutting equally spaced on both shoulders

Thrust rings

Unit: mm (in)~ ~

EngineInspection data 1200 1350* I 1500

Thickness “a”Standard 2.310 + 2.362 (0.0909 + 0.0930)

Oversize 2.437 t 2.489 (0.0959 + 0.0980)

Main -bearings

Unit: mm (in)

Thickness “a”

EngineInspection data 1200 1350 I 1500

Standard 1.832 t 1.841 (0.0721 + 0.0724)

1st 1.959 f 1.968 (0.0771 + 0.0775)

Oversize 2nd 2.086 t2.095 (0.0821 + 0.0825)

3rd 2.213 f 2.222 (0.0871 + 0.0875)

4th 2.34OG2.349 (0.0921 + 0.0925)

0 l-43 May 7983


CAMSHAFT SUPPORT, CAMSHAFT AND TAPPET BUCKET

Camshaft support

Unit: mm (in)


1200 13501

1500

Front 35.015 + 35.040 (I 3786 + 1.3795)Bore of camshaft journal

bearing diameter “a”C e n t r a l 46.500+46.525 (1.8307+1.8317)

Rear 47.000 G-47.025 (1.8504+ 1.8514)

Seat tappet bucket diameter “b” 36.000 e36.025 (1.4173+ 1.4183)

Camshaft

Front Central Rear

Unit: mm (in)

I EnaineInspection data

t 1200 I 1350 I 1500

Cam heightIntake

Exhaust8 . 5 (0.3346)

Camshaft journal diameter

Front “a”

Central “b”

Rear “c”

34.940 + 34.956 (I .3756 + 1.3762)

46.440 e46.456 (1.8283- 1.8290)

46.940t46.956 (1.8480+ 1.8487)

Tappet bucket

Unit: mm (in)


1200 1350 1500

Diameter “a” 35.973 + 35.989 (1.4163 + 1.4169)

May 1 9 8 3 01-44


CYLINDER HEAD, VALVES AND SPRINGS

Cylinder head

Unit: mm (in)

Inspection data1200

EngineI 1350 I 1500

Valve guide seat diameter “d”

Valve guide 0.0. “a”

Diameter of valve guide bore “b”

Standard

Spare

13.OOOf13.018 (0.5118+00.5125)

13.050 f 13.068 (0.5138- 0.5145)

13.064f13.082 (0.5143+0.5150)

8.013f8.031 (0.3155+0.3162)

Valve guide protrusion “e”

Min. cylinder head thickness after resurfacing “c”

Max. error of parallelism between head surfaces

Max. out of flat

9.8 + 10 (0.3858 4 0.3937)

77.25 (3.04131 (1)

0.05 (0.00201

0.03 (0.0012)

Surface roughness 1.6.10-3 (0.0630.10”3). .

(1) Resurfacing of cylinder head with hemispherical combustion chamber must be done on both banks of the same engine

Valves

Unit: mm (in)

Valve stem diameter “a”Intake

Exhaust

Engine

1200 13501

1500

7.985t8.000 (0.3144-0.3150)

7.968+77.983 (0.3137 +0.3143)

Valve head diameter “b”Intake 38.00 + 38.20 (1.4961 + 1.5040)

Exhaust 33.00+ 33.20 (1.2992 + 1.3071)I ,

oi-45 May 1983


S p r i n g s

1200Engine

I 1350 I 15w

Length of valve spring with Outer spring 25.25 (0.9941)

valve open “a”mm (in)

Inner spring 23.25 (0.9154)

Spring rating at Outer spring 425.32 + 452.76 (43-4 + 46.2) (95.68 + 101.85)

length “a”N (kg) (lb)

Inner spring 194.53+208.25 (19.85 t21.25) (43.76f46.85)

VALVE SEAT RECUTTING

recutting

Unit: mm (in)

Engine

1350 1500

Reference diametere “6 R ”Intake

Exhaust

Cut limit of valve seat top surface “a”

Cut limit of valve seat mating

surface “b”

Intake

Exhaust

2.9 (0.1142)

1.07 f 1.37 (0.9421 + 0.0539)

1.26 f 1.56 (0.0496 + 0.6614)

Valve seat top surface limit angle “a’ I1200

-.Valve seat mating surface limit angle “p’

Valve seat inner face limit

angle “y’

Intake

Exhaust

90” + 9o” 30

500

300

M a y 1 9 8 3 01-46


FITMENT PLAYS OR INTERFERENCE FITS

Unit: mm (in)

Inspection data

Cylinder bore/piston play

Ring/groove end float

Pin/small end play

Pin/seat bore play

Main bearing to-

journal play

Connecting rod bsaring-

to-crankpin play

Crankshaft end float

End float of big end

bearing

Radial clearance between

camshaft and bearing

Standard

Oversize

-First compression

ring

Second

compression ring

Oil scraper

ring

Maximum for

each ring

Standard

Maximum

Front and rear

Central

Maximum (withbearing in seat)

Standard

Maximum (with

bearing in seat)

Standard

Max

Standard

Max

Front

Central

Rear

Camshaft end float

Engine1200 I 1 3 5 0 I 1500

0.03 4 0.05 (0.0012 + 0.0020)

0.03 + 0.06 (0.0012 + 0.0024)

0.035 + 0.067 0.035 + 0.067

(0.0014 + 0.0026) 0.035 + 0.067

(0.0014 + 0.0026 \

2, (0.0014 f 0.0026)

0.035 + 0.067 (;;~4;;~;2,,l1

0.036 + 0.067

(0.0074 + 0.0026)(f;;4y(;;26)@’

(0.0014 + 0.0026)

* *

0.025 + 0.057 (opdg;;*E4)(1) 0.025 + 0.057

(0.0010 + 0.00221 0.025 4 0.057 p) (0.0010 + 0.0022)

( 0 . 0 0 1 0 + 0.0022J

0.1 (0.0039)

0.007 + 0.019 (0.0003 + 0.0007)

0.002 f 0.010 (0.0001 + O.OOO4)

0 .018 (O.OOO7)

0.024 + 0.065 (0.0009 + 0.00261

0.034 + 0.075 (0.0013 + 0.0030)

0.1 (0.0039)

Red/Blue Red/Blue

0.034+ 0.662 0.032 + 0.064

(0.0013 + 0.0024) (0.0013 + 0.0025)

0.090 (0.0035)

0.056 + 0.25 (0.0022 + 0.0098)

0.35 (0.0138)

0.2 40.392 (0.0079 + 0.0164)

0.45 (0.0177)

0.059 + 0.100 (0.0023 + 0.0039)

0.044 + 0.085 (0.0017 + 0.0033)

0.w + 0.085 (0.0017 + 0.0033)

0.10 + 0.33 (0.0039 + 0.0130)

0.011 + 0.052 (0.0004 + 0.0020)

0.1 (0.0039)

01-47 May 1983


Inspection data1200

E n g i n e

1 3 5 0I 1 5 0 0

Valve stem-to

guide play

Valve guide-to-seat

Standard 0.013 + 0.046 (0.0005 + 0.0018)

Max 0.07 (0.0027)

Standard 0 . 0 3 0 + 0 . 0 6 3 ( 0 . 0 0 1 2 + 0 . 0 0 2 5 )

Max 0 . 0 9 ( 0 . 0 0 3 5 )

I Standard 0 . 0 3 2 + 0 . 0 6 8 ( 0 . 0 0 1 3 + 0 . 0 0 2 7 )

interference fit SpareI

0 . 0 4 6 + 0 . 0 8 2 ( 0 . 0 0 1 8 + 0 . 0 0 3 2 )

(I) Borg0 Piston

(2) Mondial Piston

TEMPERATURES

P a r t T e m p e r a t u r e

Oil pump/distributor drive gear for shrinking onto the crankshaft 150°C (302°F)

GENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS

A p p l i c a t i o n

Engine oil when full

Filter

Engine oil and filter routine maintenance 3 . 6 ( 7 . 9 4 )

Camshaft supports chests (I) 0 . 2 5 0 (0.55) (2)into each chest

TYPE

OIL AGIP SIN-T 2000 lOW50

Std.rd 3631-69352

IP Super Motor Oil 1 OW50

Std.rd 3631-69353

Q-KY

kg (lb)

3 . 1 5 ( 6 . 9 4 )

0 . 4 5 ( 0 . 9 9 )

(1) Applicable only in the case of supports dismantling

(2) This quantity relates to chests supply, completely drain, up to drain holes level

SEALING COMPOUNDS

A p p l i c a t i o n Type Datwmination Q.w

Joint face, cylinder block-to41 sump CEMENT DOW CORNING: Silastick 732 RTV

Std. no. 3522-00640

-

Plugs of water galleries in cylinder CEMENT LOCTITE 601 (green) - -

block and head Std. no. 3524-00011

(I 1 Before applying LOCTITE, remove all traces of old Loctite and degrease threads using trichlorethylene or chlorothene

M a y 1 9 8 3 01-48

ENGINE MAIN MECHAN1CA.L UNIT

(1) After having heated engine until intervention of radiator cooling electric fan, on cold engine, loosen, oil and tighten the six screw

securing heat to base by following the order shown in figure

(1) In the event of in-car tightening of head nuts with the aid of the extension A.5.0198 to be applied as shown, the torque

specifications are:

torque spanner having a 300 mm (I 1.84 in) lever arm

torque spanner having a 400 mm (15.75 in) lever arm

N+m 5 7 f 6 2

kg.m 5.8 + 6.3

Ib.ft 41.9 + 45.6

N*m 62 - 67

kg.m 6.3+ 6.8

Ib.ft 45.6 + 49.2


Condition

I. Noisy engineKnocking of crankshaft andbearing

Piston and connecting rodknocking

Camshaft knocking

Water pump knocking

I I. Other mechanical troubleSeized valve seat

Probable cause

Excessive crankshaft end play

l Fi t wrong Adjust

l Pin float Adjust

l Excessive valve play

l Tappet buckets wrong fit

l Weakened valve spring

Improper shaft end play

l Improper valve clearance

l Weakened valve spring

Corrective action

Replace thrust bearing

Adjust

Replace

Replace

Replace water pump assembly

Replace and adjust

Replace

M a y 1 9 8 3 01-50


Condition

Excessive!y worn cylinderand piston

Faulty connecting rod

Faulty crankshaft bearing

Belt tensioner knocking

Faulty timed

I I I. Lubricationoil leakage

Decreased of pressure

Probable cause

l Worn fit surfaces

l Poor oil quality

l Dirty air cleaner

l Too rich misture

l Shortage of engine oil

l Poor engine oil quality

l Worn or out-of-round crankpin

l Wrong connecting rod bearing-to-crankpin coupling

l Shortage of engine oil

l Poor engine oil quality

l Worn or out-of-round crankshaftjournal

l Wrong connecting rod bearing-to-crankpin coupling

Wrong belt stretching

Wear of oil pump control gear

l Loosen engine oil drain plug

l Oil leakage from sump gasket

l Oil leakage from camshaftsupports gasket

l Oil leakage from engine gasketsand seal rings

l Oil leakage from oil filter gasket

l Dirty pression regulator valve

l Poor-engine oil quality

Corrective action

Adjust or replace

User proper oil

Replace filter

Adjust or replace carburettor

Add or replace oilCheck oil level on daily basis

Use proper oil

Grind or replace

Replace

Add or replace oilCheck oil level on daily basis

Use proper oil

Grind or replace

Replace

Restore stretch

Replace

Tighten

Replace gasket

Replace gasket

Replace gasket

Screw in filter

Clean

Replace


SPECIAL SE.RVICE TOOLS

Tool number Tool namaRefer to

paw

01-1701-1901-24

A.2.0195 Base for cylinder head support

01-1701-1901-24

A.2.0226 Yoke for cylinder head support

A.2.0378 Tool for locking the flywheel 01-15

01-1701-24

A-3.01 0316 Yoke to remove and refit valves

01-18A.3.0311 Puller of valve guides

A.3.0312 Driver of intake valve guides 01-18

01-24A.3.0314 Driver of timing gear cover Seal

Support for removing and fitting

valves

A.3.0321 01-1701-24

01-1701-24

Lever for removing and refitting

the valves

A.3.0324

M a y 1 9 8 3 0 1 - 5 2

FUEL SYSTEM

AIR CLEANER

1 C o v e r2 Cartridge3 Cool air intake sleeve4 Hot air intake sleeve5 Min. blow-by hose

REMOVAL

Remove air c l e a n e r b o d y w i t hcarriage cartridge as follows:I. U n f a s t e n the five springclips @ that secure cover @ to airc leaner body @; r e m o v e cover.

2. Remove cartridge 0.3. Disconnect coo I air intakesleeve 3 as well as hot air intake

9sleeve t.4 .4. Disconnect blow-by hosesa d 0.

0

6 Flame trap7 Max. blow-by hose8 Air cleaner body9 Spring clip

1 0 N u t

5 . i f n e c e s s a r y , r e m o v e f l a m etrap 06 from max. blow-byh o s e @ .6. Loosen the four nuts @securing air cleaner body to carbure-tor; remove air cleaner body.

CHECKS ANDIbJSPECTIONS

1. Thoroughly clean cartr idge byblowing low pressure compressed air

from within; if necessary, replace it.2. Remove f lame trap from blow-by hose, wash both with specif icproducts, then dry them with com-pressed air. Install flame trap intoblow-by hose near oil filler.

INSTALLATION

Fit air cleaner, blow-by hoses and airintake sleeves back together follow-ing removal procedure in reversesequence.

M a y 1 9 8 3 04-2

FUEL SYSTEM

IDLE COMPENSATORDEsCRlPTlONThe idle compensator actually con-sists of a thermostat 0 that checksthe temperature of the engine intakeair and as a consequence eitheropens or closes the throttle valve @located in the air cleaner’s intakeduct. The throttle valve mixes thecool air coming from outside withthat coming from the hot air intake,located on the exhaust gas pipesunder the left side cylinder head, orit works either fully closed or fullyopen.

1 Thermostat2 Hot air intake Sleeve3 Cool air intake SieW@

4 Throttle valve5 Air cleaner

CHECKS ANDINSPECTIONS

,CAUTION:When disconnecting fuel systemhoses, use a container with safety lidto collect the petrol that is left overin the hoses.

FUEL PUMP DELIVERYPRESSURE

1. Disconnect fuel delivery hosefrom pump and from carburetor.2. Replace same with a T-shapedhose equipped with cutoff cocks.3. Connect a pressure gauge to thehose’s free end.4. Start engine up and with zerodelivery (cock on carburetor side isclosed), while keeping gauge at sameheight as pump, verify that gauge

CHECKS ANDI N S P E C T I O N S ‘-HOT AIR INTAKE CLOSINGTEMPERATURE1. Warm up engine bringing it up tosteady running.2. Turn engine off.3. Remove air cleaner cover as wellas cartridge.4 . Inset-t a thermometer next to thethermostat inside the air cleaner.5. When thermometer shows speci-fied temperature, verify thermostatcommands, i.e. opening of throttlevalve thus fully closing the hot airintake.

Hot air intake closing temperature33+ 37°C (91.4+ 98.6”F)

COOL AIR INTAKE CLOSINGTEMPERATURE

1. With cold engine, remove aircleaner cover as well as cartridge.2. Insert a thermometer next to thethermostat inside the air cleaner.

FUEL PUMP

reading is within specified values atrelevant engine rpm.

3. When thermometer shows speci-fied temperature, verify thermostatcommands, i.e. closing of throttlevalve thus fully closing the cool airintake.

Cool air intake closing temperature28 + 32% (82.4 + 89B’F)

THERMOSTATREPLACEMENT

1. Remove air cleaner from engine(Refer to: Air Cleaner) _2. Remove rivets securing air intaketo air cleaner body.3. Replace air intake as well asthermostat.4. Connect air intake back to aircleaner body by riveting it.5. Fit air cleaner back to engine(refer to: Air Cleaner).

FUEL PUMP PRESSURE

FISPA P u m p17.7 G29.4 KPa(0.177 + 0.294 bar,0.18 f 0.30 kg/cm2,2.56 + 4.27 psi)

SAVARA Pump17.7 + 29.4 KPa(0.177 + 0.294 bar,0.18 + 0.30 kg/cm2 ,2.56 + 4.27 psi)

at 5000 rpm

at 6000 r-pm

5. If delivery pressure is not withinspecified values, replace the pump.6. Disconnect T-shaped hose andrestore normal operating conditions.

04-3 May 1983

FUEL SYSTEM

CARBURETORS

WEBER TWIN CARBURETOR

q(Except Switzerland, Sweden, Australia.)

- 32 DIR 51A/250 for 1200 model

- 32 DIR 81A/250 for 1350 model

- 32 DIR 71A/250 for 1500 model

* For 32 DIR 8IA/250 and 32 DIR i’7pR50 only

May 1983 0 4 - 4

FUEL SYSTEM

1 Carburetor cover including:2 - S t u d3 Starting throttle4 Starting securing screw5 Starting shaft6 Lever for starting shaft7 Corrugated washer8 Starting shaft lever securing nut9 Starting control tie rod10 Tie rod split pin11 Tie rod washer12 Dust cover cap13 Dust cover plate14 Carburetor cover gasket15 Primary auxiliary Venturi15 Secondary auxiliary Venturi16 Pump delivery valve17 Pump jet18 Pump jet gasket19 Primary corrector jet19 Secondary corrector jet20 Primary emulsioning tube20 Secondary emulsioning tube21 Carburetor body22 Secondary idling jet23 Secondary idling jet carrier24 Shim adjustment washer25 Lever return spring26 Fast idling regulation lever together.with:27 - Nut28 - Adjustment screw29 Bush for fast idling regulation lever30 Lever securing screw31 Starting control lever together with:32 Cable securing screw33 Bush for starting control lever34 Shaft securing nut

35 Safety washer36 Spring for loosen lever37 Secondary shaft securing nut38 Spring washer39 Shim adjustment washer40 Secondary throttle control lever41 Sheath securing screw42 Cap for secondar/ idling hole43 Throttle control lever44 Shim45 Loosen lever46 Bush for loosen lever47 Secondary throttle adjustment screw48 Stop lever together with:49 - Bush for sealed idling cap50 - Spring51 Adjustment screw52 Sealed cap for lever adjustment screw53 Primary shaft return spring54 Shim adjustment washer55 Spring for adjustment screw of corrector idling56 Adjustment screw for idling mixture corrector57 Gasket for de-flood device58 Securing screw for de-flood device59 Economiser body including:60 Cap for adjustment screw61 Spring washer

72 Bush for sealed idling cap73 Adjustment screw cap74 Idling mixture adjustment screw75 Sealed idling cap76 Pump cover77 Pump cover securing screw78 Pump diaphragm79 Primary shaft return spring80 Pump filling spring81 Throttles securing screw82 Primary main shaft82 Oversize primary main shaft83 * Idling cut-off together with:84 - Gasket85 Conic seal needle8 6 B u s h87 - Primary idling jet88 Secondary main shaft88 Oversize secondary main shaft89 Throttle valve90 Secondary shaft return spring91 Closing screw for pump discharge space92 Primary main jet92 Secondary main jet93 Float94 Float fulcrum pin95 Needle valve

62 - Diaphragm adjustment screw63 - Device box64 r Spring for diaphragm65 - Diaphragm66 - Device cover67 - Cover securing screw68 Retaining ring69 Retaining ring70 Washer for economiser body control lever71 Economiser control lever

96 Needle valve gasket97 Filter inspection cap98 Filter99 Tie rod spring

100 *Cut-off cbmp101 Economiser body control tie rod102 Eonomiser control lever103 Washer for cover securing screw104 Carburetor cover securing screw

* Only for 32 DIR 8 1 A/250 and 32 Dl R 7 I A/250

CHECKS AND INSPECTIONS

--

B e f o r e r e m o v i n g carburetor f r o m

engine, perform following checking

and adjusting operations:

1. Float levelingCheck f l o a t p o s i t i o n a s f o l l o w s :

(I) Remove the whole air f i l ter (see

A i r C l e a n e r ) a n d disconnet t h eg a s o l i n e f e e d i n g h o s e f r o m f l o a t

chamber cover.(2) Remove f loat chamber cov-er 40,(3) Make sure float @ is of theweight prescribed in the technicaldata, that no deformation is presentand that it freely rotates on its pin.(4) If checked parts are defective,replace them.

(5) Keep float chamber cover @ invertical position so as that float issli&tly in touch on needle valve,

which i s o f the s p r i n g - b o d y t y p e .

Using a gauge pin, check if float

distance from float chamber cover -with gasket @ firmly in qlace - iswithin specified “Qw” value.

“QW” Dimension6.75 + 7.25 mm (0.266 + 0.285 in)

(6) To correct “QW” dimension,suitably bend float stopper 0.

1 Float stopper2 Float3 Gasket

4 Float chambercuver

2. Needle valve tightnessNeedle valve tightness is checked bymeans of a vacuum gauge. Keep floatchamber cover turned over and inhorizontal position and then proceedas follows:(1) Connect gauge’s plastic hose @to petrol delivery pipe 0 on floatchamber cover.(2) Load vacuum gauge air pump byacting on cam @ ; as a consequence,mercury w i l l go up the graduated

scale.(3) Wait for about then. seconds,during which mercury will have toremain steady, contraywise, replaceneedle valve.

04-5 May 7983

FUEL SYSTEM

1 Petrol delivery 2 Connecting hosePipe 3 C a m

Remove carburetor from car in oderto. carry out the following checks(refer to: Group 01 Engine Disas-sembly - Engine Unit).1. Choke opening (air valve) byeconomiserTo adjust c h o k e 0 open ingproceed as follows:(1) Fully engage choke by movingstarting control lever @ as shown inrelevant figure and at the same timeact on the economiser controllever pushing it all the way back.(2) Insert gauged point betweenchoke edge and duct making suredimension “GWl ” is within specifiedvalue.

“GW,” Dimension5.5 + 6.5 mm (0216 + 0.256 in)

1 Ckoke air valve2 Ckoke control lever

(3) In case the verified dimension“GW,” is not within specified value,remove cap and operate on traveladjustment screw of economiserdiaphragm (see following figure).(4) At the end of adjustmentoperation, refit cap 0.

(3) If “GW2” dimension is notwithin specified value,.loosen the nutand operate on control lever adjust-ment screw of throttle valve (seenext figure).(4) Having completed adjusting op-erations, tighten the nut.

1 Nut

1 C a p 2 Economiser body

2. Thrott le valve opening (gasvalve) with choke inserted.To adjust throttle valve @ openingproceed as follows:(1) Fully engage choke by movingstarting control lever @ as shown inrelevant figure.(2)-- Insert a gauged wire betweenthrottle valve edge and first bodyduct making sure dimension “G,,,,2”is within specified value.

“GW2” Dimension0.9 + 1 mm (0.035 + 0.039 in)

1 Throttle valve2 Srarting confrol lever

3. Accelerator pump adjustmentAdjust accelerator pump as follows:(1) Secure carburetor to supportC.4.0103 (fitted with gasket) of thepump tes t ins t rument C.4.0101.(2) Supply the carburetor withpetrol by connecting it to the tool’sreservoir.(3) Set the graduated measuringtubes C.4.0105 under the foreseenexhaust pipe -on support itself.(4) Carry out twenty strokes corre-sponding to as many completeopenings and closings of throttlevalve, operating on control lever 0.(5) Check if volume of petrolcollected in the measuring tubecorresponds to specified “VW” value.

When pumping, briefly stop both inthrottle valve fully open and fullyclosed positions.

Volume of petrol “VW” correspond-ing to 20 strokes of pump controllever:

“VW” = 17 + 20 -cm3

(1.03 f 1.22 cu.inJ

( 6 ) If “VW” value is not withinspecified limit, check diaphragm ofacceleration pump and the pumpjet.

May 1983 04-6

FUEL SYSTEM

WEBER TWIN CARBURETOR

For Switzerland, Sweden, Australia.

Carry out checks and ajustments following the procedures performed for the WEBER twin carburetors, previously de-scribed and referring to the tables provided in “Technical Data and Specifications ” relevant to check dimensions.

WEBER TWIN CARBURETOR - EXPLODED VIEW

(it will be provided in the next issue)

F

May 1983 0 4 - 8

FUEL SYSTEM

KEY

(it will be provided in the next issue)

04-9 May 1983

FUEL SYSTEM

58 Central Venturi securing screw59 Sheath securing screw60 Air valve control iniermediate lever61 Air valve control return lever62 Bush63 Air valve automatic opening control lever64 Securing nut65 Washer

66 Sheath support67 Washer68 Support securing screw69 Bush70 Central Venturi71 Economisier gasket72 Economisier assy

73 Air valve spring74 Idling cut-off75 Air valve76 Air valve control tie rod77 Air valve shaft assy78 Air valve securing screw79 Stud

CHECKS AND ADJUSTMENTS

Before removing carburetor fromengine, carry out the followingchecks.1. Check of float chamber hydrau-lic levelFor float chamber hydraulic levelcheck, operate as follows:

(I) Remove the whole air filter (see:Air cleaner) and disconnect the fuelfeeding hose from float chambercover.(2) Remove float chamber cover

(3) Make sure that float is of theprescribed weight indicated in theTechnical Data, that no deformationis present and that it freely rotatesaround its pin.(4) If checked parts are defective,replace them.(5) Verify that value of distance“A” between fuel surface and floatchamber cover surface with assem-bled gasket, is within specified value.

A = 21 + 23 mm (0.83 + 0.91 in)

(6) To correct “A” dimension, re-place washer located under needlevalve of properly bend float stopper.(7) Reassembly carburetor cover, letthe engine executes a few rotationsthen repeat check operations untilthe prescribed dimension is obtained.2. Needle valve tightnessTo check needle valve tightness, seeWeber twin carburetor: Checks andInspections - Needle Valve Tightness.

Remove carburetor from car in orderto carry out the following checks(see: Group 01 - Engine Disassemble- Engine Unit).1. Choke opening by economiser.To adjust choke @ opening proceedas follows:(1) Fully engage choke by movingstarting control lever @ as shown inrelevant figure and at the sametime act on the economiser controllever pushing it al l the way back.

(2) Insert gauged point betweenchoke edge and duct making sureti;;nsion “GS, ” is within specified

“GS,” Dimension4.5 + 4.75 mm (0.177 + 0.187 in)

1 Choke (air valve)2 Starting control lever

(3) In case the verified dimension“GS. ” is not within specified valveloosen lock-nut and operate ondiaphragm travel adjustment nut ofeconomiser body 0 (see nextfigure).(4) At end of adjustment, tightenlock-nut.

1 Economiser body

0 4 - 1 1 May 1983

FUEL SYSTEM

2. Thrott le valve opening (gasvalve) with volet inserted.To adjust throttle valve @ openingproceed as folltiws:(1) Fully engage choke as shown infigure.(2) Insert a gauged wire betweenthrottle valve edge and the first bodyduct making sure dimension “GS2”is within specified value.

“GQ ” Dimension0.9 + 1 mm (0.035 + 0.039 in)

1 Throttle valve2 Starting control lever

( 3 ) I f “GS2” dimension is notwithin specified valve loose nut andoperate on control lever adjustmentscrew of throttle valve (see nextfigure) .(4) Having completed adjusting op-erations, tighten the nut.

3. Accelerator pump adjustmentTo check and adjust acceleratorpump refer to: Weber Twin Carbure-tor: Checks and Inspections - Accel-erator Pump).

Volume of petrol “VS” correspond-ing to 20 strokes of pump controllever:

Twin carburetor Solex C32 EIES 45

1st . barrel cm3 8+ 10

(in) (0.49 + 0.61)2nd barrel cm3 s+ 10

(in) (0.49-e 0.61)Total cm3 16+20

(in) (0.97 + 1.22)


1 s t b a r r e l cm3 8+ 10

(in) (0.49 + 0.61)2nd barrel cm3 9+11

(in) (0.55 + 0.67)Total cm3 17,: 21

(in) (1.04 + 1.28)


1 s t b a r r e l cm3 8+10(in) (0.49 + 0.61)

2 n d b a r r e l cm3 10+12

(in) (0.61 + 0.77)Total cm’ 18+22

(in) (1.10+1.34)

Fit carburetor back to engine (referto Group 01 - Engine Assembly -Engine Unit) tightening relevant.nuts according to specified torqueand performing idle adjustment (re-fer to: Group 00 - Engine Mainte-nance).

@ : Tightening TorqueCarburetor retaining nuts

19 + 23.5 Narn(1.9 f 2.4 kg-m13.74 + 17.35 ft.lb)

OVERHAULINGCarburetor should be overhauledonly if encountered defects cannotbe corrected neither through opera-tions. described in Checks and Inspec-tions above nor through cleaning offuel filter, float chamber or jets.When overhauling, keep followingitems in mind:

a. Remove carburetor from engineand disassemble it on bench.

All disassembled parts must bethoroughly cleaned.

b.

C.

d.

Thoroughly and carefully checkmost delicate parts such asneedle valve, throttle valveshafts, diaphragms, acceleratorpump and fuel filter.Replace defective parts onlywith original ones and alwaysreplace a I I gaskets.Use special care in cleaning jetsso as not to damage relevantratings; if possible blow themwith a jet of compressed air.

CAUTION:Once carburetor has been over-hauled, it is advisable to performadjustments described in precedingparagraph “Checks and Inspections”.

ACCELERATOR CABLE ADJUSTMENT1 . Verify that throttle valve controlcable can freely slide inside sheath.2. Verify that clearance betweenclevis slot @ and pin @ oncarburetor throttle valve openingshaft is within specified G1 limit.

Clevis slot to pin clearanceG, = 1 mm (0.039 in)

3. If required, adjust as follows:(1) Loosen adjusting screw’s @lock nut 0.(2) Turn screw @ till specifiedclearance is reached.(3) Tighten,lock nut.

CAUTION:To easy adjustment buck action ofreturn spring by manually partiallyopening the throttle valve. 1 Adjusting screw 3 Pin

2 Lock nut 4 Clevis

M a y 1 9 8 3 0 4 - 1 2

FUEL SYSTEM

REMOVAL

WARNING:Before replacing any fuel line part,carefully follow below instructions:a. Make sure shop is equipped with

suitable safety equipment.b. Disconnect battery ground ca-

ble.c. Place petrol drained from tank

into a suitable container equip-ped with a safety lid.

FUEL TANK UNIT

1. Remove filler cap from fillerhose and take out all petrol fromtank with the help of a suitable

w-w.2. Loosen clamp @ and @connecting fuel filling sleeve to tankand connecting pipe to feeding hose.3. Loosen and remove screw secur-ing g round cab le @) t o b o d y .

I Ground cable 3 Clamp

2 Clamp

4. support tank by means ofcolumn lift and loosen screws secur-ing the clamps supporting tankto body.5. Slowly lower column lift so as togain access to tank upper side.6. Remove from float the electricconnections of warning lamp andindicator of fuel level, then, operat-ing from tank rear side, removebreather pipe together with retainingvalve.7. Remove tank and, if requireddisassemble it.

FUEL TANK FLOAT

Remove float of fuel tank operatingas follows:1. Suppor t t ank by means o fcolumn lift and loosen screws secur-ing the two clamps supportingtank to body.2. Slightly lower column lift SO a sto gain access to float located ontank upper side.3. Disconnect from pipe union, onfloat, the fuel delivery pipe @ andremove electric connections @ ofwarning lamp and fuel level indicator.4. Loosen the six screws securingfloat 0 to tank and remove float.

1 Float securing screw2 Electric connections3 Fuel delivery pipe

FUEL LINE

CAUTION:Disconnect feedings pipes only ifabsolutely necessary.

1. Remove filler cap and take out

all petrol from tank with the help ofa suitable pump.2 . R e m o v e clamps from hoseunions; plug all hoses and pipes toprevent dust or dirt from goingin during disassembly operations.3. Free pipes from relevant holdingclamps on underbody.

0 4 - 1 5

CHECK VALVE

Remove check valve from supportingclip on fuel tank.

1 Tank pipe side union2 Outer side union


T A N KCheck thank for flaws or any evi-dence o f warpage; i f necessary,replace it.

HOSESCheck hoses and make sure they arenot porous and show no evidence ofabnormal wear; replace hoses that arenot flawless.

PIPESCheck and make sure pipes are notclogged, oxidized or dented.

CHECK VALVE1. Blow in an air into the valvelocated of fuel pipe side.In doing so, one should notice someresistance and some air should comeout of the outer union.2. Now blow in an air jet into thevalve from outer side union.The air jet should go right throughand come out of the fuel pipe sideunion, without encountering anyresistance.3. If check valve does not complywith above, replace it.

INSTALLATION

Carefully fit all fuel line parts backtogether following removal opera-tions in reverse sequence and payingspecial attention to below instruc-tions.

May 1983

FUEL SYSTEM

CAUTION:a. Carefully fit clamps back to line

unions without tightening themtoo much to avoid damaging the

surfaces. 2. Do not twist or crush breatherc. Do not bend or twist pipes hoses after fitting; fasten them with

during installation. relevant clamps.d. Start engine up and make sure

there are no leaks from connec- FLOAThoses.

b. Fit fuel delivery pipes securelyto relevant holding clamps onunderbody, making sure sameare properly fastened.

- *gasket eachBe sure to replace tne

time float is fitted back into tank.

tions.

FUEL TANK UNIT1. Fit tank back into car following

C H E C K V A L V E

Failure to follow this caution removal operations in reverse se-will result in damage to pipe quence.

Be sure to fit check valve accordingto proper working direction.

EXHAUST SYSTEM

1 Gasket2 N u t3 Hot air intake4 Front manifolds5 Nuts


1. Check muf f l e rs and exhaus tpipes making sure they are not in anyway damaged or cracked and showno evidence of corrosion; contrary-wise, replace them.2. Thoroughly check supports ringand do not hesitate to replace themif they are cracked, porous or worn.

6 Bolt7 Front clamp8 Central muffler9 Support ring

IO B o l t

3. Check buffer on exhaust pipeend.4. Check surface of hot air intakemaking sure there are no warps ordents that could impair normal airflow.

REMOVAL

a. Instructions hereafter describedhave been compiled so as t o

11 Rear clamp12 Rear muffler13 Support ring14 Buf fe r1 5 N u t

allow separate removal of theexhaust system’s single compo-nents.

b. Consequently, removal proce-dure may be changed dependingon the operation’s purpose.

c. When removing the entire ex--haust system, it is advisable toget someone to help you withit.

May 1983 0 4 - 1 6

FUEL SYSTEM

MANIFOLDS ANDMUFFLERSReferring to the figure on page04-16, proceed with removal asfollows:1. Raise car on lift.2. Remove rear muffler as follows:(1) Loosen clamp 0 connectingcentral element with rear one andrelease this one from support retain-ing rings @ .(2) With a suitable hammer, lightlyand repeatedly strike all around themuffler pipes connection area andthen alternately turn muffler @clockwise and counterclockwise soas to make separation easier.

(3) If necessary, use a plastic ham-mer and lightly strike the muffler inthe direction of removal till rearmuffler comes off the central muf-fler.

3. Remove central muffler as fol-lows:

(1) Remove rear muffler (refer toitem 2 above).(2) Loosen clamps connecting cen-tral element with front one anddisconnect central element fromsupport retaining rings @.(3) With a suitable hammer, lightlyand repeatedly strike all around thepipes connection area and thenalternately turn muffler @ clock-wise and counterclockwise so as tomake separation easier.(4) If necessary, use a plastic ham-mer and lightly strike the muffler inthe direction of removal till centralmuffler comes off front manifolds.

4. Remove front manifolds as fol-lows:(1) Loosen clamp connecting frontelement to central one and move itfrom its seat.(2) Loosen the nut securing hot airintake bracket to cylinder head andwithdraw the warm air intake sleeve.(3) Loosen nut @ securing mani-f o l d .flanges t o c y l i n d e r h e a d s .(4) Remove manifolds @.

SUPPORT RINGSVerify integrity of support rings andreplace them if necessary.‘

HOT AIR INTAKE1. Raise car on lift.2 . Withdraw sleeve @ from airintake @ _3. Loosen bolt @ connecting airintake to manifolds and then removeclamp @ thus separating the hot airintake half shells.4. Loosen nut @ securing supportlever to left head and remove hot airintake.

1 Sleeve 4 Clamp2 Hot air intake 5 Bolt3 Screw 6 Nut

INSTALLATIONFit single parts back together follow-ing removal operations in reversesequence and paying close attentionto below instructions:

a.

b.

C.

Always fit new gaskets betweenmanifbld flanges and cylinderheads.Having completed installation,check and make sure tha tsupport rings move freely andare free of undue stress; checkbrackets making sure they havebeen properly secured.While engine is running check allpipe connections for gas leaksand the whole exhaust systemfor unusual noises.

04-17 Mav 1983

FUEL SYSTEM

SERVICE DATA AND SPECIFICATIONS

TECHNICAL DATA

FUEL PUMP FUEL TANK

-- ITypeALFA ROMEO

part No.

-.Brand

Mechanical

510.355 FISPA

531.354 SAVARA

542.140 SAVARA

GENERAL SPECIFICATIONS

Model Overall capacity

1200 1350 1500

305.00 305.02 305.04 Reserve

I 50

Imp. Gall 11

I 6.5

Imp. Gall 1.43

4041 .Ol 4059.01

960.084.00

906.130.00


Application

Spacer on accelerator pedal rotation pin

TYPO

GREASE

Denomination

AGIP FI Grease 15

Standard 3671-69810

Q.ty

May 1983 04-18

FUEL SYSTEM

T-r+$ .-6s ‘5

11

May 1983

FUEL SYSTEM

6LL

-

B1.

-

2L

-

8L

-

P

-

-

*3

-

:J

5:

-

-

3

-

E?j

MN

-

z

-

R

*

a

04-20May 1983

FUEL SYSTEM


FUEL PUMP

Fuel pump pressure

FISPA

SAVAR A

17.7 i29.4 KPa

(0.177 + 0.294 bar)

(0.18 + 0.30 kg/cm2 )

(2.56 +4.27 psi)

at 5000 rpm

17.7 + 29.4 KPa

(0.177 GO.294 bar)

(0.18 - 0.30 kg/cm21

(2.56 f 4.27 psi)

ar 6000 rpm

ACCELARATOR CONTROL

Pump delivery

thermostat temperature-

-

Clearance between adjustment fork slot and throttle con-trol shaft pin

Gl mm (in) 1 (0.039)

Clearance between throttle control lever and relevantcomplete opening stop

G2 mm (in) 1 + 2 (0.039 f 0.079)

WARM - COLD AIR AUTOMATIC MIXER

Warm air inlet complete closing

engine temperature I warm

I

>33+37 9=

(>91.4+98.6’F)

Cold air inlet complete closing

engine temperature

thermostat temperature

cold

<28-32 93

(<82.4+89.6 “F)

04-2 1 May 1983

FUEL SYSTEM

pRIn

04-22May 1983

FUEL SYSTEM

FUEL SYSTEM

TIGHTENING TORQUES

Item

UnitN-m kg.m ft-lb

Carburerors retaining nuts


Condition Probable cause Corrective action

Fuel leakage l Needle valve is dirty or its seat isloose on thread

Thoroughly clean petrol filter andneedle valve; tighten seat firmly: ifnecessary, replace it with a new one(original parts)

l Float sticks (hard on pin or sides) oris heavy

Free the float and adjust its move-ment: if necessary replace it (originalparts)

l Pipes improperly tightened or broken Tighten pipes and unions or replacedefective ones

l Gaskets are hard, worn or improperly Replace gaskets and tighten themtightened properly

l Acceleration pump diaphragm is

l Fuel pump or pipes are overheated

Cold starting is difficult orimpossible

Replace diaphragm

Let bubbles out and try to eliminateoverheating causes

l Fuel pump is mechanically defective Overhaul pump replacing defectivecomponents or replace the wholepump

l Pipes, fuel filter or carburetor ducts Thoroughly clean pipes, filter andare clogged by foreign matter carburetor

l Fuel tank breather hose is clogged or Unclog breather hose and eliminatethere is a water deposit on tank water also from pipes and from car-bottom buretor float chamber

l Having verified that fuel level in float Restore proper fuel level in floatchamber is absolutely correct, pro- chamberteed to check following possiblecarburetor troubles.

l Starting control cable does not slide Repair or replace cablefreely, is broken, unhooked, etc.

l Choke sticks so that it tends to stay Free choke movementeither fully open or fully closed

l Starting jet, if any, is dirty or has Clean or replace jetbeen tampered with

I I

May 1983 04-24

FUEL SYSTEM

Cold starting is difficult orimpossible (continue)

Excessive fuel consumption

Slow pickup especially whenin direct drive

Engine easily knocks, over-heats or self-ignites

Probable cause

Starting control valve, if any, issticky

Ignition and starting systems are outof order

Carburation, ignition or compressionare defective, as also mentioned incase of insufficient max speed

Air cleaner intake stopped in the warmposition

Twin carburetor goes into action tooearly

Carburation, ignition or compressionare defective, as also mentioned incase of insufficient max speed (pres-ence of exhaust smoke is possible)

Accelerat ion pump not .properlyadjusted or defective or pump circuitof jet and valves is defective

Diffuser well is clogged or otherwisedefective

Carburation or ignition are defective,as also mentioned in case of insuffi-cient max speed

Octane rating of petrol used is toolow

Engine cooling system is defective

Excessive scaling of engine cylinders

Having also excluded any ignitiondefect, engine compression will haveto be tested since there could beleaks coming from piston rings,valves or cylinder head gaskets

Engine compression is poor

Corrective action

Free valve movement so that it canproperly follow control cable

Overhaul ignition and startingsystems

Checking operations to be performedsame as previously mentioned

Replace thermostat located intocleaner air intake

CAUTION:Special attention should be paidwhen checking fuel consumptionsince speed load, road type as well asdriving habits play an important partin establishing actual running fuelconsumption

Adjust relevant controls


Overhaul pump and relevant circuits

Carefully overhaul air jet, diffuserand relevant well making sure thatall components are properly rated


Replace petrol in tank with a kindhaving a higher octane rating

Check radiator, relevant thermostator shutter, if any, since the lattercould be improperly adjusted

Proceed to scale the engine

Check engine compression by meansof suitable gauge screwed onto sparkplug holes; overhaul or replace anydefective engine parts

Check compression and, if necessary,overhaul the engine

04-25 May 1983

FUEL SYSTEM

Condition

Improper engine idling orprogression phases

Power shortage (insufficientmax speed)

Exhaust system is unusuallyor excessively noisy

Probable muse

l Inadequate fuel level in float cham-ber or defective starter, ignition oroverall engine operation as previouslymentioned in connection with diffi-cult cold starting

l Adjustment of idling adjusting screwsis incorrect

D Idling jet is dirty, loose or has beentampered with

1 Progression holes or channels ofidling circuit are clogged or havebeen tampered with

b Air leaks from fitting flanges or otherconnections

b Throttle valve shaft has air leaksfrom intakes

b Throttle valve or relevant controllingparts are sticky

b Twin carburetor’s second throttlevalve does not work properly

I Inadequate fuel level in float cham-ber or defective starting, ignition orcompression as previously mentioned

m Main jet, power jet, air adjustingscrew or diffuser are clogged, looseor have been tampered with

b Fuel filter in tank or in carburetoris clogged

b Air cleaner clogged

0 Throttle valve does not fully open

l Holes in manifolds

l Holes in pipes<

l Gas leaks from loose connections

Corrective action

Perform same checks and repairs aspreviously described

Carefully repeat all relevant adjust-ments as per maintenance instruc-tions

Check or replace idling jet

Check and thoroughly clean holesand channels

Tighten as required and, if necessary,replace relevant worn gaskets

Replace shaft and, if necessary, fit anoversize shaft after having suitablyreamed relevant holes in the body

Free throttle valve

Overhaul and clean

Perform same checks and repairs aspreviously described

Check, thoroughly clean or replacedefective parts

Clean the filter

Clean air cleaner and replace car-tridge

Check throttle valve and relevantcontrolling parts

Replace damaged parts


Tighten properly as required

May 1983 0 4 - 2 6

FUEL SYSTEM

Tool number Tool name

c.4.0101

c.4.0103

c.4.0105

SPECIAL SERVICE. TOOLS

Carburetor pump EST

Twin carburetor support (to be used

with C.4.0101)

Beaker for carburetor pump tests (to

be used with C.4.0101)

Refer topage

046

04-6

04-27 May 1983

IGNITION, STARTING, CHARGING SYSTEM

CONTENTS

BATTERY . . . . . . . . . . . . . . . . . . . . . . . .05-2

STARTER . . . . . , . . . . . . . . . . . . . . . . . .05-4

Wiring diagram. . . . . . . . . . . . . . . . . .05-4

Disassembly . . . . . . . . . . . . . . . . . . . . 05-7

Checks and inspections . . . . . . . . . . . 05-l 0

Reassembly . . . . . . . . . . . . . . . . . . . .05-l 2

Test stand inspection . . . . . . . . . . . . . 05-I 2

Service data and specifications. . . . . . 05-l 2

Trouble diagnosis and corrections . . . 05-13

CHARGING . . . . . . . . . . . . . . . . . . . . . . .05-15

Wiring diagram. . . . . . . . . . . . . . . . . . 05-15

Disassembly . . . . . . . . . . . . . . . . . . . . 05-l 8

Checks and inspections . . . . . . . . . . .05-21

Reassembly . . . . . . . . . . . . . . . . . . . . . 05-24

Test stand inspection . . . . . . . . . . . . . 05-24

Service data and specifications. . . . . . 05-24

Trouble diagnosis and corrections . . . 05-25

TRANSISTORIZED IGNITION

WITHOUT CONTACTS. . . . . . . . . . . . . .05-26

Wiring diagram. . . . . . . . . . . . . . . . . . 05-26

Description . . . . . . . . . . . . . . . . . . . . 05-27

Checks and adjustments. . . . . . . . . . .05-28

Disassembly . . . . . . . . . . . . . . . . . . . . 05-31

Checks and inspections . . . . . . . . . . . 05-32

Reassembly . . . . . . . . . . . . . . . . . . . .05-33

Test stand inspections . . . . . . . . . . . . 05-33Service data and inspections. . . . . . . . 05-33Trouble diagnosis and corrections . . . 05-36

May 1983


B A T T E R Y

WARNING:a. Do not touch both the positive

and negative terminals of thebattery at the same time withyour bare hands.

b. In case of necessity use a I2-voltbooster battery with jumperleads for starting the engine.

CHECKS1. The container has no cracks init.2 . Ver i fy that e lectrolyte levelcovers electrodes of about 4 + 5 mm(0.16 4 0.2 in).3. The top of the battery is cleanand the terminals are not oxidized ordirty.4. The lead terminals are wellfastened on to the battery terminalsand make good contact.

CLEANING

1. Clean the top of the battery, itsterminals and the lead terminals witha solution of sodium bicarbonate inwater.2. Before reassembling terminals, itis necessary to grease them with theprescribed grease: Grease REINACHE 10 Tat.

WARNING:Do not let the cleaning fluid get intothe battery: it will react with theelectrolyte.The electrolyte is acid and thereforedangerous to eyes, hands and clothes.

SPECIFIC GRAVITY

1. Veri fy that electrolyte is atcorrect level.2. By means of a bulb hydrometer,extract electrolyte from each cell andcheck the specific gravity.

3. Take the temperature “t” of theelectrolyte with a thermometer.4. Calculate the specific gravity at25°C (77°F) f r o m t h e f o r m u l a

sg,, = sgt + 0.0007 (t - 25) (kg/dm3)

where:

$gt = Specific gravity of electrolyteat PC

t = Electrolyte temperature

Examples1. SElectrolyte s.g. at 15°C ( 5 9 ° F ) :

1.290 kg/dm3s.g. at 25°C (77°F) will be:

sg*s = 1.290 + 0.0007 (15 -- 25)= 1.283 kg/dm3

(35.51 Ib/cu in)

2 . E l e c t r o l y t e s.g. at 35°C (95°F):1.275 kg/dm3s.g. ar 25°C ( 7 7 ° F ) w i l l b e :

sg,, = 1.275 + 0.0007 (35 -- 25)= 1.282 kg/dm3

(35.48 Ib/cu in)

5. Compare then the clensitycalcu-lated at 25% (77°F) with the valueprescribed for an efficient battery.

An efficient battery electrolyte spe-cific gravity is

d = 1.28 * 0.01 kg/dm3

6. If necessary charge the battery.

Batteries left on the shelf or in carsunused for long periods graduallylose their charge. Therefor they needto be charged up again when they areto be used.

CHARGING

WARNING:a. Remove the negative connection

before starting to charge thebattery.

b. Do not let the electrolyte heatup above 45°C (113°F) duringcharging.

CAUTION:a. Do not use naked flames near

the battery while charging.b. First connect the battery to the

charger and then switch on thecharger.

CELLS TEST

This test should be performed withthe correct electrolyte s.g.Measure the discharge voltage at theterminals of each cell.

1. Remove the plugs from the fillerholes.2. Put the test probes in twoadjacent holes (positive and negative)as shown. The needle should flip overto the green zone (charged).3. Repeat for the other two pairsof holes.

4. If the needle stops in the redzone (low charge) at the same pointfor each cell, charge the battery.

May 1983 0 5 - 2


5. If the needle stops in the redzone ( low charge) but at quitedifferent points for the differentcells, put in another battery.

USING THE ELECTRONICBATTERY TESTER(MOTOROLA)

Connect the positive instrument clipto battery positive (+) and negativeto negative (-). Set battery voltages w i t c h @ to 12V. t e m p e r a t u r ecompensator @ to the estimatedbattery temperature, and currentcalibrator @ to the battery ampsaccording to type.

Voltage test

1. Switch selector 0 to VOLT.2. The reading on the VOLT scalemust be greater than 12.4 V.

1 Selector switch2 Temperature compensation3 Battery voltage switch4 Current calibration

3. If battery voltage shows lessthan 12.4V, charge the battery andrepeat the test. If the voltage againshows less than 12.4V. a celle maybe shortcircuited. Change the batteryfor another one.

Battery state

1. Set the instrument selectorswitch to “Cond. Batt.“.2. The needle should flip over tot h e G R E E N z o n e o n t h e RED-GREEN scale.3. If it does not, put in anotherbattery.

Power test

1. Set instrument selector switch to“kW”.2. The needle should read be-tween 2 and 4 kW on the kW scale.3. If it does not, put in anotherbattery.

Charge test

1. Set instrument selector switch toVOLT.2. Start the engine and let it idleuntil the needle settles to its reading.3. The reading should be be-tween 13.6 and 15V.4. If the reading is outside (aboveor below) these limits, check thealternator for defects, especially thevoltage regulator (see Charging -Checks and Inspections).

Also check alternator belt tension(see: Group 00 Engine Mainte-nance).

Starting test

1. Set instrument selector switch toVOLT.2. Take the ignition HT lead offthe coil.3. Start the engine and check theneedle does not drop below 9 V onthe Volt scale.4. If it does, examine the starting

system (see: Starting).


Technical Data

Battery

Car1200 1350 - 1500 1500 Quadrifoglio

Voltage

Capacity

Discharge current

Electrolyte s.g.

V

Ah

A

kg/dm3

(lb/in 3 )

12

4 3 55

45 60

181 255

185 275

1.28 + 0.01

(35.43 5 0.27)

05-3 May 1983


General Specifications

FLUID AND LUBRICANTS

Application Type Denorninatioh Q-W

Battery terminals GREASE Grease REINACH: E 10 Tat

Std. no. 3671 - 69812

-

STARTER

WIRING DIAGRAM

0A l l

A l . BatteryAl I. StarterGl. Fuseholder boxci85. Front service junctionEl. Ignition switch

May 1983 05-4


BOSCH STARTER MOTOR

II

I

1 Dust co”er2 Retaining ring3 Bush4 Commurator casing5 Brush holder6 Brush spring7 Excitation winding lug8 Brush9 Yoke

IO Electromagnet

11 Fork12 Rubber block13 Lamination14 RotorI 6 Starting clutch16 Snap ring17 Pinion stop ring18 Drive housing19 Bush

05-s M a y 1 9 8 3


DUCELLIER STARTER MOTOR

1 Washer2 Bush3 Commutator casing4 Brush holder5 Brush spring6 Brush7 Yoke8 Electromagnet9 Plate

10 Locator

11 Trunnion12 Fork13 Screw14 Rotor15 Starting clutch16 Snap ring17 Pinion stop ring18 Drive housing19 Bush

May 1983 05-6


I- Brush spring 2 Brush holder

6 . Ex t rac t theJ-h

two positive

the brushbrushes tJJ fromholder @ and take off the brushh o l d e r w i t h t h e t w o n e g a t i v ebrushes 3 .0

1 Positive brushes 3 Negative brushes2 Brush holder

7. Unscrew the excitation winding

lug @ securing nut @ from the

wi thdraw the iiri”& ?mpy?electromagnet

with excitation winding.

8. Unscrew the two screws 0securing the electromagnet @ tothe drive housing @ and take outthe electromagnet.9. Remove the rubber block @with the lamination.10. Unscrew the bolt @ serving asclutch fork pivot.

1 Electromagnet 3 Drive housingscrew 4 Rubber block

2 Electromagnet 5 Bolt

11. Withdraw the rotor 2 together8with the starting clutch 3 and theforked lever 0.

1 Fork2 Rotor

3 Clutch

Hold the rotor in a vice with caps.12. Free the pinion stop ring @from the snap ring @ with a boxspanner.13. With a pair of pliers remove thesnap ring @ from the rotor shaftand slip off the pinion stop ring.

1 Pinion stop ring 2 Snap ring

14. Withdraw the starting clutch 0.

1 Electromagnet 3 N u t2 Excitation 4 Y o k e

winding lug

M a y 1 9 8 3

1 Starting clutch

05-8


15. Unscrew the inductor wind-ing 1

8

securing screw on they o k e 2 and extract the winding.

1 Inductor winding 2 Y o k e

16. If necessary, extract the bushesfrom the commutator casing and thec’rive housing with the use of apunch.

DUCELLIER STARTERMOTORHold the motor in a vice with caps.1. Hold the pinion firm with pliersand unscrew the pinion adjustingscrew 0. Take out the screw andthe washers under it.

l1 Washer 2 Screw clamping

2. Unscrew the two nuts clampingthe commutator casing @ and thestator yoke on the pinion housing ont o t h e s t u d b o l t s . R e m o v e t h ecommutator casing with the brushh o l d e r 0.3. Unscrew the excitation windinglug @ fixing nut on the electro-

.mannet. Remove the stator and therotor 4 .0

4. Punch on the trunnion 6 for0the fork on the pinion housing 0.

1 Lug 4 Rotor2 Commutator 5 Pinion housing

casing 6 Trunnion3 Brush holder

5. Unscrew the nuts 28 andremove the electromagnet 1 .

1 Electromagnet 2 Nuts

6. Hold the electromagnet in a vicewith caps. Use a screwdriver to keepthe electromagnet shaft from turningand unscrew the pinion clutchfork @ clamping nut 0.Remove the fork, spring and striker.7. If necessary take the inductorwinding out of the yoke (see: BoschStarter Motor, step 15.) and thebushes from out of the commutatorcasing and the drive housing.

CAUTION:When unscrewing nut 0, count theexact number of threads to when it isfree so that it may be screwed up thesame amount in re-assembly a n dcorrect fork adjustment had.

8. Strip the rotor as for the Bosch(see: Bosch Starter Motor, steps 12and 13).

1 Nut 2 F o r k

MARELLI STARTER MOTOR

Hold the starter motor in a cappedvice.1. Unscrew the two screws @securing the dust cover and take itoff.2. Unscrew the two nuts @ withwashers securing the commutatorcasing 0 and remove it.

1 Commutatorcasing

2 Nut

3 Screws4 Dust cover

3. Unscrew the electromagnet ex-citation winding lug nut and take theyoke out of the starter motor con-taining the stator windings.4. Extract the pivot cotter pin andtake the starter engaging fork pivot.

05-9 May 1983


5. Remove the rotor electromagnetassemblage and take the rotor topieces as for the Bosch startermotor (see: Bosch Starter Motor,steps IZ., 13. and 14.).

1 Electromagnet 3 F o r k2 R o t o r 4 Clutch

6. If necessary, take the fieldwinding out of the yoke (see: Boschstarter motor. step 15) and thebushes out of the commutator casingand out of the drive housing.

CHECKSAND INSPECTIONS

Before making any electrical inspec-tion thoroughly blow-clean the com-ponents and especially the endsof the winding with compressed airand clean the commutator with acloth slightly wetted with petrol.

Commutator wear

1. Put the rotor on a lathe.2. Place a magnetic-based centesi-mal dial gauge on the lathe carriagewith the gauge feeler in contact withthe commutator 0.3. Bosch and Marelli Starter MotorsEccentricity should not be more thanthe stated maximum.

Max permissible commutatoreccentricity

b.06 mm (0.0024 in)

1 Commutator

4. If greater errors than these arepound or if the commutator is badlyscored, put in a new rotor unless itwould seem enough to turn the rotorand smooth it with a piece of clothfor rotors.

Bosch and Marelli Starter Motors

Max turning depth on nominalthickness

0.25 mm (0.0098 in)

Commutator continuity test

1. Set the tester to the fi x 100scale.2. Put the prods on the commu-tator segments of the pack undertest:3. The test should show currentflow.

If there is no electrical continuity,put in a new rotor.

CAUTION:Repeat steps 2. and 3. for all thepairs of commutator segments.

Rotor insulation test

1. Set the tester to c? x 1 scale.2. Put one prod on the commu-tator and the other on the segmentpack or shaft.3. There should be no sign ofcurrent flow by the tester.

4. If the insulation is broken (shortcircuit) put in another rotor.

CAUTION:Repeat steps 2. and 3. for all thecommutator segments.

Rotor shortcircuit test on teststand

1. Position the rotor between thepole pieces of the rotor testingapparatus and switch on.2. Slowly rotate the rotor and restthe steel blade on the rotor pack.

3. The blade will stick to the packin correspondence with the faultylead cables if there is a short circuit.

Excitation winding insulationtest

1. Set the tester to the ax 1 scale.2. Put one prod on the lug of theinduction windings and the otherprod on the yoke.

May 1983 O S - I O


3. The tester should give no sign ofcurrent flow.

4. I f insulat ion is broken, removethe excitation winding from the yokeand put another winding in its place(see: Bosch Starter Motor, step 15).

Excitation winding continuitytest

‘I. Set the tester to the fi x 100scale.2. Put one prod on the inductionwinding cable and the other prod onthe positive brush. (Repeat with theother brush).3. The tester should show currentflow.

4 . I f con t inu i t y i s b roken in thewindings, remove the windings fromthe yoke and put in others in theirp lace (see : D isassembly BoschStarter Motor, step 15).

Positive brush holder insulationtest

1. Set the tester to the ax 1 scale.

2. Put one prod on the brushholder plate and the other prod on apositive brush holder.3. The tester should give no sign ofcurrent flow.4. Repeat the testpositive brush holder.

on the other

5. I f insulat ion is broken, put inanother brush holder plate.

Electromagnetic efficiencycheck

1. Shortcircuit the electromagnetwith the starter pin @ and connectits positive pole @ to the positiveterminal of a battery.2. Connect the battery’s negativet e r m i n a l t oyoke 0.

the electromagnet’s

1 Yoke 3 Electromagnet2 Pin positive pole

3. The starter drive fork actuatorshould tr ip. I f i t does not, put inanother electromagnet.

Pinion efficiency check

1. Rotate the pinion clockwise asshown in the figure. It should rotatefreely.2 . R o t a t e t h e p i n i o n c o u n t e r -c l o c k w i s e , i.e. in the direction ofmeshing. It should lock.

3 . E y e c h e c k t h e p i n i o n t e e t h .

4 . I f t h e p i n i o n d o e s n o t w o r kproperly or the teeth show excessivesigns of wear replace the starterclutch.

Brush spring check1. Check that the brush springshave not lost their elasticity and stillensure good brush contact on thecommutator.2. If necessary, put in new springs.

Brush wear inspection

C h e c k t h a t t h e stator a n d r o t o rbrushes are not chipped or dirty withcarbon deposits and check that theirlengths are within the prescribedlimits.

Brush lengths (mid

Bosch 11 mm (0.433 in)Ducellier 9 mm (0.354 in)

Marelli - m m (- i n )

Bush wear inspection

1. Check that the two bushes onthe front and rear rotor shaft bear-ings are not excessively or unevenlyworn. Side play between shaft andbush should l ie within the l imits.

Shaft-bush clearance(0 bush 0 shaft) =0.02+ 0.05 mm

(0.00079 + 0.00197 in)

2. If wear is excessive, put in newbushes (see: Disassembly Bosch

05-I 1 May 1983


Starter Motor, step 16).

CAUTION:Make sure the bushes are assembledproperly and the rotor shaft turnseasily and without play.

REASSEMBLYFollow the disassembly steps in theopposite order and lubricate t h efollowing parts with the prescribedgrease.Surfaces in motion relative to thestarter motor. Commutator casing bush. Drive housing bush. Pinion gear. Starting system sliding spiral

coupling. Electromagnet push rod

TEST STANDINSPECTION

Put the starter motor on the test

stand to correspond with the crownwheel and connect up to the electri-cal system.

CAUTION:The battery used in the test shouldhave a high enough capacity to avoidvoltage variations.

1. Under-load test(I) Apply the rated voltage to thestarter motor. Switch on the starterso that the pinion turns the crownwheel and check for good working.(2) Brake the crown wheel and

SERVICE DATA AND SPECIFICATIONSTECHNICAL DATA AND INSPECTION

Starter Motor

Voltage V

Min brush length mm (in)

Max commutator eccenrricity mm (in)

Shaft-bush side play mm (in)

Under-load test (pinion meshed with crown

wheel with torque dynamometer)

- Voltage

-- Absorbed current

- Speed

- Torque

V 10 10 9 . 8

A <230 <200 215

i-pm 3 1,450 3 1,450 1,800

N.m 5 5 5

(kg-m) (0.51 (0.5) (0.5)

(ft.1 b) (3.62) (3.62) (3.62)

Across-line test (pinion meshed with

locked crown wheel)

- Voltage- Absorbed currant

- Torque

V 8 8

A G400 G380

N.m >lO.S 211

(kg.m) (21) PI.11

(ft.1 b) (2 7.231 I> 7.95)

adjust the absorber current to thevalue in the under-load test.The torque should be that shown inthe technical particulars.

2. Across-line test(1) Apply the rated voltage to thestarter motor.(2) Lock the crown wheel brake.(3) Start up the starter motor andtake a quick reading. Current, voltageand torque should be those given inthe technical particulars.

3. Test with e-m. sw i tch on thestarter motor(1) Remove the starter motor awayfrom the crown wheel so that thepinion will not engage it.(2) Apply the rated voltage to thestarter motor. Switch on the startermotor. The absorbed current shouldbe that given in the technical data.(3) PICK-UP/CUT-IN voltage shouldbe that given in the technical data.

533.051 533.052 536.611

MARELLIE95 0.9 kW

12 v

.-

8400

12

(1.2)

(8.68)

May 1 9 8 3 05-12


Starter Motor

Over running torqueN*cm 13+22 11317 15*3

(kg.cm) (1.3+2.2) (I .l + 1.7) (I .5 * 0.3)

(in-lb) 11.13+ 1.91) (0.95 + 1.48) (1.30 ? 0.261

EM Switch on starter motor

- Max absorption current at ratedvoltage

- Min pickup voltage

Pinion module

Av

G4Q

8

<40

Gs

55

7

2.116 2.116 2.116

533.051 533.052 536.611

BOSCHEF 12V 0.8 kW0001211215



Starter motor does not turn I Break in electric circuit betweenand no current flows battery and starter motor

Current flows but starter motor 1 Rotor is rubbing against the poledoes not turn, or turns slowly, pieces or is being held between theor starting does not take place poles

Starter motor turns but starting D Crown wheel teeth worn: piniondoes not take place does not engage

m Break in electric circuit betweenstarter motor and starter switch

m Battery terminals dirty or loosec.onnections

b Starter motor electromagnet or wind-ing or is earthed

1 Excessively worn brushes not makingcontact on the commutator

1 Rotor shaft seized UP

) Field winding short circuited orearthed

l Broken or earthed rotor

l Rotor short circuited

0 5 - 1 3

DUCELLIER

6246/C

MARELLIE95 - 0.9 kW

1 2 v

Corrective action

Locate and repair it Check batteryterminals and starter cable terminals.Tighten up the securing screws

Locate and repair it. Check switchcontacts and replace if necessary

Clean the terminals and tighten upthe connections

Clean the moving and fixed contactsof the switch when possible andreplace it if necessary

Replace the brushes with other origi-

nal ones after checking state of com-muTator

Replace the bearings if the bushesare too worn. Check bearing align-ment. Examine rotor shaft. See thatthe poles are well located and se-curely clamped into the yoke

Replace the rotor and the piece withthe seized-up bush

Take out rhe field coils and put innew ones

Replace the rotor

Clean the carbon and copper dustoff-the commutator and brush hold-ers and if necessary replace therotor

Replace starting ring gear

May 1983


Condition

Starter motor turns but startingdoes not take place(continued)

Starter motor turns normallybut makes excessive or un-usual noise

Starter motor does not developmax power

Excessive brush wear

Sparking at the commutator

Probable cause

l Wrong assembly: pinion engages onlypartially

l Impurities in the coupling: Clutchdoes not slide on rotor shaft

l Pinion engages ring gear properlybut the engine does not start

l Defective mechanical parts

. Foreign bodies have got into i t

l Brush contact on commutator notgood

l Brushes do not slide freely in theguides

l Ovalized commutator

l Mica projecting out of commutatorcopper sections

l Brushes press excessively on com-mutator

l Wrong brushes

l Electrical overload in general

l Slack brush springs

l Mica projecting from copper

Corrective action

Check concentricity and pinion-ringgear distance

Clean and lubricate. If necessaryclean the coupling completely

Pinion free wheel defective and mustbe replaced. Faulty clutch to over-haul or replace. Electra-magnet notworking properly: repair or replace

Check bearings. Examine bushes andif necessary replace bearings

Clean them out

Replace brushes or snug them byrunning the motor on no-load forsome time. Check brush springloading and replace them if they havelost their elasticity

Clean the brush-holder guides orreplace the brush holders if neces-sary

Turn within in prescribed limits, re-move mica and clean commutator

Remove mica and clean commutator

Check brush spring loadings forprescribed values

Replace with others of prescribed

we

Overhaul the engine

Replace brush springs

Remove mica and clean the com-mutator

. .

May 1983 05-14


BOSCH ALTERNATOR

Distance pieceSemipulleysDistance pieceFanStay boltDrive housingControl side bearingPlateFeather key

10 Rotor11 Regulator side bearing12 Stator13 Diode - holder plate14 Regulator mounting15 Brush holder-voltage regulator16 Brush spring17 Brush

May 1983 05-16


MARELLI ALTERNATOR

1 Pulley2 Cooling fan3 Stay bolt4 Distance piece5 Drive housing6 Bearing retaining plate-control side

DISASSEMBLY

CAUTION:The following procedures are in-tended for part replacement. If usedfor component checking and inspec-tion purposes, do not unsolder.

BOSCH ALTERNATOR1. Hold the alternator pulleys 2

and pulley to rotor shaft @8in a vice with caps, Release fan 1

secur-ing nut 0. Take off the nut,the lock washer, the two semipulleyswith distance pieces and the fan withwashers and feather key.

7 Feather key 13 Brush holders8 Rotor 14 Rectifier bridge guard9 Bearing-regulator side 15 Excitation Tang

10 Stator 16 Positive terminal11 Voltage regulator support 17 Insulating washer12 Diode rectifier bridge 18 Voltage regulator

'-1

.J

;\ 2. Unscrew the two screws securingthe voltage regulator @ to itsmounting @ and take out the brushholder regulator unit.

1 Fan 3 Nut 1 Voltage regulator2 Pulley 4 Shaft 2 Regulator mounting

M a y 1 9 8 3 O S - 1 8

I.. ,

I G N I T I O N , ST A R T I N G, C H A R G I N G S Y S T E M

3. Hold the drive housing @ in av ice and unscrew the s tay bo l tsclamping the regulator mounting @to the housing 0.

1 Drive housing 1 Stator

2 Regulator mounting 2 Diode holder plate

4. Remove the regulator mountingby tapp ing i t on i t s edge w i th ap las t i c hammer as shown in theillustration.

5. Extract the rotor @ by tappingthe rotor shaft @ on its end.with ap las t i c hammer as shown in theillustration.

1 Rotor 2 Rotor shaft

6. Unso lder the stator @ (ro to r )three-phase connections to the diodeholder plate 0.

7. Unscrew the screws 0 securingthe diode holder plate to the regu-lator mounting and extract the diodeholder plate,

1 Diode holder plate securing screws

8. Unscrew the two sc rews asecuring the bearing retainingplate @ to the drive housing andextract the bearing.

CAUTION :At reassembly, use a new bearing ifthe old one is worn or damaged.

1 Screws 2 Plate

0 5 - 1 9

9. Extract the bearing 0 on thed r i v e h o u s i n g e n d o f t h e r o t o rs h a f t @ wi th an ex t rac tor (seefollowing figure) or a punch presswith half-plates.

CAUTION:At reassemble use a new bearing ifthe old one is worn or damaged andput it on the press with the help of apipe which must rest only on theinner ring of the bearing.

1 Bearing 2 Shaft

DUCELLIER ALTERNATOR +

1. Ho ld the a l te rnator in a v icewith caps. Unscrew the screwsand 2 securing the voltage regula-

tor 3 to its mounting and extractthe voltage regulator.

80

1 Top screws2 Side screws

3 Voltage regulator

2. Unscrew the two sc rews 0securing the brush holder @ andthe earthing plate @.3 . U n s c r e w t h e c a b l e t e r m i n a lsecuring screw @ and take out thebrush holder.

May 1983


1 Brush holder 3 screw

2 Screws 4 Plate

4. Unscrew the two diode cov-take out the excita-

and take off the cover.

1 Pin2 Cover

3 N u t s

6. Unscrew the alternator chargeindicator pin 0 screw,6. Unscrew the three alternatorpack assembly stud bolts nuts 0.

7. Remove the regulator mountingcomplete with stator and rectifierbridge (the diode plate) by tapping iton its edge with a plastic hammer.

8. Unsolder the stator three-phaseconnections to the rectifier bridgetabs.

9. Hold the rotor in a vice withcaps. Unscrew the nut securing thepulley @ and the fan @ -to therotor shaft. In order take off the nut,the washer, the distance piece, thepulley, the second distance piece andthe fan with washers and feather key.

IO. Extract the rotor @ by tappingthe end of the shaft with a plastichammer as shown in the illustration.

1 Rotor

11. Unscrew the three screws secur-ing the bearing retaining plate to thedrive housing and extract the bearing(see: Bosch Alternator - step 6).12. Take the bearing off the drivehousing side of the rotor shift (see:Bosch Alternator - step 7).

MARELLI ALTERNATOR

1. On a vice fitted with protectivejaws, secure pulley @ of alternator.Loosen nut @ securing pulley andfan @ to rotor shaft @; removenut, washer, pulley and fan togetherwith spacers and feather.

1 Pulley 2 Fan

1 Pulley2 N u t

3 Fan4 Shaft

1 Pin 2 Nuts

M a y 1 9 8 3 05-20


2. Disconnect voltage regulatorconnec to rs @ and @ of rectifierbridge. Unscrew screw securing brushh o l d e r 48 to vo l tage regula torsupport 3 and withdraw it.

Voltage regulatorRectifier bridge connectorRest voltage regulatorSliding brush holder

3. Unscrew tie rods @ assemblingc o n t r o l s u p p o r t @ t o v o l t a g eregulator support 0.

1 Tie rod 3 Voltage regulator2 Control support support

4. Remove voltage regulator sup-port by hammering on its edge bymeans of a plastic hammer, as shownin figure.

5. Withdraw rotor @ hammer ingby means of a plastic hammer onshaft @ of rotor itself, as shown infigure.

1 Rotor 2 Shaft

6 . Unsc rew nut and screw ofrectifier bridge guard 0; withdrawpower pin @ and remove guard.

1 Guard 2 Pin

7. Unsolder connect ions of statort h r e e p h a s e s ro f i n n e d rectifierbridge,

8. Withdraw rect i f ier br idge andstator from voltage regulator sup-port; then unscrew positive terminalwith relevant washer.9. By means of an extractor (see:Regulator Alternator Bosch) or a

suitable press with plates and punch,withdraw bearing on voltage regula-tor support side from rotor shaft.

CAUTION:On reassembly, use a new bearing (incase bearing is damaged or worn) bymounting it on press with the aid ofa tube which must face bearingretaining ring.

10. On a vice fitted with protectivejaws, t ighten control support 0.11. By means of a drilling machine,remove then rivets @ securingplate @ retaining bearing to controlsupport.12. Withdraw bearing.

CAUTION:On reassembly, use a new bearing, incase the removed one is damaged orworn.

1 Control support 3 Plate2 Rivets

CHECKSAtiD IWPECTIONSCAUTION:Before starting electrical checksblow-clean all the componentsthoroughly with compressed air.

1. Slip rings(1) Inspect for wear,(2) If the rings are scored, but notbadly, put the rotor. on a lathe andrectify the rings with rotor cloth. Ifthe rings are badly scored, put in anew rotor.

OS-2 1 May 1983


2.

(1)(2)(3)

Rotor winding continuity test

Ser the tester to the AL x 1 scale.Put the prods on the slip rings.Winding resistance should be:

Bosch alternator 4 f 0.1 aMarelli alternator 3.1 * 0.2 CL

Ducellier alternator 6.5 k 0.2 a

(4) If there is no electrical con-tinuity, put in a new rotor.3. Rotor insulation test(1) Set the tester to the a x 1 scale.(2) Put one prod on a slip ring andthe other prod on the rotor core.(Repeat for the other slip ring).(3.) The tester should show no signdf current flow.

(4) If the insulation is broken, putin a new rotor.4. Stator windings insulation test

(I) Set the tester to the a x 1 scale.(2) Put one prod on the stator packand the other prod on the termi-nals 0 of the first phase, then ofthe second phase, and finally of thethird phase.(3) The tester should show no signof current flow.

I P h a s e t e r m i n a l s

(4) If there is insufficient insulation,put in a new sTator.5. Stator windings continuity test(1) Set the tester to the a x 100scale.(2) Test for electrical continuitybetween: 1-2, 1-3, 2-3.(3) In each case the tester shouldshow current flow.

(4) If there is no continuity in thewindings, put in a new stator.6. Brush wear inspection

6- 1. Bosch Alternator(1) The brushes in the voltageregulator should not be chipped ordirty with carbon deposits; theirlengths should be within the pre-scribed limits.

Brush projection min.5 mm (0.197 in)

(2) In case of excessive wear,unsolders the brush cable as shown inthe i l lustrat ion and put in newbrushes.

6-2. Ducellier Alternator and Mare//i(I) The brushes in the brush holdershould not be chipped or dirty withcarbon deposits; their lengths shouldbe within the prescribed limits.

Brush length min.

Ducellier Alternator 6 mm (0.236 in)Marelli Alternator 7 mm (0.275 in)

(2) In case if excessive brush wear,put in new brushes: the one bysimply withdrawing i t f r o m itsseaT on the brush holder and theother by withdrawing it after un-screwing its securing screw.

DUCELLIER

May 7983 05-22


7. Brush spring inspectionThe brush springs should be stiffenough to assure good brush contacton the slip rings. If they are not, putin a new voltage regulator unit.8. Brush holder unit electricalcontinuity inspection(1) Set the tester to the 52 x 100scale.(2) Put one prod on one and thenon the other brush 0.(3) Put the other prod on theterminal 0.(4) The tester should show currentflow.( 5 ) I f t h e r e i s n o eletrical conri-nuity, check the brush holder and ifnecessary put in new brushes and/orbrush holder.

1 Brushes 2 Terminal

DUCELLIER A N D MARELLI

c 9.9-1(I)

Diodes inspection

Bosch AlternatorSet the tester to zero on the fi x

1 scale.(2) Put the prods on a diode termi-nals.Then either:(2a) The tester shows no current flow(infinite resistance).

Inverse current resistanceR =w

Reverse the two prods The testershould show the prescribed re-sistance.

Diode resistance in direct conductionR = 0 -lOa

Direct current resistanceR = O+lOa

Power diodes - bridge inverted test(I) Zero tester in the a x 100 rangescale.

(2b)The rester shows current flowand therefore the prescribed resis-tance.Reverse the prods and the testershows no current flow (infiniteresistance).

CAUTION:All excitation diodes must be testedin this way.

(2) Carry out inverted-test of bridgeoperating as per direct test, byinverting (in sequence) probes be-tween positive heat sink and t hethree phases of bridge when testingpositive bridge.Inverts (in sequence) probes betweennegative heat sink and the threephases when testing negative bridge.(3) Verify on tester that current isnot present.

Diode resistance for invertedconduction

R =mcL

1 Diode holder plate

1 Positive hear sink2 Negative test sink

(3) If the tester readings are notthose prescribed, put in a new diodeholder plate.

Energirat ion Diode Direct test(1) Zero tester in the a x 1 rangescale.

9-2. Ducellier Alternator and MarelliPower diodes - Bridge direct rest(1) Zero tester in the a x 1 rangescale.(2) Carry out direct test of positivebridge, by setting the tester negativeprobe on positive heat sink of bridgeand the other probe, sequentially,on each end of the three phases ofbridge. Check, on tesrer, that resis-tance value for direct current is therequired one.(3) Carry out direct test of negativebridge, by setting the tester positiveprobe on negative heat-sink of bridgeand the other -probe, sequentially,on each end of the three phases ofbridge. Check on tester, that resis-tance values is the required one.

(2) Connect tester negative probewith output of energization diodes(terminal D+) and second probe(in sequence) with the three phases.(3) Verify on tester, that resistancevalues for direct current are therequired ones.

Diode R for direct currentR = 0+1os2

Energization Diodes Inverted test(1) Zero rester in the ax 100 rangescale.(2) Operate as per direct test byinverting tester probes between out-put of energization diodes (terminalD+) and the three phases (in se-quence). Verify,. on tester, thatcurrent is not present.

05-23 May 1983


CAUTION :If the required resistance values arenot measured, replace rectifierbridge.

REASSEMBLYReassemble the alternator followingthe disassembly steps in the oppositeorder, and taking care that:

CAUTION:When soldering the three statorcables on to the diode holder plateand, for the Bosch Alternator,changing the brushes, the solderingmust be done as quickly as possibleso the diodes are not overheated.

TESTSTAND INSPECTION1. Put the alternator on the teststand and connect it to the stand’selectric motor.2. Make the following electricalconnections:(I) Terminal B+ to test standpositive.(2) Terminal B+- to the pilot lightand to terminal D+.(3) Connection for test stand feet.

1 Terminal B + 2 Terminal D +

3 . L e t t h e a l t e r n a t o r r o t a t e a t3,000 rpm for an hour with rheostatload to give a voltage of 13 + 14V.4. Slow down the motor until thecurrent output is from 1 + 2 A andthen disconnect load rheostats to geta voltage again of 13 + 14V. Take thecurrent reading and the correspond-ing rpm.

5. Keeping the voltage constant,vary the speed and the load rheostatsand take current readings togetherwith the corresponding rpm atdifferent point up to max currentoutput.6. The output current readings atthe various speeds should all be equalto or greater than those reported inthe Technical Data.

SERVICE DATA AND SPECIFICATIONSTECHNICAL DATA AND INSPECTIONS

Alternator

0.120.489.798 125 - 14V - 45A

Brush wear limit

Voltage regulator resistance 58+72 -

Diodes resistance i2 o-10 o-10 o-10

(I) Minimum readings when hot after 1 hour’s working at 5000 rpm with loading of 25 A

M a y 1 9 8 3 05-24


T R O U B LE D I A G N O S I S ,AND CORRECTIONSBefore starting alternator troubleshooting, the battery should be fully charged (see: Battery)

Condition

Alternator does not charge

Insufficient or irregularoutput

Excessive output

Noisy alternator

Probable cause

l Slack belt

l Broken charging or earthingcircuit

l Faulty brushes

l Excitation diodes short circuited

l Broken excitation circuit

l Broken rotor winding

l Inefficient voltage regulator

l Stator winding earthed

l Slack belt

l Intermittent break in thecharging circuit

l Worn brushes

l Inefficient voltage regulator

l An excitation diode disconnectedor earthed

l Rotor partly short circuited

l Stator disconnected, earthed orpartly short circuited

Inefficient voltage regulator

l Worn belt

l Loose pulley

l Poor bearings

l An excitation diode short circuited

l Loose alternator

Corrective action

Tension the belt

Check the circuit

Put in new brushes

Put in new diode holder plate

Check the circuit

Put in new rotor

Put in new voltage regulator

Put in new stator

Tension the belt

Check the circuit

Put in new brushes


Put in new diode - holder plate

Put in new rotor

Put in new stator


Put in new belt

Tighten up the nut

Put in new bearings

Put in new diode-holder plate

Tighten up the screws on the bracket

OS-25 May 1983


DESCRIPTIONThe electronic ignition is an induc-tive discharge transistorized systemwithout contacts, constituted by thefollowing components.a. ign i t i on d is t r ibu to r w i th mag

netic pulse generator A5 with0mechanic centrifugal sparkadvance and vacuum advancecalibrator.

b. Ignition coil A8 with electronic0module.

C. Electronic module Nl0The ignit ion distr ibutor with mag-netic pulse generator differs from thetraditional type as, in the place ofcontacts and of capacitor, it has amagnet ic pu lse genera tor (stator)and, in the place of the cam, atoothed timer (rotor).High voltage distr ibut ion to sparkplugs is obtained by means of a rotor

arm and cap, The pulses are gener-ated by a magnetic pulse generatorlocated into a variable air gap circuit.During rotation of distributor shaft,each time a tooth of the timer passesin f ron t o f the f i xed po le p ieceexpansion, a signal is generated (byinduction) at the winding ends ofcoil (pulse generator), with conse-quent cont ro l o f the e lec t ron ic

module.The electronic module, constitutedby a set of integrated circuitsmounted onto a ceramic supportenclosed into a proof container is, inits turn, mounted together with coil,onto an aluminium finned supportwhich also operates as heat dissi-pator. Between the electronic mod-ule and the support, it is interposed agrease coat with thermal high con-dutivity, with the purpose of ensur-

ing heat maximum elimination andstable performances.Besides conducting or interdictingthe output transistor, the electronicmodule has a lso the purpose ofprocessing the signal provided by themagnetic pulse generator of distribu-tor, conducting one linked with theengine rotation revolution numbers.It is thus obtained a control of theco i l charge cur ren t and o f t imeduration of conduction with genera-t i o n o f c o n s t a n t e n e r g y s p a r k ,independently of engine speed andbattery voltage.A coupl ing capacitor, secured tomodule rad ia tor and electr ical lyconnected with coil terminal andto ground, al lows optimization ofprimary voltage wave form on coiland, consequently, higher perfor-mances.

r

Gl. Fuseholder boxBl. To ignition switchAl 2. Spark plugsCl . To elecrronic tachometerA6. Magnetic pulse generator

A7. Timer (Rotor)A5. Electronic distributorNl. Electronic ModuleAS. Ignition coil

O S - 2 7 May 1983


CHECKS ANDADJUSTMENTSON CARS1. Check general rules

CAUTION:Each check for presence of voltage orcurrent in electric connections, viasparking, that is, ground dischargingthe high-and low voltage points, mustbe avoided unless they are requiredspecial verifications expressely listedwith application of special devices.Besides, the following operationsmust be avoided:. Connection interruption be-

tween tap of coil high voltageand distr ibutor, by discon-necting the relevant cable (coilside) when motor is running orduring starting phase.

. Ground connection of coil lowvoltage terminal connected with

tachometer.l Use of trouble diagnosis equip-

ments which allow the short-circuit the low voltage signal,between coil primary windingand tachometer or not allowed.

WARNING:Before powering the unit, make surethat connectors of the electr icsystem are properly inserted and thatthe module coil units is securedto ground so as to ensure an effectiveconnection.

WARNING:Stroboscopic gun must always bedirect ly connected with batteryterminals.

2. System functioning verification(I) With ignition key inserted (igni-tion switch closed) and engine still,check, by means of voltmeter, thatthe voltage on terminal 15 of coilis equal to the battery voltage (12V).(2) After carrying out the ignitiontiming operation (for timing see:Group 00 Ignit ion System andSupply) check possible interruptionsin the coil windings. To this purpose,disconnect the tachometer cable and,with non-inserted ignition key, checkvia ohmmeter, that resistance valuesof both primary and secondarywindings are the prescribed ones.

Coil

Primarywinding !aresistanceSecondarywinding 5-2resistance

Mard i Bosch

0.72k.i 0% 0.7 - 1

(3) With ignition key not inserted(ignition switch open) verify func-tioning of ignition distributor bydisconnecting the connector betweenmodule coil unit and distributorand checking via ohmmeter, thatresistance of pulse generator coilcorresponds to the prescribed value.

(4) Verify that resistance internal torotor arm of ignition distributorcorresponds to the prescribed value.

Distributor Marelli BoschI I

Rotor armresistance i.2 5,000

I I1,000

(5) Proceed as follows for systemgeneral verification with ignition keynot inserted, disconnect from a sparkplug the connection high voltagecable to distributor by setting thefree end at 5 mm (0.2 in) fromengine body.

Put on insulation gloves and start theengine verifying that spark occurregularly between cable and ground.

May 7983 OS-28


BOSCH DISTRIBUTOR

/’

1 Cap2 Rotor arm3 Dust cover4 Retaining ring5 Timer6 Retaining ring7 Pulse generator (stator)8 Spring9 Retaining ring

10 Counterweight

11 Pulse generator securing screw12 Connector securing screw13 Connector14 Spring securing screw15 Spring16 Distributor body17 Advance regulator

18 Advance regulator19 Spring securing screw

05-29 May 1983

IGNITION, STARTING, CHilRGING SYSTEM

MARELLI DISTRIBUTOR

1 Cap 7 Insulating support2 Cap securing screw 8 Spring3 Rotor arm securing screw 9 Counterweight4 Rotor arm 10 Distributor body

5 Pulse generator securing screw 11 Advance regulator securing screw6 Pulse generator (stator) 12 Advance regulator

May 1983 05-30


DISASSEMBLY

In the following are prqvided thedisassembly operations relevant toignition distributors, limited to thepart on which maintenance is carriedout.

BOSCH DISTRIBUTOR

Clamp distributor on a vice fittedwith protective jaws.1. Remove cap 0 and withdrawfirst the rotor arm @ with revlimiter and then the lubricationfelt.

The rev limiter is a centrifugallocated on the head of rotor armwhich interrupts the ignition dis-tribution when the engine exceeds6800 rpm.

2. Remove dust cover 0.

1 Cap2 Rotor arm

3 Dust cover

1 Screw 2 Connector

4. Remove cap securing springs @after unscrewing the relevant 6. Lift inductive winding

screws 2 Then unscrew 1 secur-0 0 remove the advance regulator

ing stator to distributor body andscrews 30 securing advance regu-lator to distributor body.

1 Stator securing screw2 Spring securing screw3 Regulator securing screw4 Spring

1 Inductive winding2 Advance ragulator

7. From distributor shaft, removein sequence the timer, retaining

3. Operating as per figure, remove 5. Operating on screw 0, remove ring 0 and inductive winding @retaining ring of timer. connector @ of distributor body. complete of stator and supporting

plate.

OS-3 1 M a y 1 9 8 3


1 Retaining ring 2 Inductive winding

8. By means of a clamp, releasesprings @ of counterweights 1 ,

8then remove stop retaining rings 3and then withdraw counterweights.

1 Counterweights 3 Retaining ring2 Springs

MARELLI DISTRIBUTOR

Clamp distributor on a vice fittedwith protective jaws.1. Unscrew screws 2 securing cap0to distributor body; then withdrawcap (iJ.

1 Cap 2 Securing screws

2 . Unscrew screws 2 secur ing0rotor arm to body; then withdrawrotor arm 10.

1 Rotor arm 2 Securing screws

3. Withdraw springs @ and re-move counterweights 0.4. Unscrew securing screws 4 ,

8then remove pulse generator 3(stator) and magnetic insulatingsupport 50.

1 Counterweights 4 Screws2 Springs 5 Insulating3 Pulse generator support

5. Unscrew the four screws secur-ing advance regulator to lower baseof distributor body, then withdraw

body from i ts seat by using asfulchrum the regulator shaft.

CHECKSAND INSPECtIONS

MARELLI DISTRIBUTOR

By means of a feeler gauge, verifythat air gap between pulse genera-tor @ and timer 0 correspondsto the “S” prescribed value.

Air gapS = 0.4 + 0.5 mm (0.016 + 0.02 id

M a y 1 9 8 3 05-32


1 T imer 2 Pulse generator

REASSEMBLYFor reassembly reverse the order ofdisassembly and comply with thefollowing:1. Lubricate the fol lowing com-ponents by means o f d is t r ibu to rspecial grease.. Counterweights springs. Counterweights2 . L u b r i c a t e f e l t of. d i s t r i b u t o rshaft with few oil drops.

CAUTION:Marelli DistributorEvery time it is carried out a disas-sembly or replacement operation ofmagnetic pulse generator, it isanyway required to reassemble themagnetic spacer of pulse generatorsupport.

TESTSTAND INSPECTIONS1. Vacuum advance(1) Mount the ignit ion distr ibutoron a test bed and carry out electricconnections.(2) Car ry ou t spark rese t t ing ongon iometer d isc o f tes t bed byro ta t ing d is t r ibu tor manua l ly o rw i th the tes t bed motor w i thoutexceeding 50 r.p.m. speed.(3) Carry out connection of vacuumpipe to vacuometer o f tes t bed.(4) On increasing vacuum, read theadvance curve (see Service Data andSpecifications).(5) If the read curve -is not withinthe prescribed deviations, replace thevacuum advance device.

2. Counterweights advance(I) Carry out steps 1 and 2relevant to vacuum advance verifica-tion.(2) On vacuum spark advance con-t ro l d isconnec ted f rom tes t bedvacuometer, r e a d , o n increasingr.p.m., the automatic advance curve(see: Serv ice Data and Spec i f i -cations).(3) If the particulars are not withinthe prescribed values, carefully exam-ine the distributor and, particularlythe counterweights and re levantreturn springs, timer, and pulsegenerator. Replace faulty the parts.

SERVICE DATA AND SPECIFICATIONSTECHNICAL DATA AND INSPECTldNS

Ignition Distributor

Alfa Romeo Class 542.168 542.161

Type IMARELLI

I

B O S C HSM 802 AX 0.237.005.004

Firing order I - 3 - 2 - 4

Pulse Generaxor Coil Resistance

Internal resistance of distributor 1 rotor arm

i-2 730 f 5% 1 1 0 0 ’1 0 %

A-L 5000 1000

Air gap mm 0.4 + 0.5

(in) (0.015 + 0.019)

ELECTRONIC MODULE

Suppl; voltage V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4+16

Maximum controllable current A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Radiator limit temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 30 + + 185°C (- 22 + * 365°F)

0 5 - 3 3 M a y 1983


AUTOMATIC AND PNEUMATIC ADVANCE CURVES

800 5"45' 3O45'

1700 13"45' 11015'

1800 140 120

2500 13O II0

3000 12"15' lO"15'

338 7"30' 5"30'I

M a y 1 9 8 3 OS-34


IGNITION COIL

AHa Romeo Class

Type

Primary winding resistance

Sawndary winding resistance

542.167 542.162

MARELLI BOSCH

BAE 207B 0.221.6C10.002

s-2 o-72,* lO.Vo 0.75 1

n 7900f10% 6700 + 9600

SPARK PLUGS

Alfa Romeo Class 535.420

Type LODGE 25 HL

FLUID AND LUBRICANTS

Application

Spark plug thread

Type

OIL

Demmination

ISECO Molykote AStandard 4500 - 18304

Q.W

TIGHTENING TORQUES

Item

UnitN.m kg.m ft.1 b

Spark plugs in IS-EC0 oil: Molykote A 25+34 2.5 + 3.5 18.08 + 25.31

05-35 May 1983

ENGINE COOLING SYSTEM

,CONTENTS

COOLING SYSTEM . . . . . . . . . . . . . . . 07-2

General description . . . . . . . . . . . . . 07-2

Removal . . . . . . . . . . . . . . . . . . . . . 07-3

Hydraulic system leak test. . . . . . . . 07-3

WATER PUMP . . . . . . . . . . . . . . . . . . . 07-3

Checks and inspections . . . . . . . . . . 07-4

Installation . . . . . . . . . . . . . . . . . . . 07-4

THERMOSTAT . . . . . . . . . . . . . . . . . . . 07-4

Removal . . . . . . . . . . . . . . . . . . . . . 07-4


Installation . . . . . . . . . . . . . . . . . . . 07-5

RAD I AT0 R . . . . . . . . . . . . . . . . . . . . . 07-5

Removal and installation . . . . . . . . . 07-5

Leak test . . . . . . . . . . . . . . . . . . . . . 07-6

ELECTRIC FAN CONTROL

THERMAL CONTACT . . . . . . . . , . . . . 07-6

Removal and installation q I , . . . . . . 07-6

Checks and inspections . . . d _ . I . . . 07-6

HEADER TANK PRESSURIZED

PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . 07-6

Leak test . . . . . . . . . . . . . . . . . . . . . 07-6SERVICE DATA AND

SPECIFICATIONS . . . . . . . . . . . . . . . . 07-6

Inspection and adjustment . . . . . . . 07-7

Tightening torques . . . . . . . . . . . . . 07-8


CORRECTIONS . . . . . . . . 1.. . . . . . . . 07-8

May 1983


COOLING SYSTEM

GENERAL DESCRIPTION

123456789

IO111213

14

Electric fanThermostatRadiatorElectric fan thermal contactCooling drain plugsCentrifugal pumpHeader tankCooling temperature transmitterHeaterCooling temperature warning light thermal contactCooling temperature indicatorCooling temperature warning lightCooling water level sensor for check control(I 500 Quadrifoglio model)Cooling water minimum level warning light(1500 Quadrifoglio model)

M a y 1 9 8 3 07-2


CHECKS ANDINSPECTIONSThe water pump cannot be over-hauled and in case of failure must: bereplaced.1. Check pump body and impellerfor indications of wide oxidation andcorrosion; if any, replace pump.2. Verify that there is no excessiveplay in the rotation and axial move-ment of impeller.

REMOVAL1. Drain coolant up to the lowerlevel of thermostat housing.2. Detach coupling @ connectingthermostat cover to radiator.3. Screw out screws @ andremove cover 03 with relevantgasket @ _4. Withdraw thermostat @ fromImousing @ .

INSTALLATION

1. Fit water pump with newrelevant gasket to block and tightensecuring screws to specified torquevalue.

: Tightening torqueScrews securing water pump

19+24 N-m(1.9 + 2.4 kg-m13.74 + 17.35 ft.lb)

2. Check correct timing of engineand key camshaft belt on camshaft

THERMOSTAT

CHECKS ANDINSPECTlOONS

Thermostat should be checked inaccordance with the following pro-cedure:1. Fit thermostat @ to suitabletest equipment.2. Fill container with water andswitch on equipment to heat water.3. Check that, when thermostatopens, temperature value read onthermometer @ dial indicator is84 + 88°C (183.2 + 190.4”F).4. Additionally check that thermo-stat is fully open at 98°C (208.4”F)and valve travel greater than 7 mm(0.28 in).

pulley. For the timing and beltkeying procedure refer to: Group 00

- Engine Maintenance.3. Refit front cover of camshaftbelt, pulley, alternator, pump andalternator driving belt, in reverseorder of removal.

4. Stretch pump-alternator drivingbelt.For the stretching procedure of beltrefer to: -Group 00 - Engine Mainte-

nance.5. At end of pump installation,pour the coolant and letting theengine run for a few minutes checkagainst coolant leakages.

If above values are not met, thermo-stat must be replaced.

1 Thermometer 2 Thermostat

1 Coupling 5 Washer2 Clamp 6 Thermostat3 Cover 7 Gasket4 Screw 8 Housing

M a y 1 9 8 3 07-4


L E A K T E S T

I. Remove radiator from car (Referto: Radiator Removal and Installa-tion).2. Close radiator outlet and inletunions.3 . lmmerge rad ia to r in a t ankpreviously filled with water andcheck for possible leakages inflating

compressed air through radiatorbreather pipe until a pressure of98.1 + 107.9 kPa; (0.9 + 1.0 bar;1 + 1 .I kg/cm2 ; 14.22 + 15.64 psi) isreached.

4. If leakages are found, clean areato be soldered by a wire brush anddeoxidate by “baked” hydrochloricacid (zinc chloride).5. Solder the leaking area.,

6. Test again radiator for leakagesas described above and then refinishradiator with black synthetic enamel.In case of leakages from radiatorfitted with side tanks (with gaskets),replace the radiator.7. Refit radiator to car (Refer to:Radiator - Removal and Installation).Fi l l with coolant and check forleakages.

ELECTRIC FAN CONTROL THERMAL CONTACT

R E M O - V A L A N DI N S T A L L A T I O N

1. Drain coolant.2. Disconnect thermal contact ca-bles.3. Unscrew thermal contact fromradiator.4. Instal lat ion is carr ied out inreverse order of removal.5. At the end of installationprocedure, f i l l t h e c i r c u i t w i t hcoolant and let the engine rotates

until coolant reaches the temperatureof 88 + 92°C (190.4 + 197.6”F) andverify that electric fan inserts.

C H E C K S A N DI N S P E C T I O N S

Check thermal contact according tothe following procedure:1. Fit thermal contact @ to thetest equipment used for thermostattest.2. Fill container with coolant andswitch on equipment to heat water.3. When warning light 0 illumi-nates, verify that temperature shownon thermometer dial indicator corre-sponds to the thermal contact settingvalue 88 + 92°C (190.4+ 197.6”F).

1 Warning light 2 Thermal contact

HEADER TANK PRESSURIZED PLUG

L E A K T E S T

1. Screw fitting @ to test equip-ment and insert on header tankpressurited plug.2. Act on tool to increase pressureand check on dial indicator thatblowoff valve opens at the requiredsetting pressure.

Pressurited plug setting pressure69.6 kPa; (0.69 bar;

0.7 kg/cm’ ; 9.95 psi) 1 Pipe fitting 2 Pressurized plug

M a y 1 9 8 3 07-6



INSPECTION ANDADJUSTMENT

BELT TENSIONING

Load to be applied: 78.4

(817.64

Resultant arrow105.6

THERMOSTAT

TEMPERATURE

Nkglb)

mmin)

- Start of opening 84 + 88°C(183.2 + 190.4”F)

- End of opening 986(2084°F)

- Bulb travel >7(> 0.28 :;

RADIATOR

Radiator leak controlpressure 1 0 7 . 9 kPa

(1.0 bar;1 .I kg/cm2;15.64 psi)

PRESSURIZED PLUG

Pressurized @lug settingpressure 68.6 kPa

( 0 . 6 9 b a r ;0 . 7 kg/cm’;9.95 Psi)

ELECTRIC FAN

Electric fan interventiontemperature 88 - 92°C

(190.4+ 197.6”F)

GENERALSPECIFICATIONS

COOLANT

Summer

Water I 7.3

Imp. Gall 1.61

Winter

Min. tempera-

tu re T - 1 0 - 2 0

OF (14) i-4)

Antifreeze cat.

3 6 6 1 - 6 9 9 5 6 I 1.8 2.6

(Imp. gall) (0.391 (0.57:

Water I 5.5 4.7

(Imp. gall) (I .2) (I .03

Antifreeze ready

for use cat.

3 6 8 1 - 6 9 9 5 8 I - 7.3

(Imp. gall) - (1.61

- 3 5

1-31 I

3.65

10.80)

3.65

IO.801

CAUTION:Produit harmful to the paint. Avoidcontact with painted parts.

COOLING SYSTEM SCALESREMOVER

NALCO: 1006INTERPOIND: Jal Auto Cat.3681-69955

SEALING AND FIXING COMPOUNDS

Application TYW Denomination Q.W

Sealing compound for cooling &tern Sealing powder AREXONS Cat. 3522-00101 7.3 g

0.20 (az)

ALUMASEAL can be used as an alternative.

Of-7 May 1983

ENGINE -COOLING SYSTEM

TIGHTENING TORQUES

ft*lb

Cooling.temperature transmitter on feeding manifold 33441 3.4 f 4.2 24.58 + 30.37

Water pump securing Screws 19 +24 1.9 + 2.4 13.74 + 17.35


Condition

Water leakage

Poor circulation

Corrosion and scales

Overheating

Probable cause

b Radiator damaged

m Leaks in system couplings

I Loose or broken clamps

I Leakages from thermostat

0 Damaged cylinder head gasket

* Loose cylinder head tighteningscrews

l Pipes obstructed

l Insufficient coolant

l inoperative water pump

l Water pump and alternator drivingbelt loosen

l Inoperative thermostat’

l Dirty and scaled radiator

l Ignition out-of-phase

l Poor lubrication

l Faulty water pump


May 1983 07-8

Corrective action

Repair or replace

Repair

Tighten or replace

Replace gasket or thermostat

Replace. Check engine oil for contami-nation

Restore correct tightening

Check pipes and clean system

Top up

Replace

Adjust

Periodically change coolant at intervalsrecommended.Follow instructions for use shown onpackaging.

Replace

Clean pipes flushing with the specifieddescaling compound. Follow instructionsfor use shown on packaging.

Retime

Restore oil level

Replace

Restore coolant level and check systemfor leaks

CLUTCH

DESCRIPTION

This is a hydraulic controlled, dry,singledisc clutch provided with athrust bearing @ which is alwaysin contact with pressure platespring @ . Diaphragm spring @pressure engaged driven plate. Dis-engagement is obtained by a ped-

al @, operated through a mastercyl inder 7 which transmits fluid0

moves thrust bearing (self centering)and wins diaphragm spring action.

pressure increase to operating cylin- By means of gaskets performing onder @ piston. cylinder, piston takes up possibleThe latter operates on the with- slacks and therefore driven platedrawal lever @ by a push rod @, wear recovery is automatic.

(1.5 + 1.910.8 4 13.7)

(!$I15 + 23(1.5 + 2.410.8 + 17.41

1 Clutch disc2 Bleeder screw3 Operating cylinder4 Control push rod5 Flexible hose6 Brake and clutch hydraulic system reservoirJ Clutch master cylinder8 Pedal9 Clutch withdrawal lever

10 Diaphragm spring11 Direct drive shaft12 Thrust bearing support13 Self centering thrust bearing14 Clutch cover15 Pressure plate16 Flywheel17 Bush

May i983 12-2

CLUTCH

HYDRAULIC CONTROL UNIT

CLUTCH PEDALREMOVAL

1. Operating from the interiorcompartment, remove stopperring @, and remove pin @ discon-necting pedal @ Tram master cyl-inder control fork 0 and returnspring.

1 Fork2 Pin

3 Pedal4 Stopper ring

2. Operating from the engine room,remove pedal pin stopper spring @and relev’ant washer. Unscrewscrew @ securing the bracket @for sheath stopper of acceleratorcontrol cable, in order to be able towi thdraw peda l p in enough torecuperate the clutch pedal from theinterior compartment.

1 Stopper spring 3 Screw2 Bracket

3. Remove the two plastic bushesfrom pedal.

CHECKS AND INSPECTIONS DISASSEMBLY

1. Inspect pedal and pedal pad fordeformation or damage.2. Inspect bushes of clutch pedal,pin and spacer for excessive wear orseizing.3. Inspect return spring for fatigueor damage.

1. Remove boot @, remove stop-per ring 0, then remove push rodwith fork 0, gaskets @ and 0,p i s t o n @, washer andspring @ .

@

2. Reniove c o n n e c t i o n 0 andgasket @ .

INSTALLATION

Install clutch pedal on car in reverseorder of removal and apply grease tobushes of clutch pedal and to mastercylinder fork connection pin (AGIPFl Grease 15).

CLUTCH MASTERCYLINDERREMOVAL

1. R e m o v e f i l l e r p l u g 0 o nreservoir 0, relevant gasket andfilter then, with a syringe, drainenough fluid to make level fall belowconnection to master cylinder @.2. Disconnect SUPPlY flexiblehose @ from master cylinder.3. Loosen connection and discon-nect rigid pipe @ from mastercylinder.4. Operating from inside the car,remove stopper ring, remove pin anddisconnect cylinder control forkf rom peda l (see : C lu tch P e d a l -Removal).5. Unscrew screws 0 fixingmaster cylinder to pedal assy andthen remove master cylinder.

1 Plug 5 Connection2 Flexible pipe 6 Rigid pipe3 Screws 7 Reservoir4 Master cvlinder

1 Master cylinder 7 Fork2 Stopper ring 8 Washer3 Gasket 9 Spring4 Piston 10 Gasket5 Gasket 11 Connection6 Boot


CAUTION:To clean or wash all parts of mastercylinder, recommended clean brakefluid must be used. Never use mineraloils or gasoline and kerosene to avoiddamaging rubber parts.

1. Check cylinder bore and pistonfor score or rust and if found replace.2. Check cylinder bore and pistonfor wear. If the clearance betweencylinder bore and piston exceedsspecified value, replace pistonassembly or master cylinder as-

sembly.3. Check condition of boot andreplace it if damaged.4. Check all recesses, openings andinternal passages to ensure that theyare c lean and f ree f rom fore ignmatter.

12-3 May 1983

CLUTCH

ASSEMBLY

1. Lubricate sliding part surfaces.2. Install piston assembly to cylin-der body.3. Make sure that master cylinderoperates normally.4. Make sure that piston can movemaximum stroke smoothly.

INSTALLATION

1. Install clutch master cylinder inreserve order of disassembly.2. Top up oil to correct level inreservoir.3. Bleed air out of hydraulicsystem (Refer to: Hydraulic SystemBleeding).

@ : Tightening torqueClutch hydraulic piping con-nections

15+18 Narn(1.5 + 1.9 kg-m10.8 + 13.7 ft-lb)

CLUTCH OPERATINGCYLINDERREMOVAL

1. Remove operating cylinder con-trol hose, then remove clutch operat-ing cylinder lock ring @ from itsseat on engine back cover 0.2. Remove operating cylinder.

1 Lock ring2 Clutch operating cylinder3 Back cover

DISASSEMBLY1. Remove push rod @ withb o o t 0, piston @) and p is tonspringder 0.

@ from operating cylin-

2. Remove push rod from boot.3 . Remove b leeder sc rew 0.

Push rodBootGasketSpringRing


Visually inspect all disassembled

6 Cylinder body7 Bleeder screw8 Gasket9 Piston

parts and replace parts which areworn or damaged.

CAUTION:To clean or wash all parts of operat-ing cylinder, recommended cleanbrake fluid must be used. Neveruse mineral oils or gasoline andkerosene. It will ruin the rubber partsof the hydraulic system.

1. Check cylinder bore and pistonfor score or rust.2. Check cyl inder wear, springefficiency and integrity of seal rings.3. Check whether bleeder hole isclean.

ASSEMBLYAssemble clutch operating cylinderin reverse order of disassembly.

INSTALLATIONAssemble clutch operating cylinderin its seat on engine back covertogether with retainer ring.

HYDRAULIC SYSTEMPIPINGCHECKS AND INSPECTIONS

Visually inspect clutch lines forevidence of its integrity. Replacedamaged parts. If leakage occurs atjoints due to loosening, retightenand if necessary replace damagedparts.

DISASSEMBLY

1. Remove filler plug on supplyreservoir, together with gasket andfilter, and by means of a syringedrain enough fluid to make level fallbelow connection to master cylinder.2. Remove flexible hose connectingreservoir and clutch master cylinderand remove pipe.3. Loosen the rigid and flexiblepipes connections, connecting mastercylinder and clutch operating cylin-der and remove pipes.

INSTALLATION

1. Install clutch line in the reverseorder of disassembly.2. Top up oil in reservoir to correctlevel.3. Bleed air out of hydraulicsystem. (Refer to: Hydraulic SystemBleeding).

HYDRAULIC SYSTEMBLEEDINGThe clutch and brake hydraul icsystem must be bled wheneverhydraulic system has been discon-nected or air has entered it.Refer to figure on page 12-2 (see:Description) and observe the follow-ing procedure.

CAUTION:a. Do not re-use brake fluid

drained during bleeding oper-ation.

b. Exercise care to prevent splash-ing of brake fluid on paintedareas as i t wi l l damage thepaint.

c. During bleeding operation fluidlevel in reservoir must be keptabove min. mark.

1. Remove clutch and brake hy-draulic system reservoir plug and topup with recommended brake fluid(ATE “S” or AGIP Fl B r a k e

Fluid Super HD corresponding toAlfa Romeo Part No. 3681.69905).2 . Remove b leeder sc rew pro -tection b o o t @ o n O p e r a t i n gcylinder 0; install a hose on same

May 1983 12-4

* CLUTCH

’ & 1 LA.2.0378A.4.0144 A

1 Flywheel 32 Cover fixing screws

6. Remove coverdisc 0.

Clutch cover

@ and clutch

1 Clutch disc 2 Clutch cover


Wash all disassembled parts exceptclutch with suitable cleaning solventto remove dirt and grease beforemaking inspection and adjustment.

Clutch cover

Check pressure plate working sur-face @ for overheating marks,uneven wear, scoring and materialremoval.Replace clutch cover if necessary.

1 Clutch cover2 Pressure plate working surface3 Diaphragm spring

FlywheelCheck flywheel friction surface @for overheating, uneven wear, scor-ing, or removal of material. If neces-sary, disassemble flywheel ‘and grindboth working surfacecover support plane.

and clutch

Grinding limit value0.2 mm (0.01

on planesin)

1 Engine flywheel2 Pressure plare support plane3 Working surface

Clutch disc

Inspect clutch disc for burn or oilyfacings, loose rivets and brokentorsional springs.1. In case of clutch abnormalitiesdue to oil leakage at crankshaft ordirect drive shaft oil seal, replaceboth clutch disc and seals.

2. Check with a sliding gauge @for even wear of both facings andwhether clutch disc thickness is notnear to specified limit. Replacedisc if necessary.

Wear limit for disc thickness6.5 mm (0.26 in)

1 Sliding gauge

3. Check fit of clutch disc hub @on direct drive shaft @ for smoothsliding or excessive backlash. Ifnecessary replace clutch disc.

1 Clutch disc 3 Clutch disc hub2 Direct drive shaft

INSTALLATION

1. If the two oil seals on crankshaftand on direct drive shaft have beenremoved when clutch unit wasdisassembled, instal l two new oilseals (Refer to: Group 01 EngineAssembly - Crankshaft and Group 135Speed Manual Gearbox Shaftsand Gears).2. Install flywheel if removed indisassembling clutch unit (Refer to:Group 01 - Engine Assembly).Be sure to keep clutch disc, flywheeland pressure plate facings clean anddry.3. Set clutch disc and clutch coveron flywheel.

M a y 1 9 8 3 12-6

CLUTCH

SERVICE DATA AND SPECIFICATIONSGENERAL SPECIFICATIONSFLUIDS AND LUBRICANTS

1 Thrust bearing 2 Bush

Application

Thrust bearing working seat @

End crankshaft bush @

Clutch pedal-cylinder control fork

connection pin

Clutch pedal hub

Clutch hydraulic system supply

TVP~

GREASE

GREASE

GREASE

FLUID

Denomination

- AGIP Fl Grease 33 FD

Std. N . 367 I-69833134

- IP Autogrease FD

Std. N . 367 I-69833134

- ISECO Molykote BR2

Std. N. 3671-69841

ISECO Molykote Paste G

Std. N. 3671-69840

AGIP Fl Grease 15

Std. N. 3671-69810

- ATE “S” - Std. N. 3681-69905

- AGIP Fl Brake Fluid Super HD

Std. N. 3681-69905

- IP Auto Fluid FR

Std. N. 3681-69905

-

-

INSPECTIONS AND ADJUSTMENTS

FLYWHEEL AND CLUTCH COVER

Grinding limit values on working surfaces . . . . . . . . . . . . . . . . . . . . . _ . . . . . _ . , . . . _ . . _ _ . . 0.2 mm (0.01 in)

CLUTCH DISC

Disc thickness atwear limit . . . . _ _ _ . _ . . . . . . . . _ . . . . _ . . . . . . _ . . . _ . . . . . . . . . . . . _ 6.5 mm (0.26 in)

May 1983 1 2 - 8

COMPLETE CAR


Spark is good:

a. Check spark plugb. Check ignition timingC. Check fuel systemd. Check cylinder compression

Spark is not good:

Ignition system is out of order

Fuel system is out of order l Lack of fuel

Low compression

l Low or no current in primarycircuit

l Rotor arm current leakage

l Faulty spark plugs

l Improper ignition timing

l Faulty ignition coil

l Cut-off in high voltage cable

l Loose connection or cut-offin primary circuit

l Dirty fuel filter

l Dirty or clogged fuel pipes

l Faulty fuel pump

l Faulty carburetor choke

l Incorrect float level adjustment

l Improper idling

l Dirty or clogged carburetor jets

l Clogged fuel tank breather pipe

l Incorrect spark plug tightening

l Incorrect valve clearance

l Compression leaks from valveseats

l Seized valve stem

Check primary circuit for loose ordisconnected terminals

Verify that the electronic ignition unitis properly functioning

Clean or replace

Clean, adjust electrode gap or replace

Adjust

Replace

Replace

Repair or replace

Refuel

Clean

Clean

Replace

Check and adjust

Adjust

Adjust

Disassemble and clean

Repair and clean

Tighten to normal

Adjust

Remove cylinder head and lap valves

Replace valve and valve guide

00-33 May 1983

COMPLETE CAR

Condition

High engine idling

Probable cause

l Stiff accelerator cable andlinkage

l Incorrect idle adjustment

l Malfunctioning throttle valve

ENGINE POWER NOT UP TO NORMAL

Low compression Previously mentioned

Ignition system out of order

Fuel system out of order

Other

Air intake system out oforder

Overheating

Overcooling

l Incorrect ignition timing Adjust

l Dirty or worn spark plugs Clean or replace

l Incorrect advance Adjust

Previously mentioned

b Faulty fuel pump

I Clogged fuel pipes

Replace

Clean

l Clogged air cleaner

l Air sucking around manifold

Replace cartridge

Replace gasketgasket or carburetor gasket


l Broken water pump drive belt

l Faulty thermostat

l Faulty water pump

l . Clogged or leaky radiator

l Faulty electric fan

l Faulty thermal switch

l Air in cooling system

l Clogged jets (lean mixture)

l Incorrect ignition timing

Replenish

Replace

Replace

Replace

Clean, repair or replace

Replace

Replace

Restore proper cooling systemtightness

Overhaul carburetor

Adjust

l Faulty thermostat

l Faulty thermal switch

Replace

Replace

00-35 May 1983

Corrective action

Check

Adjust

Check


COMPLETE CAR

Condition

Other

NOISY ENGINE (while driving)

Engine knocking

-

Mechanical knocking

Crankshaft bearings knocking

Connecting rod bearingsknocking

Noisy pistons

Noisy water pump

Probable cause

Petrol used has low octane rating

Dragging brakes

1 Slipping clutch

b Overloaded engine

I Knocking due to carbon deposit

I Knocking due to incorrectignition timing

m Knocking due to improper petrol

. Preignition (due to wrong typespark plugs)

l Worn crankshaft bearings

This strong dull noise increases asengine is accelerated

l Worn connecting rod bearings

This is a slightly higher-pitchednoise than the one caused by knock-ing of crankshaft bearings and italso increases as engine is acceler-ated

l Pistons and/or cylinder linersare w( 2-r

This is a diffused metallic noisewhich increases as rpm increaseand decreases when engine is warm

l Play in rotor

l Improper adjustment of valveclearance

l Excessive crankshaft end play

Corrective action

Replace with petrol having specifiedoctane rating

Adjust

Adjust or replace

Use proper gear in driving

Disassemble cylinder head and removecarbon deposit

Adjust ignition timin,g

Use petrol having specified octane rating

Replace with specified type spark plugs

Replace bearings and either grind orreplace crankshaft. Check lubricationsystem

Same as for above crankshaft bearings

Overhaul the engine

Replace water pump

Adjust

Replace crankshaft axial bearings

May 1983 0 0 - 3 6

COMPLETE CAR

Condition

ABNORMAL COMBUSTION(backfire, self-ignition,detonations)

Probable cause

Incorrect ignition l Incorrect ignition timing

l Wrong type spark plugs

Fuel system out of order

Faulty cylinder heads


l Incorrect valve clearance

l Excessive carbon deposit incombustion chambers

l Damaged valve springs (backfiredetonations)

EXCESSIVE OIL CONSUMPTION

Oil leaks

Excessive oil consumption

Other

l Loose oil drain plug

l Loose oil pan screws

l Worn or damaged oil pan gasket

l Worn or damaged cylinder blockand cylinder head gaskets and oilseal rings

l Loose oil filter

l Loose oil pressure switch

l Dipstick does not fit tightly

l Worn cylinders and pistons

l Improperly assembled pistonrings

l Worn piston rings

l Worn piston rings and pistonring seats

l Worn valve guides and grommets

l Worn valve sEems

l Improper oil grade Replace with specified oil type

l Engine overheats Previously mentioned

Corrective action

Adjust timing

Replace with recommended type plugs


Adjust

Desassemble cylinder heads and removecarbon deposit

Replace

Tighten it

Tighten or replace

Replace gasket

Replace gaskets and oil seal rings

Tighten or replace, if necessary

Tighten

Replace dipstick

Grind cylinders and replace pistons

Assemble properly

Replace piston rings or, if required,grind cylinders and replace pistons

Replace pistons and rings

Replace valve guides and grommets

Replace valves

-

00-37 May 1983

COMPLETE CAR


EXCESSIVE FUEL CONSUMPTION

Engine power not up tonormal

Other

OTHER PROBLEMS

Reduced oil pressure

Excessive wear of slidingparts

Seizing of sliding parts

Previously mentioned Previously mentioned

l Idling too high

l Improper accelerator recovery

l Fuel leaks

l Clogged air cleaner

l Improperly adjusted carburetor

l Worn or damaged carburetorgaskets

Adjust idling

Adjust

Repair or tighten fuel line unions

Replace cartridge

Adjust

Replace gaskets

l Improper oil grade

l Oil is missing

l Overheating

0 Worn oil pump control valve

l Worn oil pump

l Excessive play o f sliding parts

l Clogged oil filter

l Faulty oil pressure switch

l Insufficient oil pressure

l Improper oil grade or contami-nated oil

l Faulty air cleaner

l Overheating or overcooling

l Insufficient oil pressure

l Insufficient clearances

l Overheating

Corrective action

Replace with specified oil type

Replenish with specified oil type


Disassemble oil pump, repair orreplace it

Repair or replace

Disassemble and replace worn parts

Replace cartridge

Replace


Replace with specified type oil andreplace cartridge

Replace cartridge



Adjust to specified values


COMPLETE CAR

CHASSIS

CHECKING FUELAND EXHAUSTSYSTEM

1. Check fuel and exhaust systems,especially at connections, makingsure there are no leaks.2. Check condition of all fuel andexhaust pipes replacing same ifrequired.3. Tighten all loose connections.

AND BODY MAINTENANCE

CLUTCHCHECKING CLUTCH SYSTEM

Check clutch pump @ and clutchcontrol cylinder @ making sure

there are not oil leaks. If required,tighten unions according to specifiedtorques or either overhaul or replacefaulty parts (Refer to: Group 12 -Tightening Torques).Make sure that clutch pump a n dcontrol cylinder boots are not in anyway damaged.

1 Oil supply plug 2 Oil drain plug

1 Clutch pump2 Clutch control cylinder

GEARBOX-DIFFERENTIAL

CHECKINGGEARBOX-D1 FFERENTIALOIL LEVEL

Check oil level making sure it reachesfiller lower edge; clean relevant capand tighten it.

REPLACINGGEARBOX-DIFFERENTIALOIL

1. While engine is warm, remove oilpan drain @ and supply 0 plugs.

2. Let oil drain completely (wait atleast 15 minutes); clean drainplug @ and tighten it.3 . Ref i l l o i l pan through SUPPIYhole 0 with specified oil type andquantity. Refer to “LUBRICANTS”chart for recommended oil type.

Gearbox-Differential casing Oil

wpacity2.3 + 2.4 kg (5.07 + 5.29 lb)

ASSEMBLYDRIVE SHAFT

CHECKING DRIVE SHAFTASSEMBLYVisually check drive shaft assemblyfor wear or deformation of i tsvarious components, making sureprotecting boots are not in any waydamaged or show grease leakage.If necessary, replace damaged or

worn parts.

FRONT AXLE ANDFRONT SUSPENSION

CHECKING FRONT AXLEAND SUSPENSION

1. Block rear wheels with chocksand raise front of vehicle fitting jackto proper lifting points (Refer to:“Lifting Points and Towing”).2. Check front suspension parts forwear or damage.Also check al l bolts for propertightening; refer to: Group 21 -Tightening Torques - for relevanttightening torques.Replace worn parts according torelevant procedures described inG r o u p 2 1 Front Suspension.

00-39 May 1983

COMPLETE CAR

3. Check shock absorbers for oilleaks or damage.4 . Remove wheels.5 . Check b rake pads fo r wear(Refer to: Group 22 - Front DiscBrake).

REAR AXLE ANDREAR SUSPENSION

CHECKING R E A R A X L EAND SUSPENSION PARTS

1. Check rear axle and suspensionfor loose, worn or damaged parts.2. With vehicle in nominal drivingcondition, i.e. with static load (Referto: Checking Suspension Heights),tighten loose bolts according tospecified tightening torque. Refer to:Group 25 Service Data and Specifi-cations for relevant tighteningtorques.3. Replace worn parts according tothe relevant procedures described inGroup 25.

M a y 1 9 8 3

ADJUSTING WHEELBEARING PRELOAD

After replacement or disassembly ofbearings, carry out adjustment oper-ating as follows.

For wheel bearing replacement referto Group 25.

1. Tighten wheel bearing lock-nutaccording to specified torque and atthe same time turn hub 4 + 5 timesin both directions to allow bearingsto settle.

@ : Tightening torqueWheel bearing lock-nut

25 + 29 N-m(2.5 + 3 k g - m1 8 . 0 8 + 2 1 . 6 9 &lb)

2. Partially unscrew lock-nut a n dhit the hub with a mallet to ensureouter bearing settling against washerand.nut.

3. t-land tighten the nut (moder-ately, so as to obtain a lesst h a n 1 N.m; 0.1 kg.m; 0 . 7 2 ftalb -torque).4. Check and make sure axial playis within specified value.

Bearing axial play0 + 0.05 mm (0 + 0.002 in)

5. Caulk nut taking care to avoidrotation in order not to alter clear-ance play.

Apply specified grease quantity tobearings in the suspension.

CHECKINGSUSPENSIONHEIGHTSBe sure to perform following prelim-inary operations:a. Set up vehicle with al l ref i l l

liquids at max. level and withspare wheel.

b. Check tire pressure; refer to“Wheels and Tires” for specifiedvalues.

c. Place car on lift.d. Load weights on vehicle as

shown in below figure.e. Move vehicle up and down on

suspensions a few times.

Static load equivalent to threepassengers plus luggagePassenger equivalent to

A i- 6 = 490 + 245 = 735 N(50 + 25 = 75 k g )

(110 +55= 165 lb)

Luggage C = 490 N (50 kg; 1 IO lb)

00-40

COMPLETE CAR

FRONT SUSPENSIONHEIGHT

Check front wheel alignment pickingup specified “K’ dimension which isobtained by drawing two l inesparallel to floor plane respectivelypassing through below definedpoints 1 and 2.

Point 1:it is the intersection between the

plane passing on the base of the nutconnecting hub support to controlarm, and the straight line tangent tothe hub support.Point 2:axis of the bolt securing control armto chassis.

Front wheel alignment dimensionA=12+7mm( 0 . 4 7 4 0 . 2 8 i n )

‘fi”dimension must be picked up forb o t h f r o n t r i g h t a n d f r o n t l e f tsuspensions.

DIMENSION MEASUREMENT

1 . C a r r y out measurement ofdimension relevant to step 1. makinguse of the fol lowing tools and

setting the graded movable stem ofcheck tool to the complete backwardposition (see following figure).(I) Rule @ A-4.0146.(2) T o o l for suspension heightcheck@ A.4.0149.(3) Probe 0 A-4.0150.

1 Probe2 Height check tool3 R u l e

2 . C a r r y o u t m e a s u r e m e n t o fdimension relevant to step 2. makinguse o f the fo l low ing tools a n dmoving only graded stem of checktool.

(1) Rule @ A.4.0146.(2) T o o l for suspension heightcheck@ A.4.0149.(3) Magnetic adapter @ A.4.0153.

1 Magnetic adapter2 Tool for suspension height check3 Rule ’

3. Directly read on graded scale(located on movable stem of checktool) rhe”&‘height dimension value.

REAR SUSPENSION HEIGHT

(1) Check rear wheel alignment‘bymeasuring specified ” B” dimensionwhich is the distance between thetwo lines parallel to floor plane andpassing through below definedpoints 1 and 2.

00-41 M a y 1 9 8 3

COMPLETE CAR

Point 1:Axis of bolt @ securing front rodto wheel support.Point 2:Axis of bolt @ securing front rodto body.

Car rear suspension height dimensionB = 23 * 7 mm (0.90 f 0.27 in)

Measurement of “B”dimension mustbe carried out both for right tie rodand for left tie rod of rear suspen-sion.

DIMENSION MEASUREMENT

1. Carry out measurement ofdimension relevant to point 1 and 2making use of the following tools.(1) Rule @ A.4.0146.(2) Tool for suspension heightscheck @ A.4.0149.(3) Magnetic adapter @ A.4.0206.

M a y 1 9 8 3

1 Magnetic adapter 3 Rule2 Check tool

Proceed as follows to carry outdimension measurement relevant topoint 1; set graded movable stem ofcheck tool to the completely back-ward position, then measure dimen-sion relevant to point 2. by movingonly graded stem of tool.

2. Directly read on graded scale(located on movable stem of checktool) the value of”B”height dimen-sion.In case the read values differ fromthe prescribed ones, replace springs.

WHEEL ALIGNMENT

CHECKING FRONT WHEELALIGNMENT

Be sure to perform following prelim-inary operations prior to checkingand, if necessary, adjust front wheelangles.a. Check tire pressure; refer to

Group 28 - Checking TireC o n d i t i o n s .

b. Set up vehicle with static load.c. Pick up front wheel alignment’&”

dimension as well as rear wheelalignment “B” dimension (Referto: Checking SuspensionHeights).

1. Toe-out

On aligned wheels, verify thatsteering wheel racks are properlycentred. If necessary, withdraw

0 0 - 4 2

steering wheel and centre racks.(1) Use suitable equipment andmeasure toe-out making sure it iswithin specified value.

Toe-outH - M = +4flmm(+0.157 f 0.04 in)

Front toe-out anglea= IO’

Wheel rim diameter0 = 340 mm (13 in)

(2) If necessary, adjust toe-out asfollows:- Loosen side rod lock-nut- BY means of tool A-3.0156

disconnect vertical steering leverball joint (Refer to: Group21 - Coil Springs and Shockabsorbers).

- Suitably turn ball joint stillspecified toe-out is achieved.

Min. possible toe-out adjustment is42 mm (0;08 in) on H - M difference(variation corresponds to 1 turn- 1 mm (0,039 in) thread lead - ofone ball joint) meaning that semitoe-out value is equal to:

L = (l/2 M + 2 f 0,5) mm(l/2 M + 0.08 f 0,020 in)

Orientate joint body @ locatedon side rod @ so that, afterbeing connected to steeringlever 48 , the joint’s upperlevel 1 is parallel to the lever’supper level 0.Tighten lock-nut @ and thentighten to specified torque thenuts securing ball joint tosteering lever.

COMPLETE CAR

@ : Tightening torqueNut securing side rod ball jointonto vertical steering lever

39+448 N-m( 4 + 4.9 kgdm2 8 . 9 2 + 3 5 . 4 3 ft.lb)

1 Joint’s upper level2 Joint body3 Steering lever’s upper level4 Steering lever5 Side rod6 Lock nut

(3)

2.

Recheck toe-out value.

Camber angle0 = 2015’ + 30’

3. Caster angley= 1”$30’

Camber and caster angles cannot beadjusted.

4. Max steering angles = 3 3 ” 3 0 ’

CHECKING REAR- WHEELALIGNMENT

Rear angles cannot be adjusted.

Toe- in anglea= O”1 2 5 ’

/+ I- _a 1 a

-4&’ I I

Camber anglep=O”125’

BRAKE SYSTEMCHECKING BRAKE FLUIDLEVEL

Check and make sure fluid level inreservoir is not more than l/4 belowmax. level. If fluid level is extremelylow, check brake system for leaks.

CHANGING BRAKE FLUID

1. Connect a hose to wheelbleeders and let brake fluid draininto a suitable container (referto: Group 22).

CAUTION:Be extremely careful not to drop anyof the brake fluid on painted s’urfacessince it is highly corrosive.

2. Refill system with new oil andbleed all air from the system (referto: Group 22 - Brake System Bleed-ing).

0 0 - 4 3 M a y 1 9 8 3

COMPLETE CAR

3 . I f r e q u i r e d , carry out traveladjustment by operating on nut andlock nut of adjustment fork locatedunder passenger compartment centralconsole.

4. Besides, verify the following:(1) With control lever in the testposition also jaws must be at t-est.(2) When operating control lever,tables must slide freely.(3) Indicator lamp must switch onwithin one click of parking brakecontrol lever and switch off as soonas control lever is at rest position.

(4) Maneuverability of control levermust result to be easy and smoothrunning and when control lever isengaged hooking tooth must be intoits seat in the scroll gear withoutdifficulty.

STEERING SYSTEM1. Check steering for sticking orstiffness when turning wheels in bathdirections,

2. Rotate steering wheel clockwiseand anticlockwise checking steerings y s t e m f o r e x c e s s i v e play. F o rrelevant adjustment r e f e r t o :Group 23 - Checks and Inspections -Rack Box and Guide Tube.3 . T ighten, where required, allsteering system connecting points.(Refer to: Group 23 - T ighteningtorques).4. Check condition of steering boxprotecting boots and replace them ifnecessary.5 . C h e c k s t e e r i n g r o d bal1 a n dflexible joints; replace them if worn.

B O D YLOCKS AND HINGES

1. Lubricate hinges and locks.2. Adjust lock striker plates.

CHECKING SEAT BELTS

CAUTION:. If seat belts have to be washed,

do not use chemical detergentso r solvents since t h e y coulddamage the buckles.

. After a serious accident involv-ing belt stress, replace same evenif apparently it does not seem tobe damaged.

1. Check anchors making sure theyare not loose on mountings.2. Check belts for wear.3. Check proper working conditionof buckles and tongues,4. Fasten seat belts and check if incase of sudden movement they arepromptly locked. Contrarywise,check retractors’ locking system.

If condition of any seat belt compo-nent is questionable, replace theentire belt assembly involved.


E N G I N E M A I N T E N A N C ETECHNICAL DATA - INSPECTION AND ADJUSTMENT

Engine

1200

Engines

I 1 3 5 0 1 5 0 0

Valve clearance (cold engine)

I n t a k e m m (in)

Exhaust m m (in)

Alternator-pump belt tension

Force applied to belt N (kg, lb)Deflection mm (in)

Cylinder compression

Min compression pressure kPa (bar , p.s.i. , kg/cm2)

Max compression differencebetween cylinders kPa (bar, p.s.i., kg/cm2)

0.35GO.40 (0.014+0.016)

0 . 4 5 t 0 . 5 0 (0.018+0.020)

7 9 (8 ;3.63)

15 (0.59)

1 0 3 0 (10.30,149.39;10.5)

9 8 ( 0 . 9 8 ; 14.22 ; 1)

00-45 May 1 9 8 3

COMPLETE CAR

CHASSIS AND BODY MAINTENANCE

TECHNICAL DATA - INSPECTION AND ADJUSTMENT

Axles and suspensions

Vehicle static loading arrangement (1) N kg, lb)

Front wheel alignment

Rear wheel alignment

Front wheel toe-out (2) (3)

Fronr wheel semi toc-out (21 (3)

Front toe-out angle

Wheel rim diameter

Rear wheel toe-in

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

A =12 f7 (0.47 iO.28)

8 =23+7 (0.90*0,27)

M - H =4*1 (0 .157 f0 .04 )

L = (1/2 M +2 * 0.5) (l/Z M +0.08 *O.OZ)

a=io’0 =340 (13.38)

a=oOk 25’

Front wheel camber (3) p=-2’15’&30’

Rear wheel camber p=0°&25’

Front wheel caster (3)

Max steering angle (3)

A+6 =490 -1-245 =735 (50+25 =75)

(110 +55 =165)

c = 490 (SOT; (110)

+y=1”430’

8 = 33” 30’

(1) Load vehicle, move it UP and down on suspensions a few times. Checking operations must be performed with vehicle fully set up

for driving.

(2) When turning a steering side rod joint by 360’. M - H dimension changes by 2 mm (0.079 in).

(3) These values are referred to a vehicle in nominal driving condition, i. e. with static load

Brake system

Disc brake

Disc min. thickness m m (in)

Pad min. thickness m m (in)

Drum brake

Lining min. thickness m m (in)

Max drum inner diameter m m (in)

Parking brake

Lever stroke, when applying a pulling force of

= 98 N Il0 kg) (22 lb)

9 (0.354)

7 (0.276)

0.5 (0.019)

229.6 (9.04)

2 notches

00-47 May 1983

CLUTCH

TIGHTENING TORQUES

Clutch caver to angine flywheel unit securingscrews

Gearbox unit to engine resr caver securingbons and nuts

Hvdraulic system pipe fitting securing nuts

N.m

15 + 23

39 + 47

15 + 18

kg*m

1.5 + 2.4

4 + 4.9

1.5 + 1.9

fz-lb

10.8 + 17.4

28.9 + 35.4

10.8 + 13.7

TROUBLE’ DIAGNOSIS AND CORRECTIONS

Condition

Clutch slip

Symptoms:

- Car Will not respond toengine speed during accel-eration

- lnsufficient car speed

- Lack of power during uphilldriving

- Increasing of fuel con-sumption

Clutch does not disengage well

Probable cause Corrective action

Some trouble symptoms may also be attributable to engine problems. Firstdetermine whether engine or clutch is causing the problem.

TO test for slipping proceed as follows:

- engage parking brake

- disengage clutch and shift gears into 4th

- increase engine speed and gradually release clutch pedal; if car does notmove and engine does not stop, clutch is slipping

l Clutch facing excessively worn

l Clutch facing wet with oil or grease

l Diaphragm spring weak or damaged

l Flywheel or pressure plate warped

l Impurities in master cylinder, pistondoes not return to start position

Replace clutch disc

Replace clutch disc (replace enginelgearbox oil seals) if faulty

Replace pressure plate

Repair per replace flywheel or clutchcaver

Clean cylinder or replace faulty parts

TO test for dragging clutch proceed as follows:

- disengage clutch and shift gears into Reverse

- shift gears into Neutral, then gradually increase engine speed

- after a short interval, shift gears into Reverse

If noise is heard while gears are being shifted, clutch is dragging

l Clutch disc hub splines or rusted Clean or replace clutch disc

12-Q May 1983

CLUTCH


l Flywheel and/or pressure plate Repair or replace flywheel and/or

faciw worn or warsed clutch caver

l Engine supports not efficient Inspect and/or replace engine supports

SPECIAL SERVICE TOOLS

Tool number Tool nameRefer to

page

A.2.0378 Tool for locking the flywheel

A.4.0144 Clutch disc aligning bar

12-l 1 May 1983

GEARBOX

CONTENTS

5 - SPEED MANUAL GEARBOX.. . . . 13-2

Description . . . . . . . . . . . . . . . . . . . 13-5Rear support . _ , . . . . . , . . . . . . . . . 13-5Rods and forks . . . . . . . . . . . . . . . . 13-6Shafts and gears . . . . _ . . . . . I . . . . . 13-10

Differential carriers . . . . . _ . , . . , . _ 13-19

Crown gear and pinion . . . . . . . . . . 13-22

Differential casing . . . . . _ . e . . _ . _ . 13-22Gearbox - differential casing . . . . . . 13-24

GEARBOX OUTER LINKAGE.. . . . . . 13-25Disassembly . . . . . . . . . . . . . . . . . . . . 13-25

Checks and inspections . _ . _ . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . .

SERVICE DATA AND

SPECIFICATIONS . . . . . . . . . . . . . . . .

Technical data . . . . . . . . . . . . . . . . .

General specifications . . . . . . . . . . .

Inspection and adjustment _ _ . _ _ _ _

Tightening torques . . . . . . . . . . . . .

TROUBLE DIAGNOSIS AND .

CORRECTIONS . _ , . _ . . . . _ . . . . _ _ . _

SPECIAL SERVICE TOOLS n. . . . . . . .

13-25

13-25

13-26

13-26

13-26

13-28

13-30

13-31

13-33

May 1983

GEARBOX

S-SPEED MANUAL GEARBOX

Gearbox-differentlsl unit and rear support

12345678910111213141516

b2113.74 + 17.36)

(4 + 4.928.92 + 35.43)

‘~19 + 24-.,Y . ,.C

(1.9 + 2.413.74 + 17.36)

Pin 17 Flexible bushGearbox casing 18 Oit seal ringBushing 19 BracketCentral support 20 BushingOil plug 21 Flexible supportSpeedometer sensor 22 Reverse gear switchSpring ring 23 GasketDowel 24 PlugRear caver 25 D r a i n plug

Valve 26 Oil sumpPIUJ 27 Gasket

Plate 28 Bushing

Pin 29Flexible support 3 0

Oil seal ringSupport

Rear support 31 Lock ring

@ N.m(kg-mft4b)

May 1 9 8 3 13-2

G EARBOX

S h a f t e , geara a n d differen~ial c a e i n g@ 220.5 + 245

(22.5 + 25162.70 + 180.771

QI 69 + 8 5(7 + a.750.61 + 62.91)

6 7 + 7 4(6.8 f 7.5

/49.17 + 54.23)

1 Direct drive shaft2 Spring3 Bushing4 P i n5 Bearing6 Reverse gear shaft7 Reverse gear8 Primary shaft9 longue

10 Bearing11 Lock ring12 5th speed driving gear13 Oil deflector

14 R.G. driven gear15 Bushing16 1 st speed driven gear17 Retainer18 Guide sector19 Locking sector20 Synchronizing ring21 Lock ring22 Sleeve23 HUb

24 Fietainer25 2nd speed drive gear26 Shouldered ring

27 3rd speed driven gear28 4th speed driven gear29 Shim30 Bearing31 5th speed driven gear32 Nut33 Bearing34 Shim35 Pinion36 Bearing37 Differential casing38 Bearing39 Crown gear

@ N+m(kg-mft4b)

13-3 May 1983

GEARBOX

Roda and forks

1 Lever2 Main selector rod3 Guide pin4 3rdAth speed rod5 Interlock plunger6 1 sr-2nd speed rod7 Interlock plunger8 Detent hall9 5th speed control fork

10 Ist-2nd speed lever

@ 25 + 2 6(2.5 - 2.7

11121314151617181920

Sth-speed R.G. rodPlugEallsR.G. forkBushing5th.speed - R.G. rod1st.2nd speed control fark3rd4th speed control forkSelector leverSpring pin

18.07 + 19.52)0T N*m

(kg-mftdb)

May 1 9 8 3 13-4

GEARBOX

DESCRIPTIONThe gearbox has five forward andone r e v e r s e gear. All g e a r s h a v esynchromesh except reverse gear.AII gears are in constant mesh andhave helical teeth. Reverse gear teethare straight tut. The gears are oper-ated by means of a floor-type gearlever connected to the selector shaftsb y means o f a remote l i n k a g e .Connection of rear support togearbox casing is obtained through acouple of elastic supports whichreduce to a minimum the trans-mission of vibrations to the speedcontrol lever.Differential and gearbox form asingle assembly. Crown gear-pinioncouple is of the hypoid type andhas a ratio of QI35 or 11139.

TRANSMISSION RATIOS

I Crown gear and

Gear Gearbox pinion ratio

ratio 9135 11139

Overall ratio

1” 1:3.750 1:14,580 lA3.293

2” 1: 2.050 1: 7.970 1: 7.267

3- I~I.387 1: 5.392 1: 4.916

4- 1: 1.027 2: 3.992 1: 3.640

5” 1: 0.825 1: 3.207 1: 2.924

RM 1:3.091 1:12.017 1:10.957

REMOVAL ANDINSTALLATION

Removal from vehicle

Should the whole dr ive uni t beremoved from the vehicle and thetwo units be thereafter separated,proceed as follows;1. Remove drive unit from vehicle(refer to: Group 01 - Drive UnitRemoval and Installation).2. Separate gearboxdifferentialunit from engine unit (refer to:Group OI - Separation and Assemblyof the Units).

Installation of vehicle

In case of assembly of groups andinstallation on vehicle proceed asfollows1. Assemble gearbox differentialuni t and engine uni t ( refer to .Group OI Separation and Assemblyof the Units).2. Assemble drive unit on vehicle(refer to. Group 01 Drive Unit -Removal and Installation).

REAR SUPPORTDISASSEMBLY

Set gearbox-differential unit on

3. After installing drive unit onvehicle fil1 up with prescribed oil( A G I P F I R o t r a M P S A E 8OWQOor IP Pontiax HD 8OWQO), oil shouldbe fed in slowly till the level reachesthe lower rim of filler hole, check foroil level and fit in plug.

suitable stand provided with bracketand proceed as follows:

1 . R e m o v e remote I inkage 1 re-taining clip @ from lever 38 andremove i-cd.Remove washers @ and bush 0.

1 Remote linkage 4 Washers2 Bush 5 Retaining clip3 Lever

2. Dissassemble gearbox outer link-age from rear support (see. GearboxOuter Linkage - Disassembly).3. Disconnect drive unit rear sup-port f rom f lexib le supports 0and @ which connect it to gearbox-differential casing @ by unscrewingthe two screws 3 .0

1 Upper flexible support2 Gearbox-differential casing3 Screws

4 Lower flexible support5 Rear support

13-S May 1983

GEARBOX

4. Remove pin @ inserted intoflexible support @ and remove theflexible support itself from rearsupport should its replacement berequired.

ASSEMBLY 3. Unscrew screw @ and remove1. Reassemble end flexible support plate @ securing oil bleeder valve

on rear support, the pair of flexible to gearbox casing caver and remove

supports on rear caver, then the rear valve plug @ and valve aitself.

support itself following the reverseorder for disassembly and using thesame tools previously used. .2. Reassemble the outer Iinkage ofgearbox on rear support (refer to:Gearbox Outer Linkage - Assembly).

RODS AND FORKS

1 Rear caver 3 Lower flexible2 Upper flexible support

support

1 Pin 2 Flexible supportDISASSEMBLY

5. Unscrew screws connecting flex-ible supports @ and @ to rearcaver of gearbox casing 0.Remove flexible supports.

1. Remove spring pin securing leverto main selector rod 0 and removelever.

1 Valve plug2 Screw.

3 Plate4 V a l v e

1 Main selector rod 2 Lever

4. Unscrew and remove screws @f i x i n g r e a r caver @ to g e a r b o xcasing @ . Use a plastic hammer foloosen caver and remove it togetherwith seal gasket @.

CAUTION: 2. Unscrew reverse gear lightûearbox casing is made of aluminium switch 0 and remove it togetheralloy. with relevant washer from rear cov-Handle with maximum tare to avoid er 2 .0damaging it.


1. Clean metal parts of rear supportwith solvent a n d check f o r i t s in-tegrity.2. Check amount of leverage articu-lation wear.3 . Check o n i n t e g r i t y o f r u b b e rbushings, and replace worn ordamaged ones.

1 Switch 2. Rear caver

1 Screws2 Rear caver

3 Gearbox casing4 Seal gasket

May 1983 1 3 - 6

GEARBOX

5. Remove main selector rod 2seal r i n g @ f r o m r e a r caver 18S h o u l d removal of seal r i n g t a k eplace while gearbox is fully assem-bled (on stand or vehicle), specialtool A.3.0429 must be used.

A.3.Q42g7r-i-l

1 R e a r caver 3 Seal r ing2 Main selector rod

5. Remove guide pin @ for mainselector rod @ return spring 1

87. Unscrew and remove screws 4with relevant fixing washers from oilsump; remove oil sump @ togetherwith relevanr gasket.

1 Return spring 4 Sci-ews2 Guide pin 5 Oil sump3 Main selector rod

8. Unscrew screw 0 securing 1stand 2nd sseed control fork 13) o nr e l e v a n t r o d @ a n d serez 6securing 1st and 2nd speed lever 5 .- 8R e m o v e l e v e r @ f r o m g e a r b o xcasing. Loose and remove screw 30f ix ing 3rd and 4th speed contro lfork @ on relevant rod.

1 Screw2 1st and 2nd speed rod3 Screw4 3rd and 4th speed control fork5 1st and 2nd speed lever6 Screw7 1st and 2nd speed control fork

9. Use tool A.3.0322 to remove thefollowing spring pins:- Pin @ securing reverse gear and

5th speed lever on rod @securing safety lever on

securing selector leveron rod 0.

1 Speed selector lever pin2 Main selector rod3 Reverse gear and 5th speed lever pin4 Reverse gear and 5th speed rod5 Safety lever pin

10. Remove main selector rod 4

and recover selector 0, spring 8 3

and lever 0.

1 Selector 3 Spring2 Lever 4 Main selector rod

11. Engage 5th speed and remove5th speed and reverse gear rod @lock r i n g @ place on centralsupport 0.Unscrew and remove the two hallssecuring plug @ then remove thehalls themselves.

1 Central support 4 5th speed and2 Lock r ing reverse gear rod3 Securing plug

13-7 May 1983

GEARBOX

12. Remove 5th speed and reversegear rod @ together with 5th speedcontrol fork @ and sleeve 0.

1 5rh speed and 3 5th speed controlreverse gear rod fork

2 Sleeve

13. Use a driftpin @ to remove 3rdand 4th speed rod 2 and recoverits relevant fork 8 1 from syn-chronizer sleeve. Proceed as abovefor removal of 1st and 2nd speedr o d @ t o g e t h e r w i t h f o r k @.

1 3rd and 4th speed control fork2 3rd and 4th speed rod3 Driftpin4 1st and 2nd speed control fork5 1st and 2nd speed rod

The withdrawal 3rd and 4th speedrods and 1st and 2nd speed rodsproceeds, as the millings appear,respectively circular and rectangularshaped, in correspondence with therear support of the gearbox, it isn e c e s s a r y t o rotate the rods toprevent the halls from getting in-serted into the millings themselves,preventing thus the withdrawal frombeing completed.

14. Remove the following compo-nents from the seats on the rearsupport of gearbox casing:- The three detent halls @ from

the three rods- The two interlock plungers 38a f t e r u n s c r e w i n g s c r e w 4

which give access to a channelw h i c h cari b e inspected b y ascrewdriver able to move theinterlock plungers considered.

1 Spring 3 Interlock plungers2 Detent halls 4 Screw

During removal o f s p e e d r o d s ,depending upon the operation to becarried out, i t may b e useful t okeep in their seats detent halls andinterlock plungers: use for th ispurpose tool A.3.0303.

CHECKS AND INSPECTIONSWash parts carefully before operatingon them. Superficial faults, wear andefficiency of certain organs cari bebetter detected.

1. Inspect whether speed controlforks are not excessively worn orwarped.2. Inspect w h e t h e r rods a r e n o twarped.3. Inspect whether s lots on rodsbear any nickings.4. I nspect whether detent halls andinterlock plungers bear any nickingsor seizing marks.

ASSEMBLY1. Set the corresponding 1st.2ndand 3rd-4th speed control forks onrelevant synchronirer sleeve.2 . Insert d u m m y r o d . A . 3 . 0 3 0 3into assembly seat of 3rd and 4thspeed rod. Assemble through hole ond u m m y r o d a n e w s p r i n g w i t hrelevant detent hall, after greasing,then by means of the driver toolA.3.0309 insert: and compress themSO as to be able to move backwardrool rod to keep them into position.3. Insert relevant rod into gearboxcasing seat pushing at the same timetool rod. Complete assembly of rodb y introducing i t into the smallhub of the fork and by aligning thehole on the latter with the slot onthe rod.

4. Grease and assemble the twointerlock plungers in the horizontalseats on the gearbox casing usingguide tool A.3.0304 and driver toolA-3.0309.

A.3.0304 - ,A.3.0309

May 1983 13-8

GEARBOX

5. Grease and assemble spring and1st~2nd speed rod detent hall, usingtools A.3.0304 and A.3.0309. Greaseand insert relevant bal1 into radialhole on rod. Insert then rod itselfinto its seat on the gearbox casing,paying attention to the reciprocalposition of milling and of detent hall,and make it pass through the smallhub of relevant fork.6. Use relevant securing plug toclose interlock plunger hole.7. Grease and use tools A.3.0303and A-3.0309 to assemble spring and5th speed and reverse gear roddetent hall.Insert then rod 0, together with5th speed control fork 0, intosmall hubs of 5th speed and reversegear lever @ and into reverse gearcontrol fork @ t o g e t h e r w i t hrelevant sliding sleeve.

1 5tb speed and reverse gear lever

2 5th speed and reversa gear rod3 5th speed control fork4 Reverse gear control fork

8. Al ign axes of holes a n d insertspring pin of 5th speed and reversegear lever by means of toolA.3.0322.Insert the two halls into their seatson central support of gearbox casing

together with relevant spring, thenlock securing plug and unscrew it byone quarter of a rotation.Mount lock ring of 5th speed andreverse gear rod on the end of therod itself, on the differential side.

9. Assemble partially main selectorrod, by introducing it from the rearside of the gearbox casing, insert itthen into the selector lever, into thespring and into the lever. Completethen introduction of rod.Align axes of lever holes with thec o r r e s p o n d i n g ones on rod andmount spring pins using tool

A.3.0322.

The speed selector lever pin @must be shim fitted while the otherlever% p i n @ must be fitted as astriker on the edges of the pinitself, with the excess portion of thepin protruding on the selector’s side.

1 Pin 2 Pin

10. Fit the guide pin for the mainselector rod return spring.

11. Position the 1st2nd speed le-v e r @ on the relevant rod 0.Turn rod @ SO that specified “S”clearance is established between le-ver @ and rod 0.

13-9

ScrewIst-2nd speed rod6th speed and R.G. rodR.G fork3rdAth speed rodSelectorMain selector rod1 st-2nd speed lever

“S” clearance between 1st”2nd speedlever and 3rd-4th speed rod

1.4 + 1.9 mm (0.055 + 0.075 in)

12. Align rhe holes and then fitretaining screw 0. Tightenaccording to specified torque.

0: Tightening torque

rheit

Screw securing 1st2nd speedselector lever to rod:

25326 N-m(2.5 + 2.7 kgm18.07+ 19.52 ftalb)

13. For gear synchronizing cen’terIst-2nd and 3rd-4th speed controlforks - in that order - on toothedrings with the help of a gauge; nowfit retaining screws and tighten themaccording to specified torque.

CAUTION:Prior to tightening, thoroughly cleanthe retaining screw thread withOMNIFIT surface-active agent andthen coat it with OMNIFIT 150 Hcernent

0: Tightening torqueScrew securing fork to 1st2ndand 3rd - 4th speed rod.

2 1 f 23 N-m(2.1+ 2.3 kgm15.10 f 16.63 Wb)

May 1983

GEARBOX

Check working condition of spring-plunger-rod assembly making surethat speed selection is smooth andthat speeds do not jump out of theirposition and become disengaged.

14. Fit oil sump, with a new gasket,on the gearbox casing and tightenrelevant screws.15. Position rear caver, with a newgasket, on both gearbox casingcentering seats; fit the oil bleedervalve with relevant retaining plate,and then tighten all screws.1 6 . A p p l y a c o a t i n g o f I S E C OMolykote BR2 grease to the mainselector rod ,seal ring as well as toits work seat on the rod.U s i n g 1001 A.3 .0294, fit the sealring on the rod.

1 Main selector rod

17. Fit the relevant lever on themain selector rod and then, using apunch, fit the retaining pin.

18. Fit reverse gear switch on rearcaver.

0: Tightening torqueR.G. switch to gearbox casing

40+49 N-m(4 + 4.9 kg-m2 8 . 9 2 + 3 5 . 4 3 ft-lb)

TESTINGCheck working condition of spring-plunger-rod assembly making surethat speed selection is smooth andthat speeds do not jump out of theirposition and become disengaged.

SHAFTS AND GEARS

DISASSEMBLY .

Pinion shaf-t gears1. Remove rods and forks (refer to:Rods and Forks - Disassembly).2. Acting on relevant sleeves, en-gage two speeds in order to preventpinion from turning.3 . W i t h a p u n c h , e l i m i n a t e allcaulking from the gear train topinion locking nut 0.4. With spanner A-5.0196, loosenthe nu-t and remove the hub 0, the5th speed gear 0 with relevantsynchroniting unit, and the bushing.

1 5th speed gear 3 N u r2 H u b

/

5. Remove differential casing (Re-f e r t o : G r o u p 1 7 - D i f f e r e n t i a lDifferential Casing).6. Slowly push pinion shaft towardthe differential casing and remove allparts making up the train on thepinion (I~L, 2nd, 3rd and 4thspeeds), being careful to mark thesequence and the position of gearbushings to be later followed duringreassembly.

1 Pinion2 Primary shaft

3 Direct drive shaft

May 1 9 8 3 13-10

GEARBOX

CAUTION:If friction between the pinion andthe inner race of the rear taper rollerbearing hinders withdrawal of thepinion shaft, use tool A.3,0296.

r A-3.0296- - l -

7 . R e m o v e t h e pinion 0, w i t hrelevant taper roller bearing @ andadjusting washer 0, from thegearbox-differential casing.

1 Taper roller 2 Adjusting washerbearing 3 Pinion

8. With tool A.3.i)296 remove therear bearing outer race from thegearbox-differential casing.

9. Using tools A.3.0296 a n dA.3.0297, remove the pinion frontbearing outer race from the gearbox-differential casing.

10. With the help of a press and ofplates A-3.0306, remove the frontbear ing @ inner race and theadjusting washer @ from the pinionshaft 0.

Direct drive shaft

1. Remove the lock ring 0 of theclutch drive thrust bearing supportand then remove the support 0.

13- l 1 May 7983

1

2

Pinion shaft 3 Pinion shaftfront bearing 4 PinionAdjusting washer

Synchronizing unitsR e m o v e t h e lock r i n g @ a n dthen remove in sequence: the syn-chronizer ring 0, the guide sec-ror 0, the locking sectoi-@, andthe retainers @.

1 Lock rini 4 Locking sector2 Synchronizer ring 5 Gear3 Guide secfor 6 Retainer

The 1 st speed synchronizing unit hasonly one retaiher.

GEARBOX

1 Lock ring2 Thrust bearing support

2. Remove the direct drive shaft oilseal ring located on the front of thegearbox casing.

T O remove oil seal ring, withmounted unit, operate as per figuremaking use of tool A.3.0452.

1 R.G. shaft retaining screw

-3 --- -d cl lo2

1 Pin retaining 3 Jointspring ring 4 Spring ring

2 Direct drive shaft 5 Pin

4. Having removed the direct driveshaft, if necessaryL remove the directdrive shaft bush with the help of toolA.3.0291. This tool removes alsothe oil seal ring.

3; R e m o v e t h e s p r i n g ring 0retaining the pin @ connecting thedirect drivejoint 0.

s h a f t @ t o the

Remove the pin in question and pullout the direct dr ive shaf t . Nowremove the spring ring @ retaininqthe pin that connects the primaryshaft to the joint; remove this latterpin and pull out the joint from theprimary shaft.

Reverse gear shaftLoosen a n d r e m o v e t h e R-G.1.

shaft @ r e t a i n i n q screw 01 and

then remove the shaft, with relevant“q qear @ ‘and R . G . fork @

its l o c a t i o n on gearbox-

differential casing.

2 Reverse gear3 R.G. shaft

4 R.G. control fork

Primary shaft

1. F i t lock t o o l A . 2 . 0 3 0 0 a t t h eend of the primary shaft @ in orderto prevent it from turning.

1 Primary shaft

May 1 9 8 3 13-12

GEARBOX

2. Loosen the screw securing theprimat-y shaft to its rear bearing andremove the oil deflector.3. Using tool A.3.0495 remove the5th speed driving gear 0.

1 5th speed driving gear

4. Pull out the tongue securing the5th speed driving gear to the primaryshaft.5. Loosen and remove thescrew 58 securing the primaryshaft 3 front: floating bearing @.

1 Bearing lock ring 4 Front bearing2 Fiear bearing 5 Bearing retaining3 Primai-y shaft screw

1 Bal1 bearing 2 Lock r ing

7 . F i t pinion 0 back i n t o t h egearbox-differential casing.8. Fit rear bearing on pinionshaft 0, together with the firstsection (fork shaped) o f tool

A-3.0490, at the location of the 4thspeed driving gear. Now fit thesecond sect ion of tool A.3.0490locking it on the pinion, by means ofthe relevant nut, a’t: the location ofthe 5th speed driven gear.

A.3.04907 ’P

1 Pinion

9. Fit tool A.3.0296 on thegearbox-differential casing and thenfit the A-3.0492 end piece.Carefully tighten the screws securingtool A . 3 . 0 2 9 6 to t h e gearbox-differential casing to avoid damagingthe casing’s threads.10. With the above mentioned tool,push the primary shaft toward thedifferential casing.

Now remove the f ront f loat ingbearing from the primary shaft.11. Remove the 4th speed drivinggear and relevant tongue.

6. Remove lock ring @ from rearbearing 0.

13-13

1 4th speed driving gear

May 1983

GEARBOX

12. Keeping tool A.3.0296 in place,remove pinion shaft with all the part?that are fitted on it; now totallyremove tool A.3.0490.13. Completely screw t h e t o o lA.3.0296 and insert tools A.3.0491and A.3.0500 on its nut thread.Unscrew tool A.3.0296 and removeprimary shaft rear bearing from itsseat, then separate it from the tool.

A.3.0491

A.3.0500

14. Remove the primary shaft @from the gearboxdifferential casingpassing through the Seat of the rearbearing.

1 Primary shaft 2 3rd speed gear

CHECKS AND INSPECTIONST h o r o u g h l y w a s h all parts andvisually check them with extremetare for any surface flaws.

Gears and splines ASSEMBLY1. Check that teeth contact patternof primary shaft and bevel piniongears extends to the entire workingsurface. Unevenly worn gears or gearswith broken teeth must be replacedmaking sure that relevant matinggears have not been damaged.Follow the same checking procedurefor splines of primary shaft, directd r i v e s h a f t , a n d o f t h e pinion.2 . Also c h e c k t h a t a b o v e men-tioned toothing as well as the grooveon the synchronizing ring do notshow any scores, evidence of pittingor excessive wear. Replace all partsthat are not flawless.

Primary shaft1. First fit on the primary shaft thelongue for keying of the 4th speeddriving gear.2. Fit the shaft in its seat on thegearbox-differential casing and thenfit the 4th speed gear on the shaft.3. Lock the primary shaft’s frontend with tool A.2.0300 (refer to:Primary Shaft - Disassembly).4 . Fi t tool A.3.0300 on the pr i -mary shaft’s rear end using it to keythe 4th speed gear.

BushingsCheck pinion bushings for excessivewear making sure that workingsurfaces in contact with gears do notshow any scratches or evidence ofpitting. Replace all parts that are notflawless.

Synchronizing unit

Check sliding surfaces for scores andmake sure that sleeves slide smoothlyon relevant hubs; check synchroniz-ing rings for excess wear.

Bearings

1. Carefully inspect all bearings byslowly rotating them: no vibrations,noise or sticking should be noticed ifbearings are in good working con-dition.2. Check surface of all rings androtating parts making sure there areno scores, marks or roughness due tofriction of foreign matter. Replace allparts that are not flawless.

Reverse gear shaft

If any of the parts making up thereverse gear shaf t assembly a r edefective or damaged, replace themwith new ones available as spareparts.

A.3.0300 1 w

5. Using tools A.3.0491 andA.3.0296, fit rear bal1 bearing onprimary shaft.

Carefully t i g h t e n screws o f t o o lA.3.0296 on the gearbox casing toavoid damaging the casing’s threads.

A.3.0491-

1 Bal1 bearing

May 1983 13-14

GEARBOX

6. With the help of suitable plyersfit the lock ring in its seat on thaprimary shaft’s rear bearing support.

Make sure the lock ring is properlylodged in its seat.

7 . K e e p i n g t h e p r i m a r y s h a f tlocked by means of tool A.2.0300,fit tool A.3.0300 on same shaft’srear end; center the shaft in the rearbal1 bearing.Fit primat-y shaft on rear bearing.8. Fit roller bearing on the primaryshaft’s front end being careful toalign the hole of the bearing’s outerrace with the corresponding halein the gearbox-differential casing. Fitsecuring screw into the hole in thegearbox-differential casing.Fit securing screw into the hole andfully tighten it.

Having completed primary shaftassembly, check and make sure itturns freely on the bearings, withoutsticking.

9. Fit on primary shaft the longuefor keying of the 5th speed drivinggear.10. With tool A,3.0300 fit the 5thspeed gear in its seat on the primaryshaft by the gearbox casing’s outerrear side.11. Fit oil deflector in its seat on the5th speed gear and t ighten theprimary shaft retaining screw, with-out fully locking it. .

Reverse gear shaft

1. Fit reverse gear shaft, withrelevant sliding gear and driving forkinto its seat on gearbox casing.2. Tighten to specified torque thescrew securing the R.G. shaft to thegearbox casing.

0: Tightening torqueR.C. shaft to gearbox casingretaining screw

19-24 N-m(1.9+ 2.4 kg-m13.74 + 17.36 ft-lb)

Pinion shaft gears

1 . C o a t w i t h g r e a s e ( A G I P F IGrease 33 FD) the outer surface oft h e pinion taper ro l ler bear ings

outer races and then fit them on thegearbox casing, using the same toolsu s e d during d i s a s s e m b l y ( T o o lA.3.0296 for the rear bearing race,and tool A.3.0296 - together withtool A.3.0297 - for the front bearingrace).

CAUTION:T a k e special tare during a s s e m b l ymaking sure that bearing races areexactly flat against casing surface.

2. Fit the proper shim, selected inadvance, on the pinion shaft (referto: Adjustments - How to determinepinion height).Using a press and tool A.3.0307, fitthe taper roller bearing inner race onthe pinion shaft.

3 . I f p r e v i o u s l y disassembled f o roverhaul purposes, reassemble syn-chronizing units (refer to: Synchro-nizing units).4. Apply the prescribed engine oilto outer surface of bushings and thenfit them on gears according to theirrelevant position at time of disas-sembly thus restoring the originalworking surface pattern.5. Partially insert bevel pinion intothe gearbox casing and then fit allparts making up the train, whileslowly p u s h i n g t h e pinion in tillis reaches its final position. Duringthis operation be sure to follow thesequence and positioning show in therelevant figure, paying special atten-t ion to the R.G. driven gear @and to the 4th speed shoulderwasher 0.Fit standard shim A.4.0141 @(9.60 mm (0.378 in) thick) and theinner race of the rear taper rollerbearing @, making sure that it fitsflat against the shoulder washer.

1 Reverse gear 4 Rear taper roller2 4th speed bearing

shoulder 5 Lock nut3 Standard shim

13-15 May 1983

GEARBOX

In case of friction between thebearing’s inner race and the pinion,use tools A.3.0300, A.3.0301 foreasier fitting.

6. Fit the bushing and the hub ofthe 5th speed driven gear and thentighten by hand the pinion gear trainlock nut.7. Engage two gears and thentighten the nut according to specifiedtorque, without caulking.

0: Tightening torquePinion gear train to pinionshaft lock nut

2 2 0 . 5 + 245 N - m(22.5 + 25 k g - m162.70+ 1 8 0 . 7 7 ft-lb)

8 . Now Select the shim for f inalfitting (refer to: How to determinePinion Shaft Taper Roller BearingPre-load).

Synchronizing units1. As far as 2nd, 3rd, 4th and 5ths p e e d g e a r s a r e concerned fit re-tainers @ @ on gearandbody 0 placing locking sector @and guide sector @ between them.Fit synchronizing ring @ on re-tainers and sectors and then lock intoalace all aarts w i t h r e l e v a n t lockring 0. ’

It is advisable net to exchange theparts belonging to the differentsynchronizing units.

1 Gear 5 Locking sector2 Retainer 6 Synchronizing3 Guide sector ring4 Retainer 7 Lock ring

2. Now follow the same procedurefor the 1st speed gear reme.mbering,however, that in this case rhere iso n l y one retainer (refer to: Disas-sembly - Synchronizing units):

ADJUSTMENTS

How to determine pinion height

CAUTION:Use only metric system in order toavoid confusion in computations.

T O d e t e r m i n e pinion height, àndtherefore shim thickness, proceed asfollows:1. Fit inner race of the pinion shaftfront taper roller bearing on dummypinion A.4.0142.2. Insert dummy pinion in gearboxcasing.

” ’ k.4.0142 ’

3. Fit rear taper roller bearing innerrace 2 and relevant lock nut onto0dummy pinion 0.

1 Dummy pinion2 Taper roller bearing inner race

4. Tighten the nut according tospecified rolling torque using coupl-ing tool A.2.0274, 1 dm. dia. sheave6.5.0124 and weight C.2.0037.

0: Dummy pinion rolling torquea. For original bearings being

used again:3 + 6 N.dm(0.3 + 0.6 kg-dm0.217 + 0.434 ft-lb)

b. For replacement bearings(new)12+ 14 Nqdm(1.2 + 1.5 kg-dm0 . 8 6 7 + 1 .085 f t - l b )

May 1 9 8 3 13 -16

GEARBOX

A.2.0274A.4.0142

C.5.01241

1 Front taper roller bearing inner race2 Rear taper roller bearing inner race

5. Turn dummy pinion a few timesin both directions to allow bearingsto settle.6 . F i t a centesimal dia1 g a u g e t obracket A.4.0136 and reset i t bymeans of reference gauge C.6.0161.

7. Fit crown axis reference tool 9. Repeat above operation by fit-

C.6.0162 into the differential carrier t i n g tool C.6.0162 into the Seat o f

Seat; tighten, in bias sequence and the opposite side differential carrier

according to specÏfied torque, the and take reading of “L,” value.

four screws securing it to the gearbox- 10. Read dimension “C” (plus o r

differential casing. minus) etched on pinion.

0: Tightening torqueScrews securing tool C.6.0162to gearbox-differential casing:

40+49 N-m(4 + 4.9 kgmm28.92 + 35.43 f-t-lb)

8. Place the differential carrier,w i t h dia1 gauge, on the head ofdummy pinion and then take readingof “Ll ” value.

~ A.4.0136 C.6.01627

11. Determine as follows the “S”thickness of the shim that is to bef i t t e d b e h i n d t h e pinion h e a d :

Ll + L2s = - (k C)

2

12. Among the various shims avail-able as spare parts, Select the onewith thickness nearest to the valuedetermined as per above instructions.

Example:

Ll = 0 . 8 6

L2 = 0 . 8 8

c = 0.13

L, + L2 0.86W.88s z!z- - (IC) = - (0.13)

2 2

0.86(1) + 0.88

1.74

1.74:2=(2) 0.67

(3)

Computed shimthickness

0.67

- 0.13

s = 0.74

Selected shimthicknesr S = 0.75 m m

Shim thickness thus determined inthis one ensur ing correct pinionheight since readings have been takenwith pinion in its actual operat ingposition.

13-17 May 1983

GEARBOX

How to determine pre-load ofpinion &aft taper rollerbearings

CAUTION:Use only metric system in order toavoid confusion in computations.

After having fitted all various parts asdescribed in paragraph “Reassembly -Pinion Shaft: Gears, item no. 5”,measure pinion end play by carefullyfollowing the procedure describedhereafter:

1. Fit bracket A.2.0242 to gearboxcasing with the interposed spacersA-2.0234 and then a centesimal dialgauge to the bracket.

Properly tighten the screws securingbracket A.2.0242 to the gearboxcasing in order to avoid damagingcasing threads.

2. Turn pinion @ a few times inboth directions to allow bearings @and @ to settle. Push pinion byhand in one direction and reset thedial gauge.3. Move pinion in the oppositedirection and take reading of “G”play on dial gauge.

In case of subsequent end-playreadings, it is necessan/ to rotateagain the pinion in both directions toallow bearings to settle.

4. Determine as follows the rearshim “S” thickness for pinion taper

M a y 1 9 8 3

roller bearings pre-loading:

S = 9.60 - G - 0.10

whereas 0.10 is a play-correctingfactor for taper roller bearing pre-loading.

- - F - J - -

1 Pinion 3 Rear bearing2 Front bearing

Select the shim with thicknessnearest to the value determined asper above instructions keeping inmind, however, that max. allowedtolerance is * 0.02 mm and thatthicknesses available as spare partshave a 0.05 mm variation step.

Example:

Standard shimthickness = 9.60

G = 0.37

Play -correcting factor = 0.m

S =9.60-G-0.10= 9.60 - 0.37 - 0.10

9.60(I) - 0.37

9.23

(2) 9.23

-0 . 1 0

9.13

Computed shimthickness S = 9.13

Tolerance = 0.02

Dimensional variationsteps of available spareshims = 0.05

Selected shimthickness S = 9.15 mm

5. Loosen and remove the nut aswell as the hub, rhe bushing, thebearing inner race, and the standardshim making sure that the train’s

13-18

various parts do not rotate.6. Fit the shim selected as perabove computation; now fit thebearing inner race, all the partsmaking up the 5th speed driven gearset and lastly the nut.7. Tighten the nut to specif iedtorque.

0: Tightening torquePinion shaft gear train lockingnut

2 2 0 + 2 4 5 N - m( 2 2 . 5 + 25 k g - m162.70,+ 1 8 0 . 7 7 ft.lb)

8. Coat all gears of primary andpinion shafts with specified gearbox-differential type oil (AGIP FI RotraMP SAE 8OW90 or IP Pontiax HD8OW90).Turn pinion shaft a few times in bothrotating directions to allow bearingsto settle.9. Fit coupling tool A.2.0274, the1 dm rad. sheave C.!%O124, and TheC.2.0037 weight to the pinion shaftnut.

A.2.0274 -

C - 2 . 0 0 3 7

6

10. Check that weight descendsnormally without stopping and with-out pulling the disc too fast.Check that in such condition rollingtorque is as specified.

GEARBOX

0: Rolling torque of pinion withgear train.a. For original bearings being

used again4 + 7 N-dm(0.40 + 0.70 kg-dm0.289 + 0.506 ft.lb)

b. For replacement bearings

hew)1 3 + 1 6 N-dm(1.3+ 1.6 kg-dm0.939 + 1.157 ft.lb)

In case of rolling torque valuesgreater or lower than specified ones,correct them by fitting a rear shimeither 0.05 mm thinner or thickerthan the one previously f i t ted.In this instance, rechecking of rollingtorque is required.

11. Caulk the nut with punch andhammer.12. First prevent shafts from rotat-ing by engaging two speeds and thentighten the screw securing the oild e f l e c t o r t o t h e p r i m a r y s h a f taccording to specified torque.

0: Tightening torqueOil deflector retaining screw

69; 8 5 N-m(7 + 8.7 kg-m50.61 + 62.91 ft.lb)

Direct drive shaft

1. If previously disassembled, fitdirect drive shaft bushing @ togearbox casing using tool A.3.0308.

1 Bushing

2. Fit bushing on primary shaftmaking sure that holes for sub-sequent pin fitting are aligned; fitthe pin and a new retaining springring.3. Insert direct drive shaft into itsseat and connect it to the bushing byfitting the pin and a new retainingspring ring.

Make sure that retaining spring ringsare properly lodged in their respec-tive seats so as to prevent pins fromdropping out.

4. After having app l i ed g rease( I S E C O : M o l y k o t e BR2) to i tssealing lip and to its work seat onthe shaft, fit a new oil seal ring onthe direct drive shaft with the help oftool A.3.0323. During this operationbe careful not to damage the sealinglip of coupling splines.

Use tool A.3.0453 to assemble oilseal ring on direct .drive shaft, onassembled unit.

DIFFERENTIAL CARRIERS

4 A.3.0453 1

CAUTION:Cover direct drive shaft splines withtape.

5. Fit the clutch drive thrustbearing support and secure it to itsseat on the differential casing bymeans of the relevant lock ring.

Make sure that lock ring is correctlylodged; check that its tongues arefacing the sleeve seat and thuspressing it on the casing.

TESTING

Check that hubs and synchronizingrings are in perfect working condi-tion and that engagement of gears isnoiseless and easy.

1 Taper rollerbearing

6 Shim7 Seal ring

2 Phonic wheel 8 Carrier3 King nut 9 Seal ring4 Lock ring 10 Differential shaft5 Ball bearing

13-19

GEARBOX

DISASSEMBLY ’

IMPORTANT:The following procedure refers to theright hand differential carrier.Difference between left differentialsupport and right one is only con-stituted by absence of phonic wheelin the left dif ferential support

1. Loosen and remove oil sumpretaining screws with relevant

washers, now remove the sump andthe seal gasket.2. Loosen and remove the

screws 18 securing the differential.

carrier 2 to the gearbox casingPartially pull back the carrier andremove the two shims 0, beingcareful to mark the relevant positionto be later followed during reas-sembly. Now completely disassembledifferential carrier.

1 screw 3 Shim2 Differential carrier

3. Remove seal r ing 0 from

differential carrier @.

Taper roller bearing outer racePhonic wheelRing nutSpring ringBearingOil seal ringSeal ringDifferential carrierDifferential shaft

4. Lock differential carrier in a viceand remove the ring nut securing thedifferential carrier on the bearing andphonic wheel using tool A.3.0298.

5. With The help of a press and ofplates A.3.0295, remove differentials h a f t @ f r o m t h e c a r r i e r 0.Remove the oil seal ring.

1 Differential shaft

6 . Using tool A.3.0299, remove thedifferential carrier taper roller bear-ing outer race.

7. Remove the bearing lock ringfrom its seat in the differentialcarrier.

8 . Now wi th too l A .3 .0302 , re -move the ball bearing from thedifferential carrier.

GEARBOX

Following the same procedure, disas-semble the left hand differentialcarrier.

9. In case of malfunction of speedindicator device, remove sensor @from gearbox after removing retain-ing spring @ and replace it.

ential carrier, proceed as follows:1. Apply gearbox oil to the oil sealring outer surface and fit it into itsseat on the differential carrier usingtool A.3.0430.

CAUTION:Make sure the crowfoot on the oilseal ring points in the direction ofthe differential shaft rotation.

1 Spring ring 2 Sensor


Having thoroughly washed all parts,perform following checking ope-rations:1. Carefully inspect all bearingswhile slowly rotat ing them: novibrations, noise or sticking shouldbe noticed if bearings are in goodworking condition.2. Check the surface of all ringsand rotating parts making sure thatthere are no scores, marks or rough-ness due to fr ict ion of foreignmatter.If surfaces of rings and of rotatingparts show scores, evidence ofabnormal wear, pitting or over-heating, replace them without hesi-tation.3. Check that contact surface ofdifferential shafts splines extends tothe entire working surface; if any ofthe teeth is chipped or show evidenceof abnormal wear, replace shaftsmaking sure that relevant matingparts have not been damaged.

ASSEMBLY

Referring to the right hand differ-

T Ti.- .-i

R

A.3.0430

2. With tool A-3.0302 and the helpof a press, fit the differential shaftbearing into the carrier.

I IL. .-.I

t??A-3.0302

3. Fit the differential shaft bearinglock ring.4. Using tool A-3.0292 fit the taperroller bearing outer race into thecarrier.

I-. -.FfL-.-J

1X.3.0292

5. Apply grease (ISECO MolykoteBR2) to the oil seal ring inner surfaceand to its seat on the differentialshaft. With tool A-3.0293 and thehelp of a press and a rest plate, fitnow the differential shaft.

6 . A p p l y g e a r b o x o i l (AGIP FlRotra MP SAE 8OW90 or IP PontiaxHO 8OW90) to the mating surfaceson differential shaft of the bearingretaining ring nut. Make sure to fit anew ring nut.7. On differential shaft install firstring, nut and then phonic wheel,using. tool A.3.0293 together with apress and a rest plate.8. After having applied a coating ofgearbox oil, fit the small seal ring inthe carrier’s groove.9. Fit the right hand differentialcarrier in its seat on the gearboxcasing

13-21 May 1983

GEARBOX

Following fhe same procedure, reas-semble the left hand differentialcarrier.IO . F i t o i l sump w i th re levan tsealing gasket.

CROWN GEARAND PINIONDISASSEMBLY

Crown gear

1. Remove differential carriersfrom the gearbox-differential casing(refer to: Dif ferent ial’ Carr iers- Disassembly).2. Remove differential casing fromthe gearboxdifferential casing (referto: Differential casing - Disassembly).3. Loosen and remove the screwssecuring the crown gear to thedifferential casing and then removethe crown gear.

Pinion

1. Remove gears from pinion shaftand then withdraw the shaft from itsseat in the gearbox-differential cas-ing, with relevant bearings (refer to:Shafts and Gears).


Having thoroughly washed all parts,proceed as follows:1. Slowly rotate bearings checkingthem for vibrations, noise or sticking.2. Check surface of all rotatingparts and of roiling tracks for scoresor any evidence of abnormal wear,pitting or overheating; in the affir-mative, replace the parts involved.3. Make sure that contact patternof bevel pinion teeth extends to theirentire working surface. If any of theteeth are nicked, replace the pinionand make sure the crown gear hasnot been damaged as a consequence.Check both toothings for scoresand any evidence of pitting or excesswear.

ASSEMBLY

Crown gear

1. Following the procedure de-

scribed in paragraph “DifferentialCasing - Assembly”, fit crown gearto differential casing.2. Fit differential casing back togearbox casing.

Pinion

Position the pinion into its seat inthe gearboxdifferential casing and fitbearings and gears (refer to: Shaftsand Gears).

TESTINGVerify back-lash between crown gearand pinion in four diametricallyopposite positions. Irregular back-lash, with excessive differences be-tween the measured points, is anindication of crown gear deformationwith consequent flatness errorbetween gearbox casing/crown gearplace and differential casing plane.Make sure the differential worksproperly and is completely noiseless.Incorrect assembly of’crown gear andpinion or worn taper roller bearingscould be the cause of the trouble.

DIFFERENTIALCASING

DISASSEMBLY1. Remove lef t and r ight handdifferential carriers (refer to: Dif-ferential Carriers - Disassembly).2. Remove differential casing fromgearbox-casing,

1 D i f f e r e n t i a l 3 C r o w n g e a rcasing 4 Taper roller

2 R e t a i n i n g s c r e w bearing

3 . W i t h t o o l A . 3 . 0 2 8 7 r e m o v einner races of taper roller bearingsfrom the differential casing.

A.3.0287 1 1

4. Loosen and remove the screwsand washers securing the crown gearto the differential casing.Now remove the crown gear.


Having thoroughly washed all parts,perform the following checkingoperations:1. Slowly rotate bearings checkingthem for vibrations, noise or sticking.2. Check the surface of all rotatingparts and of all rolling tracks forscores and any evidence of abnormalwear, pitting or overheating; in theaffirmative, replace the parts in-volved.3. Visually check gears, both plane-tary and side gears, making sure thatthere are no scores or evidence ofpitting, that contact pattern extendsto their entire working surface andfurther that mating is noiseless andsmooth.If necessary, replace the wholedifferential casing; in this case alsoreplace taper roller bearings.

May 1983 13-22

GEARBOX

CAUTION:.Use only metric system in order toavoid confusion in computations.

5. Compute, as shown below, theaverage value “Hm” of the fourmeasurements picked-up as per item4 above and determine the thicknessof “B” shims that will have to befitted behind the crown gear sidecarrier for pre-loading of taper rollerbearings.

B = Hm - 0.20

whereas 0.20 is correcting factor forbear ing p re - load ing .Example of computation of the fourpicked-up measurements:

HI = 1 . 8 8 H,= 1 . 9 4 ;

Hg= 1.90 e Ha= 1 . 9 6

B = H m - 0 . 2 0 =

1.88+1.94+1.90+1.96= - 0.20 =4

= 1.92 - 0.20 = 1.72 mm

6. Considering that max. allowedtolerance is -I- 0.02 mm and thatshims available as spare parts have athickness variation step of 0.05 mmselect the thickness nearest to thecomputed value (in the above in-stance one would select the 1.70 mmthickness).7. Fit selected shims behind thecrown gear side carrier and tightenretaining screws to specified torque(refer to: Step 2).

Crown gear to pinion backlash

Adjust crown gear to pinion backlashfollowing the procedure hereafterdescribed.

1. Rotate pinion and crown gear toallow relevant bearings to settle andthen use tool A.2.0243 to lock thepinion.Properly tighten screws of toolA.2.0243 on gearbox casing.2. Fit a centesimal dial gauge to amagnetic base and place the gauge’sindicating finger on the outer edge ofa crown gear tooth at right angleswith the tooth’s side.

May 1983

3. Rorate crown sear as far asbacklash will allow and read thevalue shown on dial gauge.4. Repeat the above reading onfour different points of the crown

war, equally distant one fromthe other.

Each of the four measured valuesmust fall within the range of 0.05 to0 . 1 0 m m (2*10-” + 4-10m3 i n ) .

If backlash does not fall within thesevalues, proceed as hereafter de-scribed, remembering that total shimthickness (A + B) between differen-tial carriers and gearbox casing mustremain constant otherwise it wouldcause bearings pre-load to change:- in case backlash is below speci-

fied value, move crown gearaway from the pinion by de-creasing thickness of A shimsand equally increasing that of Bshims.

- in case backlash is above speci-fied value, move crown gearcloser to the pinion by increas-ing thickness of A shims anddecreasing that of B shims bythe same extent.

When correcting shim thickness itshould be remembered that in orderto change dial gauge reading (min.distance between crown gear andpinion teeth) by 0.01 mm (0.4.10-3in), one must move a thickness of0 . 0 1 5 m m (0.59-10-3 i n ) f r d mone side to the other.

Having completed fitting of shims,tighten retaining screws to specifiedtorque (Refer to: Adjustments - Howto Determine Pre-load of DifferentialCasing Bearings). Double check back-

1 3 - 2 4

lash and if now within specifiedvalues, repeat above adjusting opera-tions.

When refitting previously disas-sembled parts (carriers, differentialcasing, bearings and crown gear), it isessential that also same A and Bshims are used - or at least new onesof same thickness - and that they areplaced back exactly where they werelocated at time of disassembly.

GEARBOX-DIFFERENTIALCASINGDISASSEMBLY1. Remove rear support (Refer to:Rear Support - Disassembly).2. Remove the clutch control forkand then withdraw the thrust bearingfrom the direct drive shaft (Refer to:G r o u p 12).3. With the help of a punch,remove the clutch control forkretaining pin.

4. Remove differential carriers(Refer to: Differential Carriers -Disassembly).5. Remove differential casing withcrown gear (Refer to: DifferentialCasing - Disassembly).6. Remove rods and forks (Referto: Rods and Forks - Disassembly).7. Remove shafts and gears (Referto: Shafts and Gears - Disassembly).

GEARBOX

CHECKS AND INSPECTIONS1. Thoroughly clean casing withsolvent and check it for scores, nicksor evidence of pitting.2. Check the casing’s mating sur-faces making sure there are no nicks,no evidence of roughness nor or oldsealants.3. Check that the clutch forretaining pin is not in any waydamaged.

ASSEMBLY5. Fit clutch control fork retainingpin.

1. Fit shafts and gears (Refer to: 6. Fit the clutch control fork and

S h a f t s a n d G e a r s A s s e m b l y ) .2. Fit differential casing (Refer to:Differential Casing -Assembly).3. Fit differential carriers (Referto: Differential Carriers - Assembly).4. Fit rods and forks. Thoroughlyclean rear cover and oil sump matingsurfaces; fit new gaskets with speci-fied sealants and then fit coverand sump (Refer to: Rods and Forks- Assembly).

then fit thrust bearing on direct driveshaft (Refer to: Group 12).7. Fit rear support (Refer to: RearSupport - Assembly).

GEARBOX OUTER LINKAGE

1. Loosen and remove the nut withwasher @ as well as the screw 0securing the main selector rod @ tothe gearbox lever 0; then removethe spacer @ and the two bush-

ings 0.

3. Loosen and remove the nut @and the screw @ securing thegearbox lever support 0 to theflexible bush @I ocated on the rearextensions; now remove side wash-ers 3 as well as the spacer0 0.

CHECKSAND INSPECTIONS1. Thoroughly clean outer linkagemetal parts with solvent and makesure they are in good condition.2. Check linkage articulated jointsfor excess wear.

DISASSEMBLY

1 Gearbox lever 5 Rear support2 Spacer 6 Main selector rod3 Bushing 7 Retaining screw4 Nut with washer

2. Loosen and remove the gearboxlever guide @ retaining screws withwashers 0; now remove the guide,the boot aand the bushing 0located at lever’s end.

1 Boot2 Screws with

washers

3 Bushing4 Guide

1 Support 5 Spacer2 Nut 6 kasher3 Washer 7 Screw4 Flexible bush

4. Remove rear support (Refer to:5-Speed M a n u a l G e a r b o x - R e a rSupport).6. Lastly remove the flexible bushwith the help of following tools: apress, a plate, a base and punch tool.

3. Make sure boot is in perfectcondition; if damaged or worn,replace it.

ASSEMB.LY1. Fit rear support (Refer to:5-Speed M a n u a l G e a r b o x - R e a rSupport).2. Apply grease (AGIP Fl Grease15 or SHELL Retinax G) to thespacer 0 on the speed selectorlever to main selector rod connec-t i o n 40 and to the spacer 0securing the fork to the flexible bushon the gearbox cover.Apply 5 g (0.176 oz) of same greaseto the speed selector lever guide 0.3. Go on to fit all gearbox outerlinkage following disassembly pro-cedure in reverse sequence.

1 Spacer2 Guide

3 Spacer4 Main selector rod

13-25 May 1983

GEARBOX


TECHNICAL DATA

Speed

Differential ratio

lll39Gearbox

differential

Speed selector

lever positions

Gearbox

ratio

9135

Gearbox-differentialoverall ratio

1 : 13.293

1 : 7.267

1 : 4.916

1 : 3.640

1 : 2.924

1 : 10.957

Speedat 1000 r.p.m.Km/h (mi/h)

7.77 (4.81)

14.21 (8.81)

21 .Ol (13.05)

28.37 (17.63)

35.23 (21.89)

9.42 (5.86)

Gearbox-differentialoverall ratio

1 : 14,580

1 : 7.970

1 : 5.392

1 : 3.992

1 : 3.207

1 : 12.017

Speedat 1000 r.p.m.Km/h (mi/h)

7.08 (4.39)

12.96 (8.05)

19.15 (11.89)

25.87 (16.07)

32.20 (20.0)

8.59 (5.34)

1 1 : 3.750

2 1 : 2.050

3 i : I.387

4 1 : 1.027

5 1 : 0.825

R.G. 1 : 3.091

1200

1350

1500Engine 1200

1350

1500



Name QwAPP.

“0.

1

Application Type

ISECO Molykote BR2

Std. No. 367159941

Inner surface of:

- Seal ring of main selector rod

- Seal ring of priman/ shaft

- Seal ring of differential shaft

- Seal lip and work seat on shaft

GREASE -

Outer surface of:

- Seal rings OIL See item 5

May 1983 1 3 - 2 6

GEARBOX

APP.“0.

2

Type Name

GREASE - AGIP: Fl Grease33 FD

Std. No. 3671 69833

Application Q.W

Outer races of differential casing and pinion

taper roller bearings

Mating surfaces of:

- Ring nut securing bearing to differential

shaft

3 OIL See item 5

Outer surface of:

- Spacer on main selector rod to speed

selector lever connection

- Spacer for lever to fork fitting

Speed selector lever guide

- AGIP: Fl Grease 15

- SHELL: Retinax G

Std. No. 3671-69811

GREASE

4

5 g (0.176 otj

Fill-up of gearbox-differential casing OIL - AGIP: Fl Rotra MP SAE 8OW90

- IP: Pontiax H.D 8OW90

Std. No. 363169408

2,300 kg

+O,lOO kg

5.07 lb + 0.22 lb)

5

OIL

Outer surface of differential carriers and

relevant seats on gearbox casing

Bushings for bevel pinion driven gears

6 See item 5 -

Outer surface of:

- Gearbox rear flexible support

- Flexible support for speed selector

lever upper joint

GREASE - UNION CARBIDE CHEMICAL

COMPANY:

Ucon lubricant 50 HE-5100

- MI LLOIL: slipping agent for

rubber sections

Std. No. 4500-I 7502

Outer surface of:

- Fin for gearbox rear flexible support GREASE - SPCA: spagraph- ISECO: Ergon Rubber Grease no. 3

Std. No. 367169816

-

SEALANTS AND SURFACE-FIXING AGENTS

Application Type Name Q.ty

Lower screws securing differential carriers

to gearbox casing

CEMENT DOW CORNING: Silastic RTV732

Std. No. 3522-00040

13-27 May 1983

GEARBOX

Application Type

- Screws securing forks to speed selector

rods

CEMENT

N.B. For surface cleaning use: SURFACEFIXINGAGENT

- Inner surface of bore for oil plug on

gearbox casing

CEMENT

Name

Omnifit 150 H

Std. No. 352400023

Omnifit - Std. No. 3514-90003

DIRING: Heldite

Std. No. 3522-00015


REAR SUPPORT RODS AND FORI<S

Q.W

-

“fl’ positioning of gearbox rear flexible support 1. ‘5” clearance between 3rd-4th speed rod 0 andlst-2nd speed selector lever @

P degree 90 4 2S mm 1.4 + 1.9

(in) (5.5. 10.*+7.4 IO-*)

2. End play between fo rk and synchron is ing un i t

sleeves

Clearance mm 0 250 + 0.375

(in1 (9.8 1 O-3 - 1 . 5 1 O-*1

ROLLING TORQUES

I tern N*dm

Dummy pinion

- Original bearings being used again

- Replacement bearings (new)

Pinion with gear train

- Original bearings being used again

- Replacement bearings (new)

3 2.6

12 + 15

4 2 7-

13 - 1 6

0.3 + 0.6 0.217 + 0.434

1.2 f 1.5 0.867 + 1.085

0.4 + 0.7 0.289 + 0.506

1.3 + 1.6 0.939 + 1.157

May 1983 1 3 - 2 8

GEARBOX

DIFF-ERENTIAL CASING

Thickness ‘3” of shims B for pre-loading of differentialcasing taper roller bearings

s = H (avg. ) - 0 . 2 0

H = clearance between gearbbx casingand flange of L.H. differential carrier

0.20 = corrective value for bearing preloading

Thicknessmm (in)

Part No.

1.00 (0.04) 1.55 (0.062) 101452 1014631.05 (0.042) 1.60 (0.064) 101453 1014641.10 (0.044) 1.65 (0.066) 101454 1014651.15 (0.046) 1.70 (0.068) 101455 1014661.20 (0.048) 1.75 (0.07) 101456 1014671.25 (0.05) 1.80 (0.072) 101457 1014681.30 (0.052) 1.85 (0.074) 101458 1014691.35 (0.064) 1.90 (0.076) 101459 1014701.40 (0.066) 1.95 (0.078) 101460 1014711.45 (0.058, 2.00 (0.08) 101461 1014721.50 (0.06) 101462

PINION

1. Thickness ‘3” of shims for setting of pinion height

C = value engroved ou pinion

Ll, L2 = crown gear shaft deviation values

Thicknessm m (in)

0.75 (0.W) 1014300.80 (0.032) 1014310.85 fO.034) 1014320.90 (0.036) 1014330.95 (0.038) 1014341.00 (0.04) 1014351.05 (0042) 1014361.10 (0.044) 1014371 .‘I5 (0.046) ‘1014381.20 (0.048) 1014391.25 (0.051 101440

Part No.

GEARBOX

2. Thickness “S” of shims for pre-loading of pinion 3. Pinion to crown gear backlashtaper roller bearings

S = 9.60 - G - 0.10

9.60 = sample washer thickness

G = clearance measured by gauge

Backlash mm

(in)

0 . 0 5 + 0.10

(Zrlo-3 + 4q0-3)

0.10 = corrective value

Thickness

mm (in)

Part No.

4.10 (0.164)4.15 (0.166)4.26 (0.170)4.35 (0.174)4.45 (0.178)4.55 (0.182)4.65 (0.186)4.75 (0.190)4.80 (0.192)

700165700166700167700168700169700170700171700172

I700173

TIGHTENING TORQUES

UnitItem

LEVER AND FORKS

Screw securing 1st - 2nd speed selector

to rod

Screws securing forks to speed control

rods

Screws securing pin for R.G. sliding gear

SHAFTS AND GEARS

Primary shaft outer bearing retaining

screw

Bevel pinion gear train retaining ring nut

N*m kg-m

25 + 26 2.5 + 2.7 18.07 + 19.52

21 + 23 2.1 - 2.3 15.10 + 16.63

19 + 24 1.9 + 2.4 13.74 + 17.36

69 f 85 7 + 8.7 50.61 + 62.91

2 2 0 f 2 4 5 22.5 + 25 162.70 + 180.77

ft-lb

M a y 1 9 8 3 13-30

G-EARBOX

Trouble

Noisy both during accelerationand deceleration (drive shaftassy already checked)

Transmission is noisy when incurve, both with speed engagedor when in neutral (drive shaftassy already checked)

Transmission is noisy when inneutral (vehicle is not moving)

Transmission is noisy when inreverse gear

Engagement/disengagement ofspeed is not easy

Speeds become disengaged

Probable cause

l Differential gears are worn ordamaged

l Excess play of hypoid gears

l Crown gear securing screws areloose

l Bevel pinion shim is worn ordamaged

l Pinion shaft retaining nut is loose

l Excess play in gear train

l Teeth of planetary and side gearsare worn, damaged or show evi-dence of pitting

l Irregular variations of drivingtorque

l Not enough oil

l Reverse gears are worn or damaged

Corrective action

Replace gears

Check and replace, if necessary

Tighten

Replace shim

Check gearbox components andthen tighten the nut

Adjust gear train

Replace differential casing

Adjust engine idling

Fill up to correct level

Replace defective parts

First of all it should be established if the trouble is caused by the gearbox or bythe control system. If the clutch still transmits torque when the pedal is pushed-down, it means that it is not disengaged. Verify if the clutch properly couples(pedal is released) and uncouples (pedal is pushed-down) the engine to the gear-box casing. If clutch is not faulty, the trouble originates either from the gearboxor from the control system.

l Bushing on outer speed selectorlever is worn

l Gearbox outer linkage needs adjust-ing and/or lubrication of joints isinsufficient

l Stroke of outer linkage parts is notsufficient due to excess play

l Not enough oil in gearbox-differ-ential casing

l Synchronizing units are faulty

l Inner controls are deformed orworn

l Sleeves and gears are worn ordefective

l Excess end-play of the gear thatbecomes disengaged (Noisy bothduring acceleration and deceler-ation)

Replace bushing

Check linkage, joints and controls

Check the system and, if necessary,repair or replace worn parts

Fill-up to correct level

Refer to “Synchronizing unit is faulty”

Repair or replace defective parts

Replace worn parts

Verify adjustment of gear train

May 1983 13-32

GEARBOX

Trouble

Speed selection is poor

Synchronizing unit is faultyor grinds

Reverse gear light do not lightup when R.G. is engaged

l Switch of R.G. light is faulty

Speed selector lever vibrates l Lever return spring is out of orderand is noisy due to fatigue

Seizure, pitting or breakage

Probable cause

l Bushing on outer speed selectorlever is worn

l Plungers are worn or damaged

l Springs can no longer be used dueto fatigue or because they arebroken

l Rod millings are ‘worn or deformed

l Selector fork and/or levers areworn or damaged

l Sleeve and gear front toothing areworn or damaged

l Distance between gear and sleevefront toothing is incorrect

l Synchronizing ring is worn

l Sleeve splines are worn or damaged

l Bushing on outer speed selectorlever is faulty

l Refer to other items concerningnoisy gearbox

l Oil level is below normal or oil isnot of the specified type

l Incorrect clearances (not enough)

l Bearing and gear ‘adjustments areincorrect

l Excessive torque or improper useof clutch

l Retaining screws are loose

Corrective action

Replace bushing

teplace plungers

Ieplace springs

Replace rods

?eplace the selector and/or the levers

3eplace defective parts

3eplace defective parts

Replace

Replace

Replace the switch

Replace faulty parts

Replace faulty parts and usespecified oil

Adjust clearances and replacefaulty parts


Replace faulty parts and tightenscrews to specified torque


Tool number Tool name Refer topaw

Spacer for locking of intermediate0 1 ~ 13-18A.2.0234 1

flange (ta be used with A.2.0242)

13-33 May 1983

GEARBOX

Tool number

A.2.0242

A.2.0243

A.2.0274

A.2.0300

A.3.0287

A-3.0291

A-3.0292

A.3.0293

A.3.0294

Tool name

Support of dial gauge to read pinion

spacer thickness (to be used with A.2.0234)

Tool for locking pinion

Adapter of sheave for checking

pinion bearing pm-load

Tool for locking mainshaft (to be

used with A.3.0300)

Adjustable span puller for differential

carnier bearing cones

Puller of bush shim and oil seal from

mainshaft and gearshift rod

Driver of differential bearing cups

CL-

Driver of bearing and phonic wheel

retainer onto differential spindle

Driver of oil seal onto gear shift rod

(with assembled unit)

May 1983

-.

13-34

Refer to

page

13-18

13-24

13-16

13-18

13-12

13-14

13-15

13-22

13-12

13-21

13-21

13-10

GEARBOX

Tool number

A.3.0295

A.3.0296

A.30297

A.3.0298

A.3.0299

A.3.0300

A.3.0301

A.3.0302

A.3.0303

Tool name

Plate for whith drawal of differential

spindle

Puller / driver of rear pinion bearing

cup and puller of pinion shaft and

mainshaft

Puller I driver of front pinion bearing

cup (use with A.3.0296)

Puller of speedometer pinion and

ring nut from shaft

Puller of differential bearing outer races

Driver of mainshaft and 5th speed

driver gear

Driver of pinion

Puller I driver of drive flange bearing

Guide for fitting striking rod balls of

3rd. 4th and rev. striking rods (use

with A.3.0309)

Refer to

paw

13-20

13-1113-1313-1413-15

13-11

13-15

13-20

13-20

13-15

13-16

13-16

13-20

13-21

13-8

13-9

13-35 May 1983

GEARBOX

Tool number

-

A.3.0430

A.3.0452

A.3.0453

A.3.0490

A.3.0491

A.39492

A.3.0495

A.3.0500

A.4.0136

Tool name

Driver of output shaft seal

Puller of drive spindle seal (with unit

assembled)

Driver of drive spindle seal

($-$D

Puller of 4th - speed gear from

mainshaft (to be used with

A.3.0296 and A.3.0492)

Puller / driver of rear mainshaft

bearing (to be used with A.3.0296)

Auxiliary shaft for removing 4th-speed

gear from mainshaft [to be used with

A.3.0296 and A.3.0490)

Puller of 5th _ speed drive gear

Tool for removing rear mainshaft

bearing (to be used with A.3.0296

and A.3.0491)

Support of dial gauge for pinion

setting (to be used with C-6.01 61)

Refer to

page

13-21

13-12

13-19

13-73

13-14

13-14

13-13

13-13

13-14

13-17

13-37 M a y 1 9 8 3

GEARBOX

Tool number Tool name

c.5.0124

C.6.0161

C.6.0162

Sheave for checking differential bearing

pm-load (to be used with A.2.0274 and

C.2.00371 . . . . . ..I

Reference gauge for pinion setting (to

be used with A.4.0136)

Tool for checking pinion setting (to be

used with A.4.0136)

Refer topaw

13-16

13-17

13-18

13-17

13-17

1 3 - 3 9 May 1983

DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY

CONTENTS

DIFFERENTIAL . . . . . . . . . . . . . . . . . 17-2

Crown gear and pinion . . . . . . . . . . 17-2

Differential casing . . . . . . . . . . . . . . 17-2

DRIVE SHAFT ASSEMBLY . . . . . . . . . 17-2

Removal . . . . . . . . . . . . . . . . . . . . . 17-3

Disassembly . . . . . . . . . . . . . . . . . . . . 17-3


Assembly . . . . . . . . . . . . . . . . . . . . . 17-4

Installation . . . . . . . . . . . . . . . . . . . 17-5

SERVICE DATA AND

SPECIFICATIONS . . . . . . . . . . . . . . . . 17-6

General specifications . . . . . . . . . . . 17-6



CORRECTIONS . . . . . . . . . . . . . . . . . . 17-6

SPECIAL SERVICE TOOLS . . . . . . . . . 17-6

a

c

May 1983


DIFFERENTIAL

CROWN GEAR DIFFERENTIALAND PINION CASING

For crown gear and pinion over- Fey differential casing overhauling

hauling procedure refer to: Group 13 p r o c e d u r e r e f e r t o : G r o u p 1 3

- 5-Speed Manual Gearbox - Crown 5Speed M a n u a l G e a r b o x Differ-

Gear and Pinion. ential Casing.

DRIVE SHAFT ASSEMBLY

1 Shaft2 Wheel nut3 Washer4 Drive shaft5 Washers6 Stopper ring7 inner race8 Cage9 Ball

10 Clamp11 Boot12 Clamp13 Clamp14 Boot15 Clamp16 Inner cover17 Seal ring18 Outer ring19 Inner race20 Cage21 Ball2 2 Stopper ring23 Outer cover24 Plate

‘fl/ %A\ 24.58 + 26.75)

A Outer jointB Inner joint

@ N*mIkgmmftdb)

May 1983 1 7 - 2


Outer cover 4 Inner cover

Outer ring 5 PlatePlates retaining 6 B o o t

screws

Mark outer ring, cage and joint’sinner race with a reference line toensure proper positioning when as-sembling.

j” 6. Use pliers to remove lock ring.

7. Now remove the. constant-speedjoint from the shaft with the help ofa press, two half-plates, a punch anda base.

8. Slip boot off the shaft andremove inner cover from the joint.9. Remove both seal rings from thejoint’s outer ring.

1. Using suitable ‘equipment,thoroughly clean all joint parts.2. Check working surfaces and bailsfor scores or any evidence of weardue to friction of foreign matter;replace the joint, if necessary.Remember that broken boots willcause loss of lubricant and will alsoallow foreign matter to enter which,in turn, will cause faulty operation ofthe constant-speed joints; usually thisproblem is easily detected duringtesting.3. Make sure that play in bothjoints is not too much since excessiveplay is the cause of noise duringsudden torque reversal; this is evi-denced by a knocking sound which iseasily detected during testing.

10. Remove steel balls from the Should disassembly by required, it isjoint and then disassemble the joint advisable to replace the joint protect-into its different components: outerring 0, cage 0, and inner

ing boots as well as the seal rings on

race 10.the constant-speed joint on gearbox-differential side.

ASSEMBLY

1 Inner race2 Cage

3 Outer ring


Reassemble joints being careful to fitparts back into their original posi-tion, as marked at time of disas-sembly, and following the procedurehereafter described.

OUTER JOINT (A)1. Thoroughly coat with grease(Molykote VN 2461 C or OptimolOlistamoly 2 L N 584) the cage, theinner race and the steel balls; packthe joint’s recess with 40 g (1.41 oz)of the same type grease.2. Fit boot on shaft being extreme-ly careful not to damage it in anyway along the splines; to this effectsplines should be covered with tape.3. Fit lock ring to groove on joint’sinner race. Make sure lock ring i sproperly and securely lodged in itsSeat on the shaft.4. Following disassembly proce-dure in reverse sequence, now fit theinner race and the cage.

Inner race should be fitted SO that itsface, on which lock ring was previ-ously fitted, faces to outside of thejoint.5. Fit steel balls as shown in thefigure.

CAUTION:Do not exchange this joint’s steelballs with those of the inner joint astheirdiameter is different.

M a y 1 9 8 3 17-4


6. Fit washers on shaft, wheel side,according to numbering marked attime of disassembly. Now fit theconstant-speed joint with the help ofa press, of two half-plates and of toolA.3.0605.

7. Finish up lubricating by packingjoint with 40 g (1.41 02) more of theabove mentioned grease and makesure that balls are completely sur-rounded by grease.8. Fit boot on joint; fit new clampsand tighten them using suitable pliersbeing careful not to damage the bootin doing so.

INNER JOINT (B)Thoroughly coat with grease (Moly-kote 2461 C or Optimal Olistamoly 2I- N 584) the cage, the inner race andthe steel balls; pack the joint’s recesswith 40 g (1.41 02) of the same typegrease.1. Fit boot on shaft being extreme-ly careful not to damage it in any

way along the splines; to this effectsplines should be covered with tape.2. Following disassembly proce-dure in reverse sequence, now fit theinner race and the cage.3. Fit steel balls as shown in thefigure and verify that the joint worksproperly.

7. Fit lock ring following disas-sembly procedure in reverse se-quence.8. Fit the boot; fit new clamps andtighten them using suitable pliersbeing careful not to damage the bootin doing so.9. Fit the three plates to the innercover, insert relevant screws andwashers, and lastly fit the outer coveronto the six screws.

CAUTION:Do not exchange this joint’s steelballs with those of the outer joint astheir diameter is different.

4. Fit inner cover to the joint andthen fit the latter on the shaft withthe help of a press, of two half-plates, of a base and a punch.

5. Pack joint with 40 g (1.41 02)more of the above mentioned greaseand make sure that balls arecompletely surrounded by grease.6. Fit both seal rings on the joint’souter ring.

INSTALLATION1. Insert shaft into wheel hub.2. Connect shaft to dif ferentialdrive shaft and lock securing screwsto specified torque.

@ : Tightening torque33 -F 36 N-m(3.4 + 3.7 kg-m24.56 f 26.75 ft-lb)

3. By means of a new nut, securewheel hub to shaft. Tighten nut tospecified torque, then caulk it .

0: Tightening torque226 + 275 Ndrn(23+ 28 kg-m166.30 + 202.46 ft.lb)

17-S May 1983


SERVICE DATA AND SPECIFICATIONSGENERAL SPECIF~ICATIONS


Application

Drive shaft assembly constant-speed

joints (for each joint)

Split grease quantity between the two

sides of each joint;s crown of steel balls

TIGHTENING TORQUES

TVP~

GREASE

Screws securing (in oil), with outer spacer, drive

shaft assembly to differential shaft

Nuts securing drive shaft assembly to wheel hub

Denomination

Molykote VN 2461 C

or Optimal Olistamoly 2 LN 584

Std. No. 3671-69843

N.m

33 + 36 3.4 + 3.7 24.58 + 26.75

226 + 275 23 f 28 166.30 + 202.46

Q.ty

8Q 9(2.82 oz)


Condition

Necking during sudden torquereversal

Probable cause

l Too much play between seats andsteel balls

l No r enough lubricating grease and

leakage from the boots

Corrective action

Replace the joint

Smear with grease and replace boots



we

A.3.0605 Base for withdrawal and fitmend of drive

shaft from constant speed joint.

May 1983 17-6

F R O N T S U S P E N S I O N

CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . 21-2

FRONT WHEELS HUB . . . . . . . . . . . . . 21-3

Removal . . . . . . . . . . . . . . . . . . . . . 21-4

Disassembly. . . . . . . . . . . . . . . . . . . 21-4


Assembly . . . . . . . . . . . . . . . . . . . . . 21-5

Installation . . . . . . . . . . . . . . . . . . . 21-6

FRONT SUSPENSION . . . . . . . . . . . . . 21-6

Coil spring and shock absorber . . . . 21-6

Transverse and semi-trailing link . . . 21-8

SERVICE DATA AND

SPECIFICATIONS . . . . . . . . . . n . . . . . 21-9

Technical data . . . . . . . . . . . . . . . . . 21-9

General specifications _ . . . . . . . . . . 21-10

Checks and inspections _ . . . . . . . . . 21-10



CORRECTIONS . . . . . . . . . . . . . . _ _ . . 21-l 1

SPECIAL. SERVICE TOOLS . . . . . . . . . 21-13

Refer to Group 00 - Chassis and Body Maintenancefor:

l Checking Suspension Heightl Wheel Alignment

May 1983

FRONT SUSPENSION

DESCRIPT ION

1 Coil spring2 Steering lever3 Strut4 JOIre boot5 Shaft6 Semi-trailing link7 Transverse link8 Ball joint9 Hub support

IO Wheel cover11 Bearing12 Hub nut13 Wheel hub14 Wheel screw15 Brake disc16 Dust cover17 Rim

May 1983 21-2

FRONT SUSPENSION

REMOVAL

1. Place the car on lift, block rearwheels and lift the front by means ofa jack, then support it on stands sitedin adjacent position to the bearingpoints (refer to: Group 00 - LiftingPoints and Towing).2. Removetive side.3. Removeand unscrewend.4. Removeential shaft

wheel from the opera-

the. nut caulking 48it out of drive shaft 3

drive shaft from differ-by unscrewing the six

securing, screws. Remove shaft withthe two constant-speed joints.5. Detach caliper @ from hubsupport, without disconnecting itfrom hose 0. 1 Screws 2 Bracket

7. Unscrew and remove nut secur-ing ball joint pin 0, on semi-trail-ing link 0, to hub support. Holdhub support properly, and by usingthe A.3.0157 withdraw pin.

12

Ball joint 3 L i n kSemi-trailing link

DISASSEMBLY1 Hose 4 Hub nut2 Caliper 5 Brake disc3 Drive shaft 6 Dowel

1. Clamp hub support in vice

6. Loosen and remove the fourscrews @securing vertical guide

provided with protective jaws, un-screw dowel and remove brake

1 Dust cover2 Dust cover securing screws

2. Using a screwdriver withdrawseal ring from hub support (shaftside).

3. Withdraw hub @ from itssupport @ by means of a press, asuitable punch and two plates.

1 Hub 2 Hub support

4. Reclamp hub support in viceprovided with jaws and using a punchremove two calkings on ring nutsecuring bearing to support. Usingand octagonal spanner with properextension unscrew ring nut and

FRONT SUSPENSION

5 . Wi thdraw bear ing f rom hubsupport by means of press pullerA.3.0302 and two plates.

-I

- A.3.0330

6. Reclamp hub in vice and using asuitable tool withdraw bearing innerrace.

1 Hub support 2 Hub

1 Hub support 2 Bearing

5. Lubricate seal ring outer surfacewith prescribed oil (AGIP Fl RotraHP SAE 8OW90 or IP Pontiax HD8OW90) and fit ring it its seat on hubsupport by means of tool A.3.0330.

2. Clamp hub support in vice pro-vided with jaws, fit a new ring andusing octagonal spanner A.5.0239screw ring nut into its seat on sup-port, tightening it to the specifiedtorque.3. Caulk ring nut edge.

@ : Tightening torqueBearing ring nut

226 + 225 N-m(23 + 27 kg-m116.3 + 195.2 ft-lb)


l . Carefully clean hub and hubsupport and visually check surfacesfor damage. Replace damaged parts,if required.2. Replace, at any rate, bearingassembly, ring nut and seal ring.

ASSEMBLY

1. Fit new bearing @ to hubsupport @ by means of press, toolA-3.0330 and stand A.3.0415.

6. Clamp hub support in viceprovided with jaws and fit dust coverand brake disc.

4. Insert support 0 into relevanthub @ using press, tool A.3.0330and plate.

2 1 - 5 May 1983

FRONT SUSPENSION

INSTALLATION

1. Reinstall hub-hub support as-sembly in the reverse order ofremoval and tighten following partsto the specified torque values:

@ : Tightening torquesNuts securing vertical guide to

bdy12+ 1 5 N-m(I,2 f I,5 kgpmEl,84 + 11 ft.lb)

Screws securing hub support tostrut braket

39-48 N - m(4 + 4.9 kg-m28.9 f 35.43 ft.lb)

Nut securing semi-trailing linkb a l l j o i n t t o h u b s u p p o r t

39-48 N - m(4s4.9 kg-m29.9 + 35.43 ft.lb)

2. Refit caliper to hub support.

@t Tightening torqueScrew fixing caliper on hubsupport

59 G-74 N-m(6 + 7.5 kg-m43.4 + 54.2 ft.lb)

3. Refit shaft, by doeing as fol-lows:(1) Insert splined end into wheelhub.

(2) Connect shaft to differentialdrive shaft by locking the six secur-ing screws to the designed torque.(3) By means of a NW nut, secure

shaft to wheel hub. Tighten nut todesigned torque and caulk it.

@ : Tightening torquesScrews securing drive shaft todifferential shaft

33+36 N-m(3.4 + 3.7 kg-m24.58 + 26.75 ft.lb)

Nut securing wheel hub toshaft

226 + 275 N-m(23 + 28 kg-m116.3 + 202.5 ft.lb)

COIL SPRING AND SHOCK ABSORBER

FRONT SUSPENSION

39.05 + 62.91) 28.9 f 35.43)

39.05 + 62.91k

I‘.lj

39.05 + 62.91)1 Washer 10 Lower washer 19 Strut bracket2 Upper washer 11 Rubber bound bumper 20 Flexible bush3 Rubber support 12 Lower cap 21 Semi-trailing link4 Complementary retainer 13 Lower retainer 22 Ball joint5 Retainer 14 Thrust bearing 23 Flexible bush6 Rubber seat 15 Bearing washer 24 Transverse link7 Upper cap 16 Seal ring 25 Flexible bush8 Boot 1 7 S t r u t9 Spring 18 Steering lever

@ N-m(kg-mftlb)

M a y 1 9 8 3 2 1 - 6

FRONT SUSPENSION

REMOVAL1. Place car on lift, block rearwheels, jack up front of vehicle, thensupport it by stands placed in adja-cent position to jacking points (referto: Group 00 - Lifting Points andTowing).2. Remove four screws and wheel.3. Unscrew nut securing ball pin ofsteering track rod @ to lever @ ofstrut 0.4. Using A . 3 . 0 1 5 6 puller with-draw upwards pin of steering trackr o d @ to lever @ of strut 0.

1 Strut2 Strut lever

3 Ball joint4 Steering track rod

5. Operating withing engine com-partment, loosen and remove fournuts @ securing strut to body 0.

1 Body 2 Nut

6. Hold strut properly, then loosenand unscrew the four screws 0securing strut bracket to hub sup-port.

1 Screw

DISASSEMBLYClamp strut in vice and carry outdisassembly as follows:1. Hook spring by’tool A.2.0251and screw two nuts @ of tool so asto progressively compress spring until-upper cap is released.

WARNING:Compress spring as minimum aspossible so as to allow upper caprotation with relevant gasket andretainer.When compressing spring, ensure thattool is always hooked firmly tospring and lower cap.

2. Unscrew shock absorber securingn u t @ as shown on fo l low ingfigure.

A.2.02517

1 Securing nut 2 Tool nut

3. Withdraw following parts (referto figure of page 21-6 1: washer 0,

upper washer 01 rubber sup--port 0, complementary retain-

e r @, lower washer 0, w i t hb o o t @, s p r i n g r u b b e r seat @with relevant retainer 05 andcap 0, rubber bound bumper 0 ,spring @ wi th re levan t lower

cap @ secured to compressiontool.If required, gradually release springfrom tool, then separate spring fromlower cap.Then remove lever retainer 130from spring lower cap.

4. Referring to the following fig-ure, dismantle cap retainer 0 tofol lowing parts, taking care innumbering them and mark directionto be kept during assembly: rollerthrust bearing @ , bearing wash-er @ and lower seal ring @ .

Mark lower capas SO as to identifythem during assembly.

1 Lower retainer 3 Bearing washer2 Thrust bearing 4 Seal ring

21-7 May 1983

FRONT SUSPENSION


Clean all the components.

j’...;-’ Self-lubricating bush

Check self-lubricating bushes embod-;..;,,,ied in strut lower cap retainers for’ : signs of excessive wear which are

showed by metallic dust appearing,,- on’bush working surface.

Shock absorberIf required verified setting data re-levant to shock absorber built-instrut. (Refer to Service Data andSpecifications-Checks and Inspec-tions).

Replace shock absorber in case theyare removed because of inefficiencyor oil leakages are detected.

Springs

Visually check springs for anomalous,signs.

Rubber parts

Replace rubber parts if deformed,damaged or aged.

ASSEMBLY

1. Lubricate seal ring and thrustbearing of spring lower cap 0retainer with grease (AGIP Fl Grease33 FD, IP Atitogrease FD).Refit all parts of retainer to strutcomplying with direction and ordermarked during disassembly.2. If previously removed, refit toolA.2.0251 to spring @ and lowercap @ with tool clamped in vice;compress spring so that subsequentassembly procedure can be carriedout.

A.2.0251

ro1

1 Lower cap

May 1983

2 Spring

Refit remaining parts of strut .as-sembly complying with sequenceshown on figure.

Spring lower and upper caps shouldbe those corresponding with the-side.(righthand .or l&hand) to whichstrut is installed.

INSTALLATION

1, Install strut in the reverse orderof removal and tighten followingparts to the specified torque:

@ : Tightening torqueScrew securing hub support tostrut bracket

39t48 N -m(4 + 4.9 kg-m28.9: 35.43 ft-lb)

Nut securing strut to body12+ 15 N-m(I,2 + I,5 kg-m8,84 + 11 ft.lb)

Nut, steering tie rod ball jointon bracket lever

39 + 48 N-m(4 + 4.9 kg-m

2 8 . 9 + 3 5 . 4 3 ft.lb)

TRANSVERSE ANDSEMI-TRAILING LINK

REMOVAL

1. Place car on lift. Support frontof vehicle on stands sited in adjacent-position to jacking points and blockrear wheels by hand brake.

2 1 - 8

2. Remove wheel from the opera-tive side.3. Loosen and remove shaft secur-ing nut (wheel side).4. Detach constant-speed jointfrom differential drive shaft byloosening the six securing screwsand remove shaft.5. Remove nut securing semi-trail-ing link ball joint pin @ to hubsupport and withdraw pin using toolA.3.0157.6. Loosen bolt @ securing trans-verse link @ to engine cross mem-ber @ and bolt @ securing tosemi-trailing link @ , then with-draw the removing transverse link.7. Loosen bolt @ securing semi-trailing link to body and remove thelink.

1 Cross member 5 Bolt2 Bolt 6 Semi-trailing link3 Transverse link 7 Bolt4 Fin

8. If required, after checking flex-ible joints: remove flexible jointsfrom semi-trailing links and trans-verse jinks by means of proper tool.

FRONT SUSPENSION


Clean all the components1. Visually check semi-trailing linksand front transverse links for blows,deformations, oxidation, cracks.2. Examine condition of flexiblebushes in semi-trailing and transverselink knuckles.3. Check that semi-trailing link balljoint pivots free from crawlings orwith notable slack in its seat.

CAUTION:To ease joints installation, lubricateouter surface with the fluid pre-scribed for rubber parts fitting tometallic seats (MILLOIL Slider forrubber sections; UNION CARBIDECHEMICALS COMPANY Ucon Lu-bricant 50 HB - 5100).

Avoid flexible joints coming intocontact with oil or grease.

INSTALLATION

2. Install transverse links and semi-trailing links to body in reverse orderof removal and torque-tighten screwsecuring semi-trailing link ball jointpin to wheel support to the specifiedvalues.

1. If previously removed, it flexible Tighten fixing points of semitrailingjoints, inserting them from the and transverse link flexible joints tochamfered side, to semi-trailing link specified torque with car having itsand front transverse link. nominal height (see: Car Height).

@ : Tightening torqueScrew securing semi-trailinglink ball joint pin to wheelsupport

39+448 N-m(4 + 4.9 kg-m28.9 4 35.43 ftdlb)

Screw securing transverse andsemi-trailing links

53+ 8 5 N-m( 5 . 4 + 8 . 7 kgm39.05 + 62.91 ftlb)

3. Refit drive shaft (see: FrontWheels Hub - Assembly).


TECHNICAL DATA

COIL SPRING SHOCK ABSORBER

Wire diameter

Coil diameter

Free length

Stiffness

mm (in)

mm (in)

mm (in)

N/mmWmml(lb/in)

13.6 (0.535)

160 (6.299)

293 (I 1.535)

2 4 . 5

(2.51(140)

Shock absorber type

Piston rod diameter

Stroke

hydraulic

mm (in) 2 0 ( 0 . 7 8 7 )

mm (in) 148.5 (5.846)

FRONT SUSPENSION



Application

Seal ring and spring lower cap retainer

thrust bearing

Hub support seal ring outer surface FLUID

Outer surface of the semitrailing link

and front link silent block

TYPeI

DenominationI

Q.W

GREASE AGIP Fl Grease 33 FD

IP Autogrease FD

Norm. 3671-69833134

-

AGIP Fl ROTRA HP SAE 8OW90

IP Pontiax HD 8OW90

Norm. 3631-69408

FLUID MILL01 L: Slider for rubber sections

UNION CARBIDE CHEMICALS COMPANY

Ucon Lubricant 50 HB-5100

Norm. 1500-l 7502

-


DATA OF SHOCK ABSORBERS SETTING

SHOCK ABSORBER I LEFT RIGHT

Alfa Romeo Part NumberI I

542.353 I 542.352

Low speedCompression N (kg) (lb) 1 0 7 . 9 + 1 8 6 . 4 (11 + 19) (24.25+ 4 1 . 8 9 )

Expansion N (kg) (lb) 215.X + 3 1 3 . 9 ( 2 2 + 3 2 ) ( 4 8 . 5 + 70.55)

Compression N (kg) (lb) 421.83559.2 (43 + 5 7 1 ( 9 4 . 8 + 1 2 5 . 7 )High speed

Expansion N {kg) (lb) 1128.15G1324.3 (115 + 135) ( 2 5 3 . 5 + 2 9 7 . 6 )

NOTE: The shock absorbers are integrated in the strut tubes

May 1983 21-10

FRONT SUSPENSION

Trouble

Steering wheel shocks,vibrations or shimmying(cont.)

Vehicle drifts or wanders

Steering wheel excessive play

Noise

Tires squeal when takinga curve

Abnormal tires wear l Refer to: Group 28-Wheels and(or uneven) Tires

Probable cause

l Excessive play in steering linkage

l Loose screws securing steeringbox

Corrective action

Check and replace if required

Tighten

l Unserviceable shock absorber orloose securing points

Tighten or replace

Drifting becomes evident when vehicle is running on a flat surface with handsoff steering wheel. Reference should also be made to: Group 25 - TroubleDiagnosis and Corrections

l Worn or faulty tire

l Improper tire air pressure and/orloose wheel nuts

l Difference in height between rightand left tire tread

l Asymmetric suspension height

l Incorrect steering geometry

l Brake dragging

l Worn suspension linkage flexiblebush

l Connection steering-suspensionfaulty

l Pinion-rack mating incorrectlyadjusted

l Worn steering components

l Loose steering box securingscrews

l Improper tire air pressure

l Damaged and worn ball pin orsteering parts; or lack in lubri-cation

l Loose steering or suspensionlinkage

l Faulty shock absorber

l Faulty wheel bearing

l Faulty suspension linkage bush

l Damaged coil springs

l Loose shock absorber securing nut

l Improper tire air pressure


l Incorrect driving

Replace

Adjust and/or tighten

Replace tire with thinnest tread

Restore

Restore

Check and restore working conditions

Replace worn components

Replace faulty components

Adjust

Replace worn components

Tighten

Adjust

Replace or lubricate

Tighten

Replace

Replace

Replace

Replace

Tighten

Adjust

Restore

Avoid incorrect driving

Wheels and tires

M a y 1 9 8 3 21-12

FRONT SUSPENSION

Trouble Probable cause Corrective action

Stiff steering wheel

1

l Improper tire air pressurel Excessively worn tire

l Pinion-rack mating incorrectlyadjusted

Adjust

Replace

Adjust

After these preliminary operations, if trouble persists, check and operate asfollows.Jack up front of vehicle and support on safety stands. Separate strut knuckledarm from track rod and move steering wheel.

a) If steering wheel is light to move, check and locate cause of trouble in steer-ing linkage, suspension or front axle

b) If steering wheel is hard to move, check and locate cause of trouble in steer-ing box or steering column.

Improper steering box’lubricationor/and oil contamination (b)

Improper steering linkage lubri-cation, grease contamination orabnormal steering wheel wear (a)

Worn or seized ball pin (a)

Deformed steering linkage (a)

Incorrect steering geometry (a)

Lubricate

Correctly lubricate, replace greaseor worn parts

Replace

Replace

Restore


Tool number Tool nameI

Refer topage

A.2.0251 Tool for compressing and retaining spring

A.3.0156 Puller of upper pin from stub axle

A.3.0157 Puller of wheel hub support lower joint

pin

21-13 May 1983

FRONT SUSPENSION

Tool number

A30302

A.3.0330

A.3.0415

A.5.0239 Wrench for bearing front hub nuts

Tool name

Puller/driver of cup of front hub

bearings

Driver of seal and bearing of front hubs 0 \

(to be used with A.3.0415) I\

Base of withdrawal fitment (to be used

with driver A.3.0330)

cl

IO

Refer to

Page

21-5

21-5

21-5

21-5

M a y 1 9 8 3 21-14

FRONT AND REAR BRAKES

CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . 22-2

Brake system bleeding . . . . . . . . . . . 22-3

Pedal assembly . . . . . . . . . . . . . . . . 22-4

Brake master cylinder . . . . . . . . . . . 22-6

Hydraulic system piping . . . . . . . . . 22-8

Brake pressure regulator valve . . . . . 22-8

Servobrake . . . . . . . . . . . . . . . . . . . 22-9

Vacuum system . . . . . . . . . . . . . . . . 22-l 0

Front disc brake . . . . . . . . . . . . . . . 22-10

Rear drum brake . . . . . . . . . . . . . . . 22-15

PARKING BRAKE . . . . . . . . . . . . . . . . 22-17

Control lever . . . . . . . . . . . . . . . . . .

Control cables . . . . . . . . . . . . . . . . .

SERVICE DATA AND

SPECIFICATIONS . . . . . . . . . . . . . . . .

General specifications . . . . . . . . . . .

Inspection and adjustment . . . . . . .

Tightening torques . . . . . . . . . . . . .

TROUBLE DIAGNOSIS ANDCORRECTIONS . . . . . . . . . . . . . . . . . .

SPECIAL SERVICE TOOLS . . . . . . . . .

Refer to Group 00 - Chassis and Body Maintenancefor:

l Brake System

22-17

22-18

22-l 9

22-19

22-20

22-21

22-22

22-26

Mav 1 9 8 3


SERVICE BRAKE

BRAKESYSTEM BLEEDING

Bleed brakes following the proceduredescribed hereafter and being carefulto perform the following:

a. Check that during bleeding thefluid level in the reservoir doesnot go below the “MIN” level.

b. Do not reuse the oil drainedduring bleeding operation.

c. Work with extreme care in orderto avoid damaging painted sur-faces through contact with thefluid.

1. Place car on a lift.2. If required, refill reservoir withspecified fluid (ATE “S” or AGIP FlBrake Fluid Super DE or IP AutoFluid FR).3. Remove dust covers from bleed-ers located on calipers or on wheelcylinders.4. Carry out bleeding operationsclosely following the instructionsdescribed hereafter.(1) Fit a small hose to the bleeder ofeach front brake caliper, of each rearwheel cylinder, and of bleed screw ofbrake pressure regulator. Place thehose other end into a transparentcontainer previously partially filledwith specified brake fluid.(2) Loosen the above mentionedbleeders and press a few times thebrake peda l a l l the way down,releasing it very slowly and waiting afew moments in between pressings.Repeat this operation till the fluidcoming out of the hoses is free of airbubbles and then press once more

the pedal all the way down; nowtighten the bleeders.

It is up to the operator whether tocarry out the operation by operatingat the same time or separately on thefire bleeder screws.

CAUTION:During bleeding operation alwayskeep the level of fluid in reservoirabove the “Ml N” level.

(3) Remove hoses from bleeders andfit relevant caps.5. Press brake pedal all the waydown and check whether; immediate-ly after the pedal’s initial free travel,you feel a direct action on the fluidwithout elasticity, if not so, repeatbleeding operation.6. Restore fluid level in the reser-voir and close it with relevant cap.

2 2 - 3 M a y 1 9 8 3


PEDAL ASSEMBLY

@ N-m(kg-mft-lb)

1 Retainer2 Washer3 Gasket4 Pedal assy bracket5 Stop light switch6 Pin

DISASSEMBLYCarry out removal of pedal assemblyoperating as follows:

a. Engine seat1. Disconnect electrical wiring @of brake fluid level warning light andwith a syringe take out all brake andclutch fluid from reservoir @2. Unscrew unions @ connectingthe four pipes that start out from thebrake master cylinder 0. F r o mclutch master cylinder @ removethe pipe @ and the hose @ con-necting it to the reservoir.3 . From servobrake remove thesleeve 90 connected to the vacuumintake pipe.4 . R e m o v e s c r e w @ securingsheath clamp plate of the acceleratorcontrol cab le.

7 Bull ring8 Spacer9 Accelerator pedal

10 Bolt11 Plastic bush12 Pin

1 Hose 5 Brake master2 Clutch master cylinder

cylinder 6 Brake liquid tank3 Pipe 7 Electric cables4 Pipe unions 8 Screw

9 Sleeve

13 Brake pedal14 Bull ring15 Spring16 Spacer17 Clutch pedal

b. Passenger compartment1. Separate from accelerator pedalthe control cable @ and releaseelectric connection @ of the stoplight switch.2. By removing retaining rings,return springs and connecting pinsdisconnect the brake and clutchpeda ls f rom con t ro l fo rks @a n d @ o f t h e r e l e v a n t mastercylinders.3. By unscrewing the four securingnuts 0, separate from pedalassembly the servobrake - brakermaster cylinder unit.4. By unscrewing the two securingb o l t s @ remove clutch mastercylinder from pedal assembly.5. Unscrew the six nuts (set inevidence by figure) securing pedala s s e m b l y t o b o d y a n d r e m o v epedal assembly from engine seat.6. Remove, if necessary, the acce-lerator pedal from hinge to pedalassembly support by unscrewingbolt @.

M a y 1 9 8 3 2 2 - 4


1 Electricconnection

2 Cable3 Nut4 Bolt

5 Clutch mastercylinder fork

6 Brake mastercylinder fork

DISASSEMBLY

Disassemble pedal assembly operat-ing as follows:1. Remove retainer @ of pedalspin @ and washer @ .2. Withdraw Pin and recover ped-a ls @ and 0, and spacer ‘@.3. Remove plastic bushes @ frompedals.

1 Retainer2 Washer3 Pin4 Bush

5 Pedal6 Spacer7 Pedal

CHECKS AND INSPECTION

1. Verify condition of pedals, ofpedal assembly and gasket.2. Check against presence of excessive wear and mesh in bushes, pinand spacer.3. Check against presence of yieldin return springs.4. If necessary, remove and replacethe stop light switch.

REASSEMBLY

For pedal assembly, reassembly,reverse the order of disassembly andapply a coat of the prescribedgrease (AGIP Fl Grease 15) to theparts subject to sliding and to returnsprings.

10.85 + 13.74 ft-lb)INSTALLATION

1. Reinstall pedal assembly to bodyby reversing order of removal andcomplying with the following.(1) Replace, if required, the gasketbetween pedal assembly and body.( 2 ) T i g h t e n , t o t h e p r e s c r i b e dtorque, t h e n u t s secuging p e d a lassembly to body.

6. Fill the brake and clutch oil tankup to maximum level.7 . Carry out bleeding of brakehydraulic system (see: Brake SystemBleeding) and of clutch (see: Group12 Hydraulic Control Sub-assemblyHydraulic System Bleeding).

0: Tightening torque of pedalassembly nuts

9+15 N-m( 0 . 9 5 1.5 k g - m6.51 + 10.85 ft.lb)

(3) Lubricate forks connecting bothbrake and clutch pedals to therelevant master cylinders, with AGIPFl G R E A S E 1 5 ; t h e n riconnectthem.2. Reconnect to pedal assembly theservobrake together with brake mas-ter cylinder and then clutch mastercylinder.3. If previously removed, reconnectaccelerator pedal after lubricatingspacer. Make sure that acceleratorpedal can freely rotate after tight-ening securing nut to the prescribedtorque.

0: Tightening torqueSt10 N - m(0.8 f 1 kg-m5 . 7 8 + 7 . 2 3 f t - l b )

22-5 M a y 1 9 8 3

4. Lubricate end of acceleratorcable before connecting it to pedal.Then, after securing the sheath clampplate to pedal assembly, adjust itstravel (see: Group 04 - AcceleratorControl Adjustment).5. Tighten to the prescribed torquethe unions of brake master cylinderpipes and the union of clutch mastercylinder pipe.

0: Tightening torquesUnions of brake master cylin-der pipes

8+10 N-m(0.8+ 1 kgam5.78 + 7.23 ft.lb)

Union of clutch master cylin-der pipe

15 + 19 N-m(1.5+ 1.9 kg-m


BRAKE MASTER CYLINDER

1 Level indicator2 Reservoir3 Union4 Seal ring5 Spring6 Support disc7 Spring8 Washer9 Gasket

10 Space sleeve11 Intermediate piston

12 Gasket13 Tab washer14 Lock ring15 End washer16 Gasket17 Washer18 H shaped gasket19 Bush20 Push rod piston21 Space sleeve22 Gasket

23 Washer24 Spring25 Support disc26 Return spring27 Setscrew28 Washer29 Master cylinder body30 Filter31 Gasket32 Cap

N-m(h-m*lb)

May 1983 2 2 - 6


b. Tighten to the prescribed torquetwo new nuts securing brakemaster cylinder to servobrake.

(T): Tightening torqueBrake master cylinder nuts toservobrakeBENDITALIA

12+ 1 5 N-m

syringe in order to suck thel iquid of brake clutch tank.

b. AS piping is removed, rememberto plug up the ends in order toavoid foreign matter from en-tering.

. To remove pipes, loosen unionson both ends.

(1.2+ 1.5 kgmm8.68 + 10.85 ft4b)

. T o r e m o v e hoses, unscrewunions collecting pipes-to hosesand remove them. Then, discon-nect hose on the other side.

ATE21 + 28 N-m(2.1 + 2.9 kg.m15.2 + 21 ft4b)

c. Pipes must be connected tomaster cylinder and tightened tothe indicative prescribed torque.

@ : Tightening torqueUnions securing pipes to brakemaster cylinder

8-10 N-m(0.8 + 1 kgmm

c. At the end of installation on car,both front and rear f lexiblecables must not result to bekink. For their check, take asreference the writing with therelevant manufacturer marklocated on end of pipes, or thelight coloured band (for frontcables) located along pipe itself.

d. Having completed installation ofpiping, fill up brake fluid reser-voir to proper level and bleedthe brakes (Refer to: BrakeSystem Bleeding).

5.78 + 7.23 ft.lb)

d: Fill reservoir up to proper levelusing only specified fluid (ATE“S” or AGIP Fl B r a k e F l u i dSuper ED, or IP Auto Fluid FR).

2. Bleed brake system (Refer to:Brake System Bleeding) and, i frequired, also clutch system (Referto: Group 12 Subgroup HydraulicControl - Hydraulic SystemBleeding).

Tightening torquesHose unions of brake hydraulicsystem

IO+ 1 5 N - m(1 + 1.5 kgmm7.23 + 10.85 ft-lb)

Pipe unions of brake hydraulicsystem

8+10 N-m(O-S+ 1 kg-m5.78 + 7.23 ft.lb)

HYDRAULICSYSTEM PIPING


Thoroughly check all brake systempiping (pipes and hoses) making surethey are not out of shape or crackedand that outer surfaces of pipes donot show any evidence of oxidation.Replace parts that are not flawless.

BRAKE PRESSUREREGULATOR VALVE

REMOVAL


CAUTION:a. In case of removal or reinstal-

lation of brake pipings, use a

1. Unscrew the three unions 1 of0the brake pressure regulator pipes,taking care to close, by means ofcaps, the two feeding pipes of brakepressure regulator, in o r d e r t oprevent tank emptying.2. Remove from body, the brakepressure regulator valve by unscrew-ing the two securing screws @ andremovingspring 0.

f o r k @ f r o m c o n t r o l

May 1983 2 2 - 8

3. Loosen and remove bolt @connecting the Panhard rod @ tobody and loosen the equalizersecuring bolt @.

1 Unions 5 Bolt2 Fork 6 Bolt3 Spring 7 screws4 Panhard rod

4. Lower Panhard bar in order toeasy spring @ withdrawing frompin 0, and from rubber ring @located on rod itself. Remove springby withdrawing i t f r o m equaliz-er 405. If necessary, remove bolt @and equaliter.

1 Spring2 R i n g3 Pin

4 Equalizer5 B o l t

CAUTION:Do not disassemble components ofthe brake pressure regulator.

INSTALLATION

1. Reinstal l to body the brakepressure regulator valve by tighteningbolts to the prescribed torque:15 + 24 N.m ( 1 . 5 + 2 . 4 kg.m)( 1 0 . 8 5 + 1 7 . 3 5 ft.lb) and ( i f pre-


INSTALLATION1. On bank, reconnect master cyl-inder to servobrake tightening secur-ing nuts to the prescribed torque(see: Brake Master Cylinder - Instal-lation).2. For reinstallation on car of thewhole unit, reverse order of removaland comply with the following.(1) Tighten unions of pipes to theprescribed torque: IO + 14 N.m(1 + 1,4 kg-m) (7.23 + 10.84 ft.lb).(2) Lubricate connecting pin withprescribed grease (AGIP Fl GREASE15); then reconnect fork to brakepedal.(3) Restore level of brake fluid; thencarry out bleeding (see: BrakeSystem Bleeding).

VACUUM SYSTEM1. Visually check hoses makingsure they are in no way damaged orclogged; also make sure clips are allproperly tightened.

FRONTDISC BRAKEDBA CALIPER

@ 59 + 73(6 + 7 .543.38 + 54.23)

1 Caliper setting 7 Dust coverclip 8 Piston

2 Caliper support 9 Seal ring3 Pad 10 Floating caliper4 Pad retaining 11 Bleeder

clip 12 Bracket5 Retainers 13 Washer6 Plate 14 Screw

2. Remove non-return valve (iJafter having removti relevantclips 0,

Valve 2 Clips

3. Check valve thoroughly makingsure it works properly, meaning thatit allows air flow only in the direc-tion shown by crawfoot.

4. When fitting non-return valveback to hose, be careful to position it

so that the crawfoot in the abovefigure points towards the intakemanifold _

A Intake manifold side (black)B Servobrake side (white)

(0.2 f 0.351.45 + 2.53) b

@ N.m(kg+mftilb)

May 1983 22-10


Pad replacement

I . Lift car’s front end positioning iton safety stands (Refer to: Group 00- Lifting Points and Towing).2. Using suitable pl iers removeretainers @ from setting plates 0as shown in the figure below.

1 Plares 2 Retainers

3. With the help of a punch,plates 0 and @ and takeout.

Plates are not interchangeable.

pushthem

1 Upper plate2 Lower plate

3 Floating caliper

4. Press floating caliper so as topush it toward the lower groove andthen remove it from the support.

1 Caliper support 2 Floating caliper

5. Remove both pads, each withrelevant dowel pin 0, and thenremove pins from pads,

-1

1 Fad dowel pin

CAUTION:When pads are off, do not push brakepedal in order to avoid piston frombeing ejected from its seat on float-ing caliper. When replacing pads useonly original spare parts and replacethem on both calipers.Pad assembly must be carried out bypos i t ion ing the crawfoot in theforward rotation direction of thebrake disc.

6. Clean pads seats on caliper withalcohol.

CAUTION:Do not lubricate in any way eitherthe pad’s resting seats on calipers norpad dowel pins.

7. Fit dowel pins on pads and thenfit same into relevant seat.8. Push piston towards its positioninto floating caliper.

CAUTION:To avoid overflow of brake fluidwhen the piston is pushed back, it isadvisable to suck some of the fluidfrom the reservoir by means asyringe.

9. Now fit the floating caliper andboth setting plates.

CAUTION:Do not lubricate setting plates.

10. Fit relevant retainer on eachplate,

11. Restore proper brake fluid levelin reservoir (ATE “S” or AGIP FlBrake Fluid Super ED or IP AutoFluid FR).

CAUTION:To restore correct braking, pushbrake pedal all the way down a fewtimes.

Caliper unit

REMOVAL

Remove caliper unit as follows:1. By means of a syringe, suckbrake fluid from feed tank.2. Disconnect brake fluid hose 0.3. Loosen and remove the twoscrews @ securing caliper unit tohub support and then remove thewhole caliper unit.

CAUTION:In case of caliper unit replacement,make sure that on front axle aremounted calipers of the same typeonly.

1 Securing screws 2 Hose

INSTALLATION

Fit back caliper unit as follows:1. Fit caliper unit and bracket forbrake fluid hose and then tightenrelevant retaining screws to specifiedtorque.

0: Tightening torqueCaliper retaining screws

59+73 N-m(6 + 7.5 kg-m43.8 f 54.23 ft-lb)

22-11 May 1983


2. Connect brake fluid hose (Referto: Hydraulic System Piping).3. Fill brake fluid reservoir up tomax. level (ATE “S” or AGIP F 1Brake Fluid Super ED or IP AutoFluid FR).4. Bleed brake system (Refer to:Brake System Bleeding).

Floating caliper

DISASSEMBLY

If required, carry out disassembly ofbrake caliper operating as follows:1. Empty brake fluid reservoir witha syringe.2. Disconnect brake f luid hose.3. Remove floating caliper (Referto: Pad Replacement) and close it ina vice equipped with protecting jaws.4. Remove dust cover @ and thenuse a jet of compressed air to removebrake p is ton @ from cyl inder.5. Remove seal ring @ from itsseat on cylinder.

1 Floating caliper 3 P i s ton2 Dust cover 4 Seal ring

May 1983


Thoroughly wash all parts in alcoholand dry them with a jet of com-pressed air.

CAUTION:Do not use metal tools and deter-gents containing mineral oil.

Floating caliper body

1 . C h e c k c y l in d e r s u r fa c e fo rcracks, evidence of excessive wearand presence of rust or foreignmatter.2 . T o r e m o v e rust or foreignmatter, clean the surface with a veryfine emery cloth.3. In case of more severe damagereplace floating caliper body.4. Check bleeder and make sure itis in good working condition.

Piston

Check piston outer surface forcracks, evidence of excessive wear,deterioration and presence of rustor foreign matter. In case just one ofabove flaws is present, replace thepiston or the whole floating caliper.

CAUTION:Do not clean piston surface withemery cloth but go on and replace it.

Seal ring and boot

Replace seal ring and booteach timethey are disassembled.

Caliper support

Check element good condition andreplace it if necessary.

Clips

Make sure they are not damaged orabnormally worn; replace them ifnecessary.

INSTALLATION

If previously disassembled, carry outreassembly of floating caliper operat-ing as follows:1. G r e a s e cyl inder, piston andsealing ring applying a coat of rheprescribed brake grease (Grease ATEBremsrylinder Paste or DBA Grease);fit seal ring on cylinder and theninsert control piston.

2 2 - 1 2

2. Lubricate boot inner surfacewith the above mentioned grease,and fit it into its seat.3. Fit floating caliper on relevantsupport (Refer to: Pad Replace-ment).4. Connect oil pipe back to floatingcaliper and tighten relevant union tospecified torque; fill reservoir upwith specified brake fluid (ATE “S”or AGIP Fl Brake Fluid Super ED orIP Auto Fluid FR).

0: Tightening torqueBrake pipe to caliper union

IO+14 N-m(1 + 1.5 kg-m7.23 f 10.84 ft.lb)

5. Bleed brakes (Refer to: BrakeSystem Bleeding).

CAUTION:At the end of installation on car,make sure that hose are not kink.

Brake disc

REMOVAL AND INSTALLATION

1. Remove from hub support, thewhole brake caliper without discon-necting it from hose (see: Group 21 -Front Wheel Hub).2. Remove brake disc from hubsupport after having removed thedowel pin.3. Install disc and caliper followingremoval procedure in reverse se-quence.


1. Thoroughly clean brake discsand check that working surfaces arenot deeply scored or porous. Replaceor machine them if necessary.2. Should machining of disc work-ing surfaces be required, keep inmind the following:

(1) Always machine both surfaces ofeach disc, removing the same amountof material from each surface.(2) Machining must be performedaccording to tolerances indicated inthe Service Data and SpecificationsSection - “Checks and Adjustments”.


Pad replacement

1. Lift car’s front end positioning iton safety stands (Refer to: Group 00- Lifting Points and Towing).2. Using a suitable punch, push paddowel pins @ as shown, in thefigure that follows:

1 Pins

3. Remove, in sequence: the lowerpin, the cross spring plate 0, andthe upper pin.

1 Cross spring plate

4. With suitable pliers, remove thepad on cylinder’s side.5. With a plastic hammer, strikefloating caliper on cylinder’s sidethus removing the other pad.

1 Pad on cylinder’s side2 Brake disc

May 1983 2 2 - 1 4

CAUTION:When pads are off, do not push brakepedal in order to avoid piston frombeing ejected from its seat on float-ing caliper. When replacing pads useonly original spare parts and replacethem on both calipers.Pad assembly shall be carried out bypositioning crawfoot towards theforward rotation direction of brakedisc.

6. Clean pads’ seats on caliper withalcohol.

CAUTION:Do not lubricate in any way thepads’ retaining seats on calipers.

7. Push piston back into floatingcaliper.

CAUTION:To avoid overflow of brake fluidwhen the piston is pushed back, it isadvisable to withdraw some of thefluid from the reservoir with asyringe.

8. Fit pads into their relevant seatand then complete assembly byfitting, in sequence: the first dowelpin, the cross spring plate, and thesecond dowel pin.9. Restore proper brake fluid inreservoir (ATE “ S ” o r -AGIP FlBrake Fluid Super ED or IP AutoFluid FR).

CAUTION:To restore correct braking, pushbrake pedal all the way down a fewtimes.

Caliper unit


Removal and installation proceduresof ATE calipers are like those ofDBA calipers (Refer to: DBA CaliperRemoval and Installation).

Floating caliper

DISASSEMBLY

If required, carry out disassembly offloating caliper, operating as follows.

1. Empty brake fluid reservoir witha syringe.2. Disconnect brake fluid hose.3. Remove pads (Refer to: PadReplacement).4. With a plastic hammer, strikefloating caliper @ till it comes offfrom its support @ _

1 Floating caliper 2 Caliper support

5. Fit caliper on a vice equippedwith protecting jaws and remove thedust cover’s @ lock ring 0 as wellas the boot.6. Use a jet of compressed air tor e m o v e b r a k e p i s t o n @ f r o mcylinder on floating caliper body

a7. Remove seal ring @ from itsseat on cylinder.

1 Lock ring2 Oust cowr3 Piston

4 Seal ring5 Floating caliper


For checks and inspections of ATEcalipers, refer to: DBA cal iper -Checks and Inspections.

INSTALLATION

If previously disassembled, carry out


assembly of floating caliper, operat-ing as follows.1. Apply a coating of the pre-scribed brake grease to cylinder,piston and seal ring; fit seal ring oncylinder and then insert controlpiston.2. Lubricate boot inner surfacewith the mentioned brake grease;then secure it with relevant lock ring.

Make sure boot and relevant lockring are properly fitted.

3. Fit floating caliper on relevantsupport.4. Connect oil pipe back to floatingcaliper.

0: Tightening torqueBrake pipe to caliper union

IO+ 14 N-m(1 + 1.5 kg-m7.23 + 10.84 ftelb)

5. Using a square caliper with a 2@angle, ver i fy that brake controlpiston is properly positioned.

REAR DRUM BRAKE

6. If the step on the piston doesn o t m a t c h t h e square caliper’sdiagonal, rotate the piston withsuitable pl iers t i l l the posit ionrequired by the square caliper isreached.

7. Proceed and complete the as-sembly fitting the pads and securingthem by means of relevant dowelpins (Refer to: Pad Replacement).6. Fill reservoir up with specifiedbrake f luid (ATE ‘5” or AGIP FlBrake Fluid Super ED or IP AutoFluid FRI.9. Bleed brakes (Refer to: BrakeSystem Bleeding).

CAUTION:At the end of installation on car,make sure that hose are not kink.

Brake discFor all operations concerning brakediscs refer to: DBA Caliper BrakeDisc.

1 Bleeder cap2 Bleeder3 Dust cover4 Piston5 Seal ring6 Spring7 Cylinder body8 Knuckle pin securing plate9 Jaw driving plate

10 Jaw return spring11 Spring

@ N-m(kg-mft.lb)

14 Vibration -damping springVibration - damping spring stop

19 Adjustment lever2 0 J a w21 Shoe holder disc

2 2 - 1 5 May 7983


JAW REPLACEMENT

Removal

I. Remove wheel and brake drumtogether with hub (see: Group 25Rear Hub).2. Operating from passenger com-partment, loosen cormol cables ofparking brake, by operat ing onadjustment nut and lock-nut.3. Operating from wheel side, re-lease control cable end @ fromlever @ and release it from fair-lead 0,4. By means of a suitable clamprelease, in the following order: shoeupper return spring 0, shoe lowerreturn spring @. Remove then thejaw vibration _ damping springs 0.

12

,3

Upper spring 4 Control cable endLever 5 FairleadVibrat ion 6 Lower springdamping spring

5 . R e m o v e t h e t w o j a w s f r o mbrake holder disc and if required,separate them, after releasing

spring 0 from jaw jointingsquare 0.

1 Spring 2 Square

6. Disassemble, (if required) theadjustement device, operating as

follows:(1) Remove retain spring 0, Thenfrom jaw, withdraw pin @ togetherwith spring @ and lever @ of theadjustment device.(2) Remove seal ring @ andseparate from jaw the swinging le-ver 10 of the adjustment device.

The removed seal rings must anywaybe replaced during reassembly.

1 Swinging lever 4 Pin2 Spring 5 Retain spring3 Lever 6 Seal ring

7. If previously disassembled, reas-semble the adjustment device afterlubricating the following contactsurfaces:. Swinging lever nut and adjust-

ment device lever nut.. Contact surfaces between

adjustment device and swinginglever.

Installation

To correctly position the new jawson brake holder disc, operate byreversing order of removal andcoupling with the following:a. Lubr ica te w i th b rake g rease

contact surfaces between theunder mentioned components.jaws and opening control cyl-

inder.toothed surfaces of the jaw

adjustment device.gears of the jaw return springs.

b. On installed jaws, before assem-blying drum, set the adjustmentdevice lever so as to maximumreduce opening of jaws.

c. On installed drum, adjust dis-tance between jaw-drum b yrepeatedly operating on brakepedal.

d. Adjust travel of parking brakecontrol lever (see: Group 00Chassis and Body Maimenance).

CYLINDER FOR JAWOPENING CONTROL

Removal

1. Remove jaws (see: Jaw Re-placement - Removal).2. Disconnect The oil delivery pip-ing to jaw opening cyl inder, byoperating on union 0, as shown infigure.3. Unscrew and remove the twoscrews @ securing cylinder to brakeholder disc; then remove cylinder.

1 Screws 2 Union

Disassembly

1. Remove dust covers @ fromcylinder body @, then, pitk up thejaw opening control pistons 0,together with gasket 0, whichare ejected by spring 0; thenwithdraw spring itself.2 . R e m o v e bleeder protectioncap @ and remove bleeder.

1 Dust cover 5 Spring2 Piston 6 Bleeder3 Gasket 7 Cap4 Cylinder body

M a y 1 9 8 3 22-16


placed between support and body.

1 Lever2 Screws3 Nut

4 Lock nut5 Bracket

DISASSEMBLY

With reference to the fol lowingexploded view remove the controllever operating as follows.1. Withdraw cotter p i n f r o m

pin @ c o n n e c t i n g l e v e r @toadjusting fork @ , withdraw pinwith washers from fork and separatethis one from the lever.2. Unscrew bolt @ securing thelever to its relevant support @ andseparate the two components.3 . Wi thdraw bush @ and h a n -d le @ f r o m l e v e r , r e m o v e p i nstopper cotter @ on which ratchetgear paw1 @ rotates and withdrawthe pin from its seat.4. Separate from lever the wholeblock of ratchet gear control withpushbutton 0, spring @, stop-p e r 0, r o d @ a n d pawl 0.5. If necessary, remove switch ofthe parking brake indicator frombrake support.

1 Handle2 Lever3 Pushbutton4 Spring5 Stopper6 Rod7 Paw18 Pin

6 . 5 1 + 10.84)

9101112131415

CHECKS AND INSPECTIONS REASSEMBLY1. Check components visuallyagainst excessive wear and otherdamages.Check, in particular, surface con-ditions of the lever coupling bush tosupport, and wear conditions of pawlteeth and scroll gear.2. Check against presence of elec-tric cable discontinuity and thatparking brake indicator switch isproperly functioning.3. Replace worn or faulty com-ponents.

For reassembly of the support andlever unit, reverse the order ofassembly and, in particular complywith the following:1. Lubricate brake lever bush andratchet gear components with speci-fied grease (AGIP Fl Grease @orSHELL Retinax Gll).2. Tighten to specified torque of

9 t 15 N.m (0.9 + 1.5 kg.m),(6.51 f 10.84 ft.lb) bolt hinging leverto brake support.

BushSector gearLight switchBoltsupportPinAdiustment fork

REINSTALLATION

To reinstal l control lever withsupport, reverse the order of removaland complying with the following:1. Apply a coat of specified grease

(AGIP Fl Grease 15 or S H E L LRetinax Gll) to surfaces wherecables slide in the incovered sectionand to fork adjusting screw.2. Carry out parking brake adjusT-ment (see: Group 00 Chassis andBody Maintenance).

CONTROL CABLES

REMOVAL

1 . O p e r a t i n g f r o m t h e d r i v e r scompartment remove rear consoleand, by operat ing lock nut andn u t o f ad jus tment fo rk loosencontrol cables and withdraw themfrom equalizer.2. Remove rear wheel and drumtogether with hub (see: Group 25 -Rear Hub - Removal).3. Operating on wheel side releasecontrol cable end @ from lever @and free it from fair- lead @.Release control ,cable from brakeshoe holder 0, withdraw it fromthis last and remove it after releasingit from the underbody clamps.

1 Brake shoeholder

2 Lever

3 Control cable4 Fair lead


Make sure that control cables aresound; replace them if necessary.

May 1983 2 2 - 1 8


Application

Brake pedal hub (inner GI)

Clutch pedal (inner 0 )

.Dowel pin connecting brake pedal

to master cylinder control clevis

Spring adjustment square bush for

brake pressure regulator

Spring seat fork on brake pressure regulator

Parking brake cable sliding surfaces

Knuckle of parking brake cables on rear

brake shoes

Terminals of parking brake cables

Adjustment fork screw

Screw (or spacer) fixing parking brake

lever to support plate

Parking brake trip

Knuckle bush for parking brake lever

GREASE

GREASE


Denomination

AGIP Fl Grease 15

Std. 3671-69810

Dimension for brake disc burning

AGIP Fl Grease 15

Std. 3671-69810

SHELL RETINAX - G - 11

Std. 3671769811

FRONT BRAKES

Brake pad - rotor clearance

- when installing 0.1 mm

(3.94 . lop3 in)

- on operation (clearance

determined by pad auto- 0 . 0 5 + 0 . 2 m m

matic feed) ( 1 . 9 7 low3 + 7.87. 1O-.3 in)

Q.W

Brake pad thickness

Min. S (wear limit or min.

serviceability thickness) 7 mm (0 .276 in )

REAR BRAKES

Brake shoe lining min. thickness 0 . 5 m m ( 0 . 0 2 i n )

Drum wear limit dimensions- max. inner diameter 229.6 mm (9.04 in)

Dimension for brake drum burning

M a y 1 9 8 3 22-20


BRAKE PRESSURE HANDBRAKE LEVERREGULATOR VALVE ADJUSTMENT

Adjustment. Number of free notches

- Unloaded car on the sector gear before

- Valve piston at end of travel wheels locking 1 G-3

- Load: 60 N (6 kg) (13.22 lb) ap-plied to hook of fixture A.4.0148

TIGHTENING TORQUES

Unit

ItemN*m

Unions of brake hydraulic system pipes

Unions of brake hydraulic system (on calipers and

union of shoe holder plate)

Union of clutch system pipe

Screws retaining caliper to wheel hub

Screw securing front brake disc to wheel hub

8 + 10

IO + 15

15 + 19

59 f 73

A6 8

Bolts securing knuckle pin to axle

Nut securing pedal assembly unit to body

Intermediate piston setscrew for ATE

brake master cylinder

3 9 f44

9 f15

5 f. 8

Nut jointing brake master cylinder to servobrake

BENDITALIA

ATE

Securing bolt of brake pressure regulator valve

Equalizer securing nut

Panhard bar securing bolt

Screws securing wheel cylinder to back plate

Bolt fixing parking brake lever to support

12 f 15

21 f 28

15 f 24

39 f 48

69 f 85

6 -5 .9

9 f 15

I kg*m ft.lb

0.8 + 1

1 + 1.5

1.5 + 1.9

6 f 7.5

0.6 + 0.8

4 + 4.5

0.9 + 1.5

0.5 + 0.8

1.2 + 1.5

2.1 + 2.8

1.5 f 2.4

4 + 4 . 9

7 + 8 . 7

0.6 + 0.9

0.9 + 1.5

5 . 7 8 f 7 . 2 3

7.23 + 10.84

10.84 + 13.74

43.8 f 54.23

4.34 + 5.78

28.9 + 32.53

6.51 + IO.84

3 . 6 1 + 5 . 7 8

8.67 + 10.84

15 + 21

10.84 t 17.3

2 8 . 9 - 3 5 . 4

50.6 + 62 .9

4.34 + 6.51

6.51 + 10.84

22-2 1 May 1983


TROUBLE DIAGNOSIS AND C.ORRECTIONSThe following are the indispensable presuppositions for any trouble diagnosis of braking system verification of:

- Tyre wear- Tyre pressure- Brake fluid or any way, verification of compliance with programmed maintenance specifications.

Condition

Excessive pedal travel

Spongy pedal

Poor braking effect

Probable cause

l Leakage in brake master cylinder

l Leakage in clutch master cylinder

l Faulty no-return valve of vacuumsystem

l Fluid leakage from brake pressureregulator

l Fluid leakage from braking systemunions

l Air in system

l Faulty brake adjustment

l Air in system

l Faulty brake adjustment

l Reservo i r f i l l e r cap vent ho leclogged

l Swollen hose due to deteriorationor use of poor quality hose

l Distorted brake shoes, or exces-s ive ly worn or cracked brakedrum

0 Soft or swollen caliper seals

l Use of a brake fluid with too lowboiling point

l Flu id leakage i n b r a k e l i n e s

l Air in brake lines

l Excessive shoe-to-drum clearance

l Grease oil mud or water on lin-ings or pads

Corrective action

Overhaul brake master cylinder

Overhaul clutch master cylinder

Replace check valve

Adjust or replace

Tighten unions

Bleed system

Adjust shoe-to-drum clearance

Correct as necessary

Adjust shoe-to-drum clearance

Clean and bleed system

Replace hose and bleed system


Drain hydraul ic system, f lush withalcohol and replace all seals

Replace with specif ied brake f luidand bleed system

Check master cyl inder, piping andwheel cylinder for leaks, and repair

Bleed system

Adjust

Clean brake mechanism and check forcause of problem. Replace lrnrngs orpads

22-22


Condition

Poor braking effect(continued)

Unbalanced brakes

Brakes fade

Probable cause

l Deterioration of linings or pads

l Local fit of linings or pads

l Master cylinder or wheel cylindersin poor condition

l Frozen or seized caliper pistonson disc brakes

l Binding mechanical l inkage atbrake pedal and shoes

l Improper tire inflation

l Improper adjustment of shoes-to-drum clearance

l Grease oil mud or water on liningsor pads

l Mud in brake drum

l Excessive wear or deterioration oflinings or pads

l Wheel cylinder in poor condition

l Poor sl iding condit ion of brakeshoe

l Looseness of cylinder body orback plate securing bolts/nuts

l Scored or ou t -o f - round drums

l Brake pressure regulator incor-rectly adjusted or not eff icient

l Deteriorated wheel cylinder sealrings

l Incor rec t ad jus tment o f whee lbearings

l Incor rec t ad jus tment o f whee lalignment

Use of improper l inings or brake

linings are contaminated

Corrective action

Replace linings and/or pads. If neces-sary grind discs a n d t u r n d r u m s

Replace linings and/or pads. If neces-sary g r ind d iscs and tu rn d rums

Repair or replace

Disassemble caliper and free up asrequired

Free up as required

Inflate to correct pressure

Readjust

Clean brake mechanism and check forcause of problem. Replace linings orpads

Clean

Replace

Repair or replace

Adjust

Fasten or replace

Recondition or replace brake drum asrequired. Check for improper liningcontact with drum and grind lining ifnecessary

Adjust or overhaul ( i f required) orreplace brake pressure regulator

Recondition or replace cylinder

Adjust

Adjust

Replace linings


Condition

Pedal pulsates

Rear lock (Under light brakepedal force)

Rear lock (Under heavybrake pedal force)

Servobrake out of order

Not adjustable engine idlespeed (no leakage at con-nectors)

Parking brake does not brake

When parking brake controllever is released, the car re-mains braked

Probable cause

l Out-of-rround or off-center drum

l On disc brakes, lateral runout ofbrake rotor is excessive

l Excessive variation in thickness ofbrake rotor surfaces

Faulty brake pressure regulator

l Poor front braking effect

l Grease oil mud or water on liningsor pads

l Excessrve wear of linings or pads

l Local fit of linings or pads

l Master cylinder or wheel cyllndetIn poor condition

l Air leakage at check valve

l Ait- leakaye at seal ring betweenvacuum box and cont ro l body

l Air leakage at disc valve

l Ai r leakage a t p is ton sea l riny

l Air leakage at seal ring betweenmaster cylinder and servobrake

l D a m a g e d prplng or connectors

Engine sucks air through servobrake

l Impt-opet- adjustment

l Front and rear cables damaged orbroken

l Faulty connection of rear cablesto brakes

l S h o e s a r e j a m m e d o n d r u m s

l Return travel of cables is ob-

structed

22-25

Corrective action

Fur-n drum or replace as necessary

Check with dial indicator, turning discmy hand. If runout exceeds specifica-ions, repair or replace disc

illeasure around disc face with micro-neter. Replace disc as required

?eplace

Disassemble and adjust front brakes

Jean or replace

3eplace

shave or [replace

3epair or replace

nspect check valve

Replace set-vobrake assembly

Replace seal ring

Repair or replace

Replace check valve or servobrake as-semblv

Adjust

Replace cables

Check cable connection

Unlock or replace faulty parts

Remove obstacle and replace cables

May 1983


Condition

When parking brake controllever is released, the car re-mains braked(continued)

The brake ON indicator doesnot illuminate

Probable cause

l Control lever release pushbutton Disassemble lever, and release or re-does nor spring back place if

l Wires disconnected

l Faulty switch

l Faulty lamp

Corrective action

-

Restore connection

Replace

Replace


T o o l n u m b e r T o o l n a m eI

Refer to

page

A . 4 . 0 1 4 8 Tool for calibrating brake pressure

regulator

May 1983 22-26

STEERING SYSTEM

-

CONTENTS

STEERING SYSTEM . . . . . . . . . . . . . . 23-2

GENERAL DESCRIPTION . . . . . . . . . . 23-2

STEERING WHEEL AND COLUMN . . 23-2

Steering wheel . . . . . . . . . . . . . . . . . 23-2

Steering column . . . . . . . . . . . . . . . 23-3

Steering lock-ignition switch . . . . . . 23-4

STEERING LINK RODS . . . . . . . . . . . 23-5

Removal . . . . . . . . . . . . . . . . . . . . . 23-5


Disassembly . . . . . . . . . . . . . . . . . . . 23-6

Assembly. . . . . . . . . . . . . . . . . . . . . 23-6

Installation . . . . . . . . . . . . . . . . . . . 23-6

STEERING BOX . . . . . . . . . . . . . . . . . . 23-7

Removal . . . . . . . . . . . . . . . . . . . . . 23-7

Disassembly _ . . _ . . . . . . . . . . . . . . . 23-8

Checks and inspections. . . I . . . . . . . 23-9

Assembly _ . _ . . . . . . . . . . . . . . I . . . 23-9

SERVICE DATA AND

SPECIFICATIONS _ . . . . _ . _ . _ _ _ . _ . . 23-l 1

General specifications _ . . . _ . _ . . . . 23-11

Inspections and adjustments . . _ . _ . 23-12

Tightening torques . . . . . . . . . . . . . 23-l 2

TROUBLE DIAGNOSIS ANDCORRECTIONS . _. . _ _. _. . . _. . . _. , 23-13

SPECIAL SERVICE TOOLS . . . . . . . 23-13

May 1983

STEERING SYSTEM

STEERING SYSTE.M

28.92 + 35.43)

39 4 48

1 Track rods2 Steering rack3 Universal joints

4 Lower column (4 + 4.95 Upper column 28.32 + 35.43)

@ N.mkg-mft.lb)

GENERAL DESCRIPTION

Steering is by rack and pinion. they reduce the variation of wheel

The track rods are connected to the movement resulting from suspension

centre of the rack by means of movements. The steering column is

flexible joints. Owing to their length, in two sections The lower part

is positioned so as to collapse underaxial loads. The upper part is pivotedto allow adjustment of the steeringcolumn height.

STEERING WHEEL AND COLUMN

STEERING WHEEL

REMOVAL1. Remove hub 0, to gain accessfo screws @ securing warning hornpushbutton @ on steering wheeland remove them.2. Disconnect eletric connec-tion @ of warning horn push-button and remove it.3. Unscrew and remove nut 0with washer @ securing steeringwheel to column.

ft-lb)1 Hub 4 Electric con-2 Screw nection3 Horn push- 5 Nut

button 6 Washer

4 . By means o f too l A .3 .0451 ,withdraw steering wheel from COI-

umn operating as per figure.

M a y 1 9 8 3 2 3 - 2

STEERING SYSTEM

9. Remove the whole column.

DISASSEMBLY1. Unscrew bolt securing universaljoint to upper column section.Remove lower column.2. Remove steering lock operatingas follows.Secure column support @ togetherwith upper column @ on vice fittedwith protective jaws and, operatingas shown in figure, unscrew thebroken head screw securing steeringlock to column support; withdrawsteering lock.

1 Column support 2 Upper column

3. Keeping the unit on a vice,hammer, on upper column, by meansof a plastic hammer (as shown infigure) as long as column can bewithdrawn from support with re-levant upper bearing.

4. Withdraw lower bearing fromcolumn support.


1. Check against presence of dam-ages or malfunctions in columnbearings. Lubricate them with theprescribed grease and replace them

if necessary.2. Check against presence of dam-ages or absence of lubrication inuniversal joints. Replace lower col-umn if necessary.

3. Verify integrity of upper columnand, in particular, that: workingsurfaces of bearings are safe from

scratches; tooth of splined parts arenot damaged or worn; hole where pinof steering lock works, is sound.

4. Verify integrity of column sup-port -and replace it if necessary.

ASSEMBLYFor reassembly reverse order ofdisassembly and comply with. thefollowing:a.

b.

C.

d.

e.

Apply a coat of grease (AGIP F 1Grease 33 FD or IP AutogreaseFD) to bearings where uppercolumn rotates.Lower bearing must be com-pletely introduced on columnsupport and upper bearing mustbe assembled so as it faces upperplane of support.Verify that upper column canfreely rotate and that no exces-s.jve clearance is present.For securing of steering lock -ignition switch to column sup-port, make use of proper screwsupplied as spare part, whichmust be tightened into its seatuntil breaking of Tts head .During junction of lower columnto upper one make sure thatsecuring bolt positions correctlywith respect to cutout portion.

INSTALLATIONAssemble column by proceeding inreverse order and fol low theseinstructions.

WARNING:Make sure that undue stress is notapplied to steering column duringassemblv.

a. Loosen the wheels and couplethe column lower universal jointto pinion of steering box,then insert securing bolt 3making sure that it positionscorrectly with respect to pinioncutout portion 0.

1 Bolt 2 cutout

b. Adjust tightening of steeringwheel inclination lever so as toobtain correct stop of steeringwheel in the required position.

C. On steering wheel and coverassembled, make sure that, on alllowered position of steeringwheel, B dimension (betweencover of steering column andsteering wheel structure) cor-responds to the prescribed value.

Distance between cover and steeringwheel structure

B=O+6mm(O+00.236in)

d. After tightening of components,verify that on maximum travelcondition of steering wheel,(straight ahead and straightdown) functioning is correct.

a. At the end of assembly, verifyproper functioning of combina-tion switch unit and efficiencyof warning horn.

STEERING LOCK-- IGNITION SWITCHREMOVAL ANDINSTALLATION

1. Remove lower cover of columnsupport (see: Column - Removal).2. Disconnect harness of the steer-

May 1983 23-4

STEERING SYSTEM

ing lock - ignition switch.3. Remove the broken head screwsecuring steering lock to columnsupport.4. Remove steering - lock unitwithdrawing i t f rom i ts seat incolumn support.5. For installation, reverse order ofremoval and secure steering lock @to column support by means ofspecial screw @ provided as sparepart, and tighten it as long as its headbreakes.

CHECKS AND INSPECTIONS1. Verify good conditions of cablesand connectors.2. Check proper operation of thewhole assembly by verifying allpositions are reached smoothly;check also the locking device opera-tions properly, after rotating steeringwheel and extracting key.

1 Steering lock2 Screw

STEERING LINK RODS

REMOVAL

@ N.m(kg-mfMl)

1. Place car on lift, block rearwheels, jack up front of vehicle, thensupport it by stands placed in adja-cent position to jacking points (Referto: Group 00 - Lifting Points andTowing).2. Remove four screws and wheel.3. Unscrew nut securing ball pin ofsteering track rod @ to lever @ ofstrut 0.4. Using puller.A.3.0156 withdrawball joint pin @ of steering trackrod upwards, taking it out from strutlevers.

1 Spacer 7 Nut2 Plate 8 Elastic joint3 Rod 9 Nut4 Nut 10 Washer5 Ball joint 11 Plate6 Washer

1 Strut2 Strut lever

@39 f 4 8(4 + 4.928.92 + 35.43)

5. Turn steering wheel to the rightto make easier the disassembly ofr o d s 0 from steering box 0,remove nuts 30, washersplate 0, then remove rods.

@, and

@-I

3 Ball joint 1 Rod 4 Washer4 Steering track tocl 2 Steering box 5 Plate

3 Nut

2 3 - 5 May 1983

STEERING SYSTEM

CHECKS ANDINSPECTIONS1. Check against damage or wear inthe steering rods ball joints, .andverify that pivot free from crawlingor with notable sla.ck in their seats. Ifnecessary, replace them.2. Check elastic joints againstdamage, wear or excessive slack. Ifnecessary, replace them.3. Check steering rods againstdamage or deformations. If neces-sary, replace them.

DISASSEMBLY1. Extract elastic joints from rodsby means of a press and of suitabletools (a punch and a base).

2. Measure articulation jut in orderto maintain it on reassembly.

3. Loosen fixing nut 0, unscrewball joint @ and remove it fromrod 0.

1 Rod2 Nut

3 Ball joint

ASSEMBLYProceed in reverse order to disas-sembly and use the same toolspreviously used.On reassembly of ball joints, makesure that the two tie rods have thesame length they had before disas-sembly.

INSTALLATIONAssemble steering link rods onvehicle by proceeding in reverseorder of removal.1 Assemble rods on steering boxstuds and f ix them with plate,washers and nuts without lockingthem.2. Connect rods to levers onsteering tubes by tightening the nutssecuring the ball joint pin to thespecified torques.

During tightening of bolts, make surethat on the static load position,upper plane of ball pin is parallel togasket face.

3. Lock the elastic joint fixing nutsto the rack studs, with the frontsuspension in nominal height, corre-sponding to static load.

@ : Tightening torqueNut fixing ball joint to lever onsteering tube and elastic jointto rack.

39-48 N-m(4 f 4.9 kg-m28.92 + 35.43

4 . V e r i f y toe-out

ft.lb)

( R e f e r t o :Group 00 - Chassis and Body Main-tenance).

May 1983 23-6

STEERING SYSTEM

STEERING BOX

1 upper cap2 Adjusting screw3 Spring4 Plunger5 Seal ring6 Bush7 Rack box8 Left cap

REMOVAL1. Place vehicle on ramp a n dsupport it by stands placed in thejack seats (refer to: Group 0 0Lifting Points and Towing).2. Remove left wheel after screw-ing up fixing screws.3. Turn steering wheel to the rightand disconnect rods from steeringbox (refer to: Steering Link Rods -Removal).4. Disassemble b o l t 0 f i x i n glower universal joint @ to pin-ion @5. Remove plast ic cap @ p r o -tecting rack.

9 PinionIO Bearing11 Lock ring12 Lock ring13 Lower cap14 Boat15 Sleeve16 Clamp

1 Universal joint 3 Pinion2 Bolt 4 Protection cap

6. Remove screws @ fixing

s tee r ing box @ to body, thenremove brackets 0.

7. After disengaging pinion @from universal joint 0, remove

17 Bush18 support19 Right cap20 Pad21 Studs22 Rack

steering box by estracting it from thesteering rod slit on the left side andremove rubber supports @.

(4 4 4.9 -J (kg-m28.92 + 35.43) ft-lb)

1 Steering box 4 Support2 Pinion 5 Bracket3 Universal joint 6 Screw

2 3 - 7 M a y 7 9 8 3

STEERING SYSTEM

DISASSEMBLY

1. Remove clamp @ fixing rightb o o t @ t o s l i d i n g s l e e v e 0.2. Extract end cap 0, r e m o v eplastic support @ and extract rightboot 0.

CAUTI0.N:Plastic bellows be replaced wheneverdisassembled from steering tube forany reason.

1 End cap2 Support3 Right boot

4 Clamp5 Sleeve

3. By means of nut and lockunscrew and extract studs 0, thenremove plate @ and spacer @ forrod support.4 . Remove c lamp @ fixing leftboat 48 a n d e x t r a c t i t f r o msleeve 1 , then extract sleeve fromrack tube.

1 Sleeve 5 Plate2 Spacer 6 Nut and lock nut3 Clamp 7 Studs4 Left boot

5. Remove the sliding member @from rack guide tube 0.

6. Remove the cover @ from rackb o x 0, s c r e w U P a n d e x t r a c tadjustment screw 0, spring @and plunger @ for backlash. Thenlever with a screwdriver and removelower protection cap @ of rackcontrol pinion.

1 Covei- 4 Plunger-2 Adjustment 5 Rack box

screw 6 Lower cap3 Spring

7. Extract rack @ from guidetube 0.

1 Rack 2 Guide tube

8 . Remove lock r ing @ f i x i n gpinion bearing to rack box.

9. Remove pinion from rack boxtogether with the bearings, by meansof a plastic hammer and a supportingbase.

10. Remove lock ring 1 fixingbearing @ on pinion 3 , after8placing it in a vice provided withprotective jaws.

1 Lock ring2 Bearing

3 Pinion

11. Disassemble bearing @ frompinion 0 by means of a punch anda suitable base.

1 Tube 2 Sliding member

May 1983

1 Lock ring

2 3 - 8

STEERING SYSTEM

-0-0

1 Pinion 2 Bearing

3. Provide internal room of steeringbox with 40 g (1.41 oz) grease (AGIPFl grease 33 FD or IP AutogreaseFD), lubricate p in ion bush andassemble pinion by means of apunch, a base and a plastic hammer.

00

1 Bearing 2 Rackbox

4. During assembly use plunger andadjusting screw of the same material(plastic or metal).5. Lubricate rack with grease (refer

to point 3) and introduce it into theguide tube after rotating pinion, inorder to realite, when assembly isready, reciprocate positioning be-tween rack and pinion verified bydimension “A” with pinion orientedwith cutout downwards (obtainangle u = 90”f 26”).

Reference dimension for pinion-rackpositioning

A = 125mm (4.921 in)

6 . Se lec t rack s l id ing memberdepending on the available guidetube, as follows:

a. Employment of already existingsteering tube.(1) Check that the sliding mem-ber @ slides the whole steeringtube @ if pushed by handwith a slight stress; by means ofa thickness gauge 0 verifybacklash ’ G” between pad andslot does not exceed the recom-mended value in any position.

Maximum allowed backlash “G”between pad and slot

G = 0.1 mm (3.94 - 10m3 in)

Thickness gauge 3 Steering tubeSliding member

(2) In case of defect, selectanother sliding member from therange of available thicknesses,for the above recommendedconditions to be met. (Thick-nesses may be distinguished bydifferent-color paint spots onthe pads, as follows in increasingo r d e r : w h i t e - ye l low - r e dgreen blackish blue).(3) If tolerance “G” cannot bemet with any of the availablesliding member, replace steeringtube.

Employment of a new steeringtube.Replace also the sliding memberand use a new one with paintspot of the same color as thesteering tube. Maximum back-lash in this way is 0.044 mm(1.73 - 10m3 in).

Apply 15 g (0.53 oz) of grease,as per item 3, inside the sliding sleeveand lubricate rack tube externalsurface.8 . Assemble l e f t boo t , s l id ingmember, sliding sleeve, then insertstuds, spacer and plate. Assembleright boot, a new guide support,checking that the internal tooth fitsthe tube seat; then place end cap.9. Lubricate plunger and backlashadjustment screw with grease re-commended at point 3. With rackrod in central position assembleplunger, spring and screw and adjustpinion-rack backlash, as follows.(I) By means of spanner A.5.0204,tighten plunger adjustment screw tothe indicative torque: 3 N.m(0.3 kg.m; 2.17 ft.lb).

May 1983 23-10

STEERING SYSTEM

I CJ4

1 Steering box2 Adjusting screw2 Aligned space and notch4 Screw rotation

(2) Check with space in the screw ismost centered with respect to anotch in the box; loosen screw untilthe diametrically opposite space tothe one centered with the f irstnotch on the box is aligned.

10. Verify that steering pinion ro-tates up to the rack rod end-of-strokein both directions smoothly.11. Tighten boots fixing clamps, forboth ends of each boot not to be

rotated with respect to each other,with reference to the boot bodyjunction line.12. Center steering stroke by ob-taining dimension “A” as per figureindicated at step 5.

INSTALLATION1. Mount steering box assembly onvehicle by tightening securing screwsat the prescribed torque 39 + 48 N.m(4 t 4.9 kg.m, 28.92 + 35.43 ft.lb).Refit end cap on the rack box.2. With the wheels in the straightahead position, mount steering rodsand Tighten them at the prescribedtorque 39 + 48 N-m (4 + 4.9 kg.m,28.92 + 35.43 ft.lb) with vehicle atnominal height.3 . Check toe-out ( R e f e r t o :

Group 00 - Chassis and Body Main-tenance).




Application

Column supporf spacer for hinging to

body (external surface)

Steering column bearings

Steering rack rod (ext. surface)

Pinion bush

Rack-pinion backlash take-up plunger

Backlash adjustment screw (on thread)

Rack sliding sleeve (internal surface)

Rack box tint. room)

Side rod silentblock (ext. surface) FLUlD

GREASE

GREASE

Denomination

AGIP Fl grease 15

Std. No. 3671-69810

AGIP Fl grease 33 FD

IP Autogrease FD

Std. No. 3671-69833

UNION CARBIDE CHEMICALS

COMPANY: Ucon lubricant 50HB - 5100

Ml LLOI L: lubricant for elastomer seal

Std. No. 4500-17502

Q.ty

-

15 9

(0.53 02)

2 3 - 1 1 M a y 1 9 8 3

STEERING SYSTEM

INSPECTIONS AND ADJUSTMENTS1. Dimension “A’ for rack rod centering in the steeringtube

A mm (in) 125 (4.921) B mm (in) O f 6 (0+0.23)

3 . L i g h t “5” between steering column covers andsteering wheel structure

2. u cutout positioning angle on rack pinion (rackcentered as per point 1)

a degrees 90426

TIGHTENING TORQUES

Unit

Item

Nut securing track rod ball joint to lever

on strut

39 + 4 8

Nut securing steering wheel to steering column

Nuts securing track rod to steering box

Bolts securing upper steering column to lower

steering column and to steering box pmron

17 + 21

39 + 48

27 + 31

Bolt securing steering column lower support

to body

14 f 18

Nut securing steering column upper support

to body (“1

16 + 20

Nut for toe-out adjustment on track rod 55 f 69

Screw securing steering box to body 39 + 4 8

4. Thickness of rack guide pad. The available thickness,in increasing order are provided in the below list (theycan be distinguished by the paint mark on pads):white yellow red green blackish blue

5. Maximum clearance “G” between pad and slot

G mm (in) 0.1 (0.3.10-2)

N.m kg*m

4 + 4 . 9

1.7 + 2.1

4 + 4.9

2.7 f 3.1

1.4 + 1.8

1.6 + 2.0

5.6 + 7

4 + 4 . 9

frlb

28.92 + 35.43

12.29 + 15.18

28.92 + 35.43

19.52 + 22.41

10.29 + 13.01

11.56 + 14.46

40.49 + 50.61

28.92 + 35.43

(‘) With steering wheel release lever to the locked position

M a y 1 9 8 3 23-12

STEERING SYSTEM


Condition

Excessive steering wheel backlash

Column noise in drive Worn column bearings

Drive noise l Loose steering box screws

l Worn steering levers

l Excessive pinion-rack backlash

Drive hardening

Probable cause

l Loose steering box screws

l Damaged steering rods or universaljoints

l Inadequate suspension angles

l Worn or deflated tyres

l Scarce pinion-rack backlash

l Scarce lubrication

l Damaged universal joints

l Interference of column withswitch unit

Corrective action

Tighten screws

Replace defective components

Replace bearings

Tighten screws

Replace defective parts

Calibrate backlash

Restore proper angles

Check and restore

Calibrate backlash

Lubricate

Replace joints

Calibrate backlash

SPECIAL SERVICE> TOOLS


paw

A.3.0156 Track rod ball joint puller 23-5

2 3 - 1 3 M a v 1983

CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . 25-2 SERVICE DATA AND

REAR HUB . . . . . . . . . . . . . . . . . . . . . . 25-3 SPECIFICATIONS . . . . . . . . . . , .

Removal . . . . . . . . . . . . . . . . . . . . . 25-3 Technical data . . . . . . . . . . . . . . . .

Checks and inspections . . . . . . . . . . 25-4 General specifications . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . 25-4 Controls and regulations . . . . . . . .

REAR SUSPENSION . . . . . . . . . . . . . . 25-5 Tightening torques . , . . . . _ . , . .

Shocks absorbers . . . . . . . . . . . . . . . 25-5 TROUBLE DIAGNOSIS AND

Coil springs . . . . . . . . . . . . . . . . . . . 25-7 CORRECTIONS . . . . , . . . . . . . . . . .

Rear rigid axle . . . . . . . . . . . . . . . . . 25-7 SPECIAL SERVICE TOOLS . . , . .

Refer to Group 00 - Chassis and Body MaintenancefClr:l Rear Axle and Rear Suspensionl Wheel Alignmentl Checking Suspension Height

25-8

25-8

25-925-9

25-9

251025-l 1

May 1983

REAR SUSPENSION

DESCRIPTION

1 Shock absorber2 Spring3 Rear tension rod4 Wheel hub

5 Front tension rod6 Rigid axle7 Panhard b a r

The rear suspension is a rigid axle The transversal connection is carriedone. The axle longitudinal anchorage out by means of a tension rodis carr ied out by means of two (Panhard b a r ) anchored on onetension rods, on each side, connected side to the axle and on the other toto the body and placed according to the body, in order to prevent bodya Watt parallelogram, so as to limit side movements with respect to thecar raising when braking. wheels.

Between axle and body near thewheel hubs are interposed thesuspension springs with coaxial shockabsorberry. The wheel rebounds arelimited by rubber pads assembled onthe shock absorbery.

May 1983 25-2

REAR SUSPENSION

-.

REAR HUB

1 Grease seal ring 5 Washer2 Inner bearing 6 Nut3 Drum 7 Hub cover4 Outer bearing

REMOVAL

1. Block front wheels with asuitable system, then lift rear part ofcar and position it on support stands(see: Group 00 - Lifting Points andTowing).2. Remove wheel from the opera-tive side.3. Withdraw dust cover from itsseat.4. Operating as per figure, removewheel hub stop nut caulking andremove it.5. Move hub with drum, withdrawwasher and outer bearing.

CAUTION:Do not drop bearing.

6. Operating in bench and using ascrewdriver withdraw grease seal ringfrom hub.The seal ring must not be reutilited.

7. Withdraw inner bearing from itsseat.8. Using tool A.3.0349, w i thdrawfrom its seat outer ring of outerbearing.

9. Using tool A-3.0355 withdrawfrom its seat outer ring of innerbearing.

2 5 - 3 M a y 1 9 8 3

REAR SUSPENSION

CHECKS ANDINSPECTIO’NS

Clean bearings and other detailscarefully, then dry them with com-pressed air.

WHEEL BEARINGIf the surfaces of tracks and conicalrollers present pittings, roughnessesand ovalizations, replace bearingunit.

CAUTION:Should a bearing be no more utili-zable, replace both the inner and theouter one at the same time.

KNUCKLE PINMake sure knuckle pin is not dam-aged and thread is sound; replace pinif necessary (for replacement see:Rigid Axle).

INSTALLATION

1. By using taker-in A-3.0328 as-semble outer ring of outer bearing onhub, inserting it wholly in its seat.

A.3.0328

/

2. By using taker-in A.3.0329,assemble outer ring of inner bearingon hub, inserting at wholly in itsseat.

3. Lubricate outer rings of bearingswith bearing specified grease (AGIPFl Grease 33 FD, or IP AutogreaseFD), and insert 40 + 55 g. intothe hub inner chamber.

1 Dust cover 3 H u b2 Bearings outer 4 Grease

rings

CAUTION:The grease must not get in touchwith drum braking surface.

4. Lubricate hub inner bearingwith 9 specified grease and insertinto its seat. Lubricate seal ring withspecified grease and insert it into itsseat on hub by using tool A-3.0459.Lay off a coat of the same grease onthe knuckle pin, on its relevantthreaded end, on washer and onsecuring nut.

5. Assemble hub on stem pin andthen insert outer bearing lubricatedwith specific greade, washer and newcheck nut.9. Carry out wheel bearings pre-loading adjustment (see: Group 00Maintenance of Mechanical Com-ponents and Body), then peen nut.7. Apply specific bearings greaseonto the dust cover lid then assembleit on the stem pin; re-assemble wheel.

May 1983 25-4

REAR SUSPENSION

REAR SUSPENSION

(7 + 8.750.63 + 62.93)

Upper cupRubber bumpersLower cupUpper gasketUpper capShock absorber

@ 33.35 + 36.26(3.4 + 3.924.58 + 28.2)

SHOCKS

ABSORBERS

REMOVALAfter duly blocking front wheels,lifting car front and placing it onsupports stands (see: Group 00 -Lifting Points and Towing) removeshock absorbers as follows:1. Remove wheels.2. Release bolts 2 securing front0tie rods @ to body.

24.58 + 28.2)

7 Coil spring6 Shook absorber anchor fork9 Rear tie rod

10 Stud plate11 Stem pin12 Gaskets

@ N-m(kg-mh-lb)

13 Front tie rod14 Brake adjuster15 Panhard bar16 Pin17 Rear axle

3. Release bolts 0 and bolt @securing rear tie rods and Panhardbar to body respectively.

1 Front tie rod 2 Bo l t

2 5 - 5 May 1983

REAR SUSPENSION

1 Bolt2 B o l t

3 Tie rod

4. Screw out rigid tube connectiono f b r a k e hydraulic system andextract flexible hose from supportsquare. Apply a cap to rigid tube.

1 Rigid tube2 Square

3 Flexible tube

5. Place column hoist providedwith A.2.0070 support under theaxle and lift it to release shockabsorbers from end-of-stroke.

6. From luggage compartment re- b. Insert springs coaxially to thelease and remove lock nut and nut of shock absorbers and make sureupper shock absorber fastener, the caps and upper spring supportremove cap and anti-shock rubber gaskets are properly assembledbumper. and positioned.

7. Release and remove nuts andwashers of lower shock absorberfastener, then lower hydraulic hoist,remove springs from axle and shockabsorbers.8. Separate from schock absorberrubber bumper, cap, and attachingfork, after removing the relevantfastening screw.


1. Check shock absorber efficiencyand replace it, if oil leaks are found.2. If necessary, verify shock ab-sorber calibration data (see: ServiceData and Specifications - inspectionand Adjustment); replace shockabsorbers, if required.3. Check wear status, damages anddeformations of rubber components.Replace them, if required.

INSTALLATION

Assemble shock absorbers on car inthe inversed order with respect toremoval and remember the followingindications:a. Assemble shock absorber com-

ponents and secure their upperpart to the body.

c. Set up car in nominal position,corresponding to static load(see: Group 00 Maintenanceof Mechanical Components andBody) and set the bolts securingtie rods and Panhard bar to bodyto the prescribed torque.

@ : Tightening torquesBolts securing tie rods to body

33.35 + 38.26 N-m(3.4 + 3.9 kg-m25.28 + 28.2 ft.lb)

Bolts securing Pahnard bar to

body68.67 + 86.35 N - m(7 + 8.7 kg-m50.63 + 62.93 f-t-lb)

d. Restore rear brake oil deliverytube connection and performbrake system air bleeding (see:G r o u p 2 2 - F ron t and RearBrakes - Brake Air Bleeding).

M a y 1 9 8 3 25-6

REAR SUSPENSION

COIL SPRINGS

REMOVAL

Remove co.il springs with the sameprocedure followed for removal ofshock absorbers; only remember notto disjoin shock absorber from upperbody coupling.


1. V e r i f y the springs has nostretches or deformations.2. Verify spring efficiency by com-paring its stiffness values with theprescribed ones (see: Service Dataand Specifications).3. Check wear status, verify pres-ence of damages or deformations ofrubber components. Replace ifnecessary.

INSTALLATION

Assemble coil springs onto car againin the inversed order of removal andbear in mind all indications and notesreported in paragraph Shock Ab-sorbers Installation.

REAR RIGID AXLE

REMOVAL ANDINSTALLATIONPlace car on hoist bridge, support itsrear part by placing some stands inthe jack seats and remove the wholerear suspension as follows.1. Remove wheels.2. Working from passenger com-partment, remove rear console forparking brake equalizer to be ac-cessible. Then act on adjustment forknut and lock nut and loosen parkingbrake control cables as much as toallow their releasing from equalizer;extract them from sheath lockingbracket.3. After providing the column hoistwith support A.2.0070, remove coilsprings with caps and gaskets (see:Coil Springs - Removal).

M L A.2.0070

4. Slightly lift column hoist andremove the previously loosened tierod and Panhard bar bolts.5. Slowly lower hoist driving theaxle and extracting the brakeadjustment spring from stud on thePanhard bar.

Assemble again the whole suspensionon the car by the inversed procedurethan for removal.

IMPORTANT. With static load car (see: Group

00 - Maintenance of MechanicalComponents and Body) set thebolts securing t ie rods andPanhard bar to the prescribedtorque.

@) : Tightening TorqueTie rod and Panhard barsecuring bolts

3 3 . 3 5 + 3 8 . 2 6 N-m(3.4 + 3.9 kg-m24.58 f 28.2 ft-lb)

Lubricate with prescribed grease(AGIP Fl Grease 15) the hole inthe brake adjustment springsupport stud on the Panhard barand the fork.Carry out brake adjustmentspring calibration (see: Group 22- Brake Adjustment).Set the brake hydraulic systemconnections to the prescribedtorque and perform air bleeding(see: Group 22 - Brake SystemAir Bleeding).

@ : Tightening TorqueRigid tube connections

7 . 8 5 + 9.8 N-m(0.8 + 1 kg-m5.78 - 7.23 ft-lb)

Flexible hose connections9 . 8 t 1 4 . 7 N - m(I + 1.5 kg-m7.23 + 10.85 ft.lb)

. Adjus t pa rk ing b rake l eve rstroke (see: Group 00 - Mainte-nance of Mechanical Compo-nents and Body).

REMOVAL

If necessary, disassemble axle asfollows:1. Release and remove bolts secur-ing tie rods to axle; remove tie rods.2. If necessary, disassemble silent-blocks from tie rods and Panhard barby using adequate bases and ex-tractors.

3. Extract dust cover from brakedrum and caulk wheel hub nut.Remove nut and drum complete withhub and bearings.4 . S c r e w o u t c o n n e c t i o n 2 o f0brake hydraulic system rigid tube onjaw control cylinders and removerear tubes @.5. Screw out and remove nuts @fastening stem pin and brake shoeplate @J to rear axle. 7

1 Block shoe plate 3 Nuts2 Connection 4 Rear tubes

2 5 - f M a y 1 9 8 3

REAR SUSPENSION

NOTE FOR CAR OVERLOADED ON REAR AXLE

Should high overloads be applied to the rear axle, like in the case of gas installation. the series rear springs can be replacedon sedan versions with springs having part number 705.507, in case of overload of about 980 N (100 kg)(220.46 lb)with respect to static load, they allow a “rear position” level increased by about 15 mm (0.59 in) with respect to the oneindicated in Group 00 - Checking Wheel Alignment.



Wheel hub inner cavity and dust cover

Seal ring rim

Bearing inner rings and relevant outer races

Bearing housings on pin

Internal diameter of hole in brake adjustment

spring support stud on Parrhard bar.

Brake adjustment fork

Tie rod end (front and rear) silentblock

outer surface and Panhard bar (at

assembly)

FLUID UNION CARBIDE CHEMICALS CO.

Ucon Lubricant 50 HB-5100

Outer surface of rubber bound bumper MILLOIL Lubricant for elastomer seal

(at shock absorber assembly) Std. No. 4500-17502

Outer surface of wheel hub seal ring OIL AGIP Fl ROTRA MP SAE S O W 9 0

IP Pontiax HD SOW90

Std. No. 3631-69408

Type

GREASE

GREASE

CONTROLS AND REGULATIONS

STEERING GEOMETRY

(See: Group 00 - Rear Axle and Suspension)

Denomination

AGIP Fl Grease 33 FD

IP Autogrease FD

Std. No. 367 l-69833/34

AGIP Fl Grease 15

Std. No. 3671-69810

Q.ty

40+55 g

1.41+1.94 oz.

WHEELS BEARINGS PRELOADING ADJUSTMENT

(See: Group 00 - Rear Axle and Suspension)

2 5 - 9 May 1983

REAR SUSPENSION

DATA FOR SHOCK ABSORBER CALIBRATION

Alfa Romeo Part Number 542.147

Low speedCompression

Extension

N (kg) (lb)

N (kg) (ib)

5 9 f 1 4 7 (6+ 1 5 ) (13.23G33.07)

78+ 1 7 7 (8e-18) (17X4+39.68)

Compression N kg) (lb)High speed

Extension N (kg) (lb)

NOTE: Values to be measured with shock absorbers at 20 L PC (68 f 3.BF) temperature

2 7 5 f 4 1 2 (28+42) (61.73G92.59)

638 f 834 (65 + 85) (14XW87.39)

TIGHTENING TORQUES

Item

Bolts securing Panhard bar to body

Bolts securing front and rear tie rods to body

Bolts securing stem pin to axle

Brake hydraulic system rigid tube connections

Brake hydraulic system flexible hose connections _.

N-m kg-m

68 .67 + 86 .35 7 + 8.7 50.63 + 62.93

3.4 + 3.9 24.58 + 28.2

4 + 4.9 29.92 + 35.43

0.8 + 1 5.78 + 7.23

1 + 1.5 7.23 + 10.85

33 .35 + 38 .26

39.24 + 48.1

7 . 8 5 + 9 . 8

9 . 8 + 1 4 . 7

Ib+t

TROUBLE DIAGNOSIS AND CORRECTIONSWhen rear suspensions are suspected of being noisy, carry out a careful check to determine if the noise actually originates inthe rear suspensions or if it is due to the tires, road surface, exhaust system, engine, transaxle or wheel bearings.

Condition

Noise

Probable cause

Loose wheel screws

One or more attaching bolts loosen

Lack of lubricating grease onbearings

Faulty shock absorber

Damaged or worn wheel bearing

Wheel and tire out-of-balance

Damage to rubber parts such aslower arm bushing

Corrective action

Tighten to specified torque


Lubricate as required

Replace

Replace

Balance


May 1983 2 5 - 1 0

REAR SUSPENSION


Instability in driving.This trouble is also related tofront suspensions. For troublediagnoses also refer toGroup 21

l Loose wheel screws

l Shock absorber malfunction


l Yielded coil spring

l Damaged tie rod silent-blocks

l Loosen tie rod connections


Repair or replace

Yielded coil springs

Replace

Replace

Tighten or replace



page

A.2.0070 Rear axle support 25-6

25-7

A.3.0328 Driver of rear hub outer conical

bearing outer race

A.3.0329 Driver of rear hub inner conical

bearing outer race

A.3.0349 Hub outer bearing outer race

extractor

A.3.0355 Hub inner bearing outer race

extractor

A.3.0459 Driver of front hub seal 25-4

25-11 May 1983

WHEELS AND TIRES

CONTENTS

CHECKING TIRE CONDITIONS . . . . . 28-2 CHECKING WHEEL CONDITIONS . . . 28-4

Checking tire . . . . . . . . . . . . . . . . . 28-2 Wheel balance . . . . . . . . . . . . . . . . . 28-4

Tire inflation . . . . . . . . . . . . . . . . . . 28-2 SERVICE DATA AND

Tire rotation . . . . . . . . . . . . . . . . . . 28-3 SPECIFICATIONS . . . . . . . . . . . . . . . . 28-5

TIRE REPLACEMENT . . . . . . . . . . . . . 28-3 General specifications . . . . . . . . . . . 28-5

Replacement . . . . . . . . . . . . . . . . . . 28-3 Inspections and adjustments . . . . . . 28-5

Wheel screw . . . . . . . . . . . . . . . . . . . 28-4 Technical data . . . . . . . . . . . . . . . . . 28-6

M a y 1 9 8 3

WHEELS AND TIRES

CHECKING TIRE CONDITIONS

CHECKING TIRE

1. Check tread thickness. If belowmin. allowed limit (1 mm; 0,04 in.)replace tires.

If tires are provided with “tread wearindicator”, when marks appear, re-place tires.

2. Remove pebbles, glass or anyother foreign material embedded inthe threads.3. Check tread and side walls forcracks, holes, separation or damage.4. Check tire valves for air leakage.

TIRE INFLATION

1. Check tire pressure. If necessary,adjust it to specified value.

Tire pressure should be measuredwhen tire is cold.

2. After inflating tires, check valvesfor leakage. Whenever tire pressure ischecked, be sure to tighten valve capsfirmly by hand to keep dust andwater out.

Abnormal tire wear

Correct abnormal tire wear according to below chart.

Trouble

Shoulder wear

Center wear

Feathered edge

Toe-in or roe-out wear

Uneven wear

Probable cause

1 Underinflation(both sides wear)

1 Hard cornering

1 Lack of rotation

Iverinflation

Incorrect toe-in ortoe-out

b Unbalanced wheel

l Malfunctioningdampers

. Lack of rotation

Corrective action

Check and adjustpressure

Reduce speed

Rotate tires

Check and adjustpressure

Adjust as required

Balance or replace

Replace dampers

Rotate tires

May 1983 28 -2

WHEELS AND TIRES

TIRE ROTATIONOperation to be carried out every5,000 km (3,107 miles).

1. Tires tend to wear unevenly and 0become unbalanced after a certainrunning distance. Uneven tire wearoften results in problems that,however, one tends to tink as beingcaused by other car components.Front tires also tend to wear un-evenly because of improper align-ment of front wheels.2. Therefore, to equalize tire wear,

--:,

it is necessary to rotate tires periodi-cally. Following are some different -t

allowed arrangements for tire ro-tation.

TIRE REPLACEMENT

CAUTION:Different types of tires, such as bias,bias belted and radial tires, must notbe under any circumstances. Differenttypes of tires can adversely affectvehicle handling and may causedriver to lose control.

a. When replacing a worn ordamaged tire, use a replacementtire of the same size and loadcarrying capacity as that withwhich the car was originallyequipped with by the Manu-facturer. The use of tires havingdifferent size and/or load ca-pacity than those approved bythe manufacturer is not allowedsince it changes the car’s tech-nical characteristics.

b. For the same above mentionedreasons, do not use tires andwheels other than those re-commended, and do not mixtires of different brand or treadpattern.The use of tires and wheels otherthan those recommended or themixed use of tires of different

adversely affect riding, braking,_handling, ground clearance,body-to-tire clearance, andspeedometer calibration.

C. It is recommended to fit newtires in pairs on the same axle.When replacing only one tire, itshould be paired with the onehaving the most tread in order toequalize braking action.

d. When replacing tires refer to theprocedure described in the re-levant paragraph: “Replace-ment”.

REPLACEMENT1. To replace a tire using a jack in asafe manner, refer to: Lifting Pointsfor jacking up.

WARNING:Never get under the vehicle while it issupported only by jack.Always use safety stands to supportside member of body constructionwhen you must get beneath the

2. After having posit ioned thewheel, fit the four screws properlyinto place.3. Tighten screws by hand as far aspossible keeping the wheel in correctposition4. Tighten wheel screws with prop-er wheel wrench in crisscross andprogressive fashion.

@e sure to check wheel screws fortightness, after the wheel has beenrun for the f i rst 1 ,000 km (621miles); do the same thing in case offlat tire repair, tire rotation, etc.

WHEELS AND TIRES

WHEEL SCREW

CAUTION:Two types of wheel screws are used:one is designed for use with steelwheels and the other for use withl ight al loy wheels. Do not mixdifferent type wheel screws.

Be careful not to smear threadedportion of screw not relevant seat

@-Fc with oil or grease.

1 Screw for light alloy type wheels2 Screw for steel type wheels

CHECKING WHEEL CONDITIONS

Inspect wheels thoroughly payingspecial attention to the followingpoints, in order to ensure satisfactorysteering condition as well as maxi-mum tire life. If any defect is pres-ent, repair or replace as required.

1. Check wheel rim, especially rimflange and bead set, for rust, dis-tortion, cracks or other faults whichmight cause air leaks. Proper func-tioning of tubeless tires depends oneffective sealing between tire beadand wheel rim.2. Thoroughly remove rust, dust,oxidixed rubber or sand from wheelrim.Rim’s bead seats should be suitablycleaned (for ex. using neutral typedetergent, cloth, etc...) being carefulnot to damage the wheel surface’sprotecting film.3. Replace wheel when any of thefollowing occurs:. Bent, dented or heavily rusted

wheel. Bolt holes are out-of-round. Excessive side or radial runout. Air leaks through welds

WHEEL BALANCEInspect wheel and tire for properwheel balance; if unbalanced, correct

it taking the following points intoconsideration:1. Correct unbalance as soon a s

relevant symptoms appear such aswheel tramp and shimmy.2. Balance wheel with tire bothstatically and dynamically.

WHEEL BALANCINGPROCEDURE

CAUTION:Considering the special constructionfeatures of the differential assembly,it is imperative that balancing ofwheels - especially of front ones -be performed according to theprocedure hereafter described inorder to avoid serious damage.

Front wheels1. Lift car front with a dolly-typehydraulic jack placing same underrelevant lifting point (Refer to:Lift ing Points for jacking up).2. Place two stands in line withfront jacking points located undercar body.3. Lower car till it rests on standsbut locking the jack as well (thusachieving a three-point support).

4. Lock rear wheels by means oftwo wedges, one for each wheel.5. Set up balancing machine andauxiliary equipment; make sure indi-cating finger is placed under suspen-sion’s cross arm and in line with thearm-wheel support joint.6. Start up the engine, engage 4thspeed and then rev engine up to max.speed as per speedometer reading.7. Perform wheel balancing accord-ing to usual “Equitron” type balanc-ing machine procedure.

Rear wheels1. Lock front wheels by means oftwo wedges, one for each wheel.2. Lift car rear, inserting jack underaxle. Position two stands in corre-spondance with stand rear seats andthen lower the car.3. Set up balancing machine andauxiliary equipment; make sureprobe is placed under the suspensionspring. Let the wheel rotate bymeans of a wheel accelerator device,then carry out balancing operationswith the modalities for balancingmachine of the .“Equitron” type.

May 1983 28 -4

WHEELS AND TIRES

BALANCE WEIGHTSPOSITIONING a.

QLi

1. Balance weights

Maximum allowable at rim flange:8 g (0.28 OL)

Balance weights:10 4 40 (0.35 + 1.40 02)

at 10 g (0.35 02) interval

b.

c.

d.

L, =D =s =

Ls =

location of balance weightstramp directionshimmy directionlocation of unbalance causingheavy area

Be sure to place correct balanceweights on inner edge of rim.Do not pure more than twoweights on each side.Two types of balance weightsare used: one is designed for usewith steel wheels and the otherfor use with light allowy wheels.D o n o t m i x d i f f e r e n t t y p ebalance weights.Properly rebalance wheel andtire whenever puncture is re-paired.




Application TYW Denomination Q-v

Tire beads FLUID UNION CARBIDE CHEMICALS

COMPANY: Ucon lubricant 50 HE-5100

MILL01 L: lubricant for elastomer seals

Stel. No. 4500-17502

INSPECTIONS AND ADJUSTMENTS

DYNAMIC BALANCEMax. allowed residual unbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 g (0.280 04

Thread thickness limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.04 in)Wheel screws tightening after the first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,000 km (621 miles)

Balance weights (at 10 g (0.35 oz) interval) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 + 40 g (0.35 + 1.40 OZ)

28-S May 7983

WHEELS AND TIRES

TECHNICAL DATA

. .

2 8 - 6May 1983

ELECTRICAL SYSTEM

CONTENTS

HOW TO READ THE WIRING

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 40-2

Wiring diagram . . . . . . . . . . . . . . . . 40-2

Power supply routing . . . . . . . . . . . 40-3

POWER SUPPLY ROUTING . . . . . . . . 40-4

Schematic/Power supply routing . , . l 40-4

Fuses . . . . . . . . . . . . . . . . . . . . . . . . 40-5

Ignition switch . . . . . . . . . . . . . . . . 40-6

ELECTROMECHANIC AND

ELECTRONIC DEVICES . . . . . . . . . . . 40-7Relays and timer . . . . . . . . . . . . . . . 40-7

Electronic devices and intermittence; 40-7

LIGHTING SYSTEM . . . . . . . . . . . . . . 40-10

Lamps . . . . . . . . . . . . . . . . . . . . . . . 40-10

Combination switch assembly . . . . . 40-l 1

Outside lighting . . . . . . . . . . . . . . . . 40-13

Front combination lamps . . . . . . . . 40-17

Rear combination lamps . . . . . . . . . 40-l 9

Inside lighting . . . . . . . . . . . . . . . . . 40-20

BOARD INSTRUMENTS AND

TRANSMITTERS . . . . . . . . . . . . . . . . . 40-22

Cluster. . . . . . . . . . . . . . . . . . . . . . . 40-22

Engine cooling and lubrication , , . . 40-24

Fuel supply, brake and clutch oil

minimum level transmitter, tachy-

metric pulse generator . . . . . . . . . . . 40-26

WINDSCREEN WASH/WIPER ANDHEADLIGHT WASH/WIPER . . . . . . . . 40-28

Windscreen wash/wiper . . . . . . . . . .

Windscreen wiper . . . . . . . . . . . . . .

Headlight wash/wiper . . . . . . . . . . .

Headlight wiper . . . . . . . . . . . . . . . .

Windscreen washer and headlight

washer . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC ACCESSORIES . . . . . . . . .

Horns, heated rear window, cigar

lighter, clock . . . . . . . . . . . . . . . . . .

Horns . . . . . . . . . . . . . . . . . . . . . . .

Heated rear window . . . . . . . . . . . .

Power window. . . . . . . . . . . . . . . . .

Power windows and door locks . e . ,

Door lock control unit . . . . . . . . . .

Check Control and Trip Computer. .

ELECTRIC COMPONENT LOCATION.

Engine compartment . . . . . . . . . . . .

Passenger compartment . . . . . . . . . .

HARNESS LAYOUT . . . . . . . . . . . . . .

General harness . . . . . . . . . . . . . . . .

Engine compartment . . . . . . . . . . . .

40-28

40-29

40-32

40-33

40-34

40-36

40-3640-37

40-38

40-3940-4 1

40-42 1

40-43

40-45

40-45

40-45

40-46

40-4640-46

Passenger compartment and luggage

room (LH) . . . . , . . . . . . . _ . . . . . . 40-47u

‘

Dashboard ( LH) . . . . . . . . . . . . . . . 40-48SWITZERLAND-AUSTRALIA MODEL

VARIATION . . . . . . . . . . . . . . . . . . . . . 40-49Tachymetric control unit - fast idle.electromagnet - hand brake switch. . 4049

Cl RCUIT DIAGRAM . . . . , . , . . . . . , , 40-50

May 1983

ELECTRICAL SYSTEM

r-----7ii 1’iP%?-

The chain line, on wiring diagram,delimits those areas containing thespecific variations for the modelsindicated by “U .,.I’.

The connection identifies two wiringvariations, present in alternative andconnected in the same way. Thewiring variations are referred to the

models indicated by “U . . . “,

In the horizontal line, table showsposition of control or of switch to beoperated. In the vertical line it showsthe terminals between which conti-nuity generates.

The example shows continuity be-tween terminals 2 and 3 with thecontrol set to position 1.

I-----p @The detail shows a reference to knotrelevant to electronic device N ._.

l+++(m)FT(‘)

The figure shows the type of diagramused to identify the two connectorsrelevant to each joint: for the maleconnector it is applicable diagram(m); for the female one it is applica-ble diagram (f).

Cable colors

A Light blueAB Light blue - whiteA N Light blue - blackAR Light blue _ red

6 WhiteRN White -blackBR Whi te redBLN Blue - blackBLR Blue - red

POWER SUPPLY ROUTING

This type of diagram is helpful inidentification of specific troublesrelevant to the part of e lectr icdiagrams concerning supply i.e.: thewindscreen wiper is not functioning.A first check’ shows efficiency ofinstrumentation supply. From dis-tribution diagram it can be noted

that supply of both instrumentationand windscreen wiper are realized viaignition switch and fusebox. Theresult is then that ignition switchoperates correctly and no failure ispresent along wiring between batteryand switch itself.

C OrangeCN Orange - blackCB Orange -whiteH GreyHG Grey - yellowHN Grey - blackHP? Grey - redHV Grey - greenG YellowGB Yellow-whiteG N Yellow - blackGR Yellow - redGV Yellow - greenN BlackNZ Black - violetM BrownMB Brown -white

MG Brown - yellowR RedRN Red - blackS PinkSB Pink -whiteSN Pink - blackV GreenV B Green -whiteV N Green -blackz VioletZN Violet - black

In case of mixed color, the base coloris indicated first, followed by thepresent stripe col.or.i.e. BN = White with Black stripes

Cable section

Cable section not indicated is0 . 5 mm2 (0.39 . 10m3 in2).

Failure must then be due either tofusebox (see.: Fuses- Services protect-ed by fuses) or to the following partsof the electric system, that is inthe wiring windscreen wiper or in theground connection.For fault identification, refer then tothe windscreen wiper wiring diagram.

4 0 - 3 M a y 1 9 8 3

ELECTRICAL SYSTEM

POWER SUPPLY ROUTINGSCHEMATIC/POWER SUPPLY ROUTING

r - - - - 1 4IO(f \E0:

I I

I

I\-

”;LL

--

--

II,--

m+z

-

--

/c\

“!Nr

--

--

-

I

I\-

YP0

--

--

-

I

I\-

YnII

-

-

-

May 1983

ELECTRICAL SYSiEM

FUSES CHECK

LOCATION?he fusebox is integral part of thesupport board and is lo&d on leftside of the intermediate bulkhead, inthe engine compartment.

1 Fuse

CAUTION:a. In case a fuse blows, before

replacing it, make sure that thecause of failure has been re-moved.

b. Use fuse having the prescribedamperage, only. Do never usefuses having amperage greaterthan the prescribed one.

C. Correctly insert fuse into fuse-box, aligning it carefully withrespect to its seat.

cl. Should car remain stationaryfor a long time, remove fuseprotecting supply circuit of

SERVICES PROTECTED BY FUSES clock.

In the following table, for each model, it is specified which are the services protected by each fuse.

Protected Service

Power windows

Door lock control unit

Heated rear window

Clock

Horns-cigar lighter

Passenger compartment roof lamp- Intermittence of direction and.hazard lights- Stop switch

Roof lamp timer

Trip Computer- .--Windscreen wiper-Windscreen Wiper electronic intermittence genera-

tor. Windscreen wiper controlWindscreen washer pump control-

Cluster

Heated rear window switch- Hazard lights switch -

Heater switch

Power window switch Power window

Clock

16 176 X

X16

X

%

X

8

8 X--l---

Model

1350 1500 Q.*905.02 905.04---I-905.03 905.05

X

I x

1500

905.06

905.07I

X

40-S May 1983

ELECTRICAL SYSTEM

Modal

Ampere 1200905.00

8 X

81:

8

9

1500905.06905.07

Protected Service 1360905.02305.03

X

X

X

X

X

X

1500 a.*905.04905.05

X

X

Cut-off solenoid valve - Reverse switch

Trip Computer - Check Control

Side lights left front and right rear-R. H.number plate light

Clock

Check Control

Cigar lighter

Side lights right front and left rear-i. H.number plate light

Check Control -Trip Computer-Headlights wiper

Heater control lighting lamp - Cluster lighting lamp -

Side light warning lamp

10

11 Risht low bean X X

X X12 XLeft low beam - Rear fog light switch

Rioht full beam X X13 X

X X X14 Left full beam - Headlights warning lamp

a* = Quadrifoglio

IGNITION SWITCH

REMOVAL ANDINSTALLATIONFor removal and installation of theignition switch - antitheft steeringlock group, refer to: Groupe 23 -Steering Wheel and Column.

M a y 1 9 8 3 40-6

ELECTRICAL SYSTEM.-

ELECTROMECHANIC AND ELECTRONIC DEVICES

RELAYS AND TIMER

LOCATIONThe relays and the roof lamp timerare inserted into the special socketwhich is integral part of the fusebox

support board, located on left side ofintermediate bulkhead. For location,refer to “Electric Component Loca-tion”.

CHECKThe relays and the timer, must be ofthe type indicated in the specifictable on page 40-8.

ELECTRONIC DEVICES AND INTERMITTENCES

LOCATIONThe electronic device for headlightsand flashing changeover, and thewindscreen wiper electronic intermit-tence generator, are mounted on asupport board, located in the inter-mediate bulkhead, in proximity tothe fuse holder box.

The device which controls intermit-tences of both side lights and hazardlights, is located in the dashboardinside.For identification of the variousdevices, see: “Electric Component.Location”.

CHECKThe electronic devices and intermit-tences must be of the type indicatedin the specific table on page 40-g.

40-7 May 1983

ELECTRICAL SYSTEM

“Relays and Timer” Table

Passenger compartment

roof lamp timer NlO

Horns relay 13

Heated rear window

relay 12

Headlight wiper relay 14

Front power windows

relay 112

External view Symbols

4%+L

Position

1

2

3

4

5

M a y 1 9 8 3 40-8

ELECTRICAL SYSTEM

“Intermittences and electronic devices

Component

Windscreen wiper electronic

ihtermittence N14

Electronic device for

headlights and flashing

changeover N18

Hazard and direction

lights intermittence N13

External view Symbols

L

++

P - +

2

40-9 M a y 1 9 8 3

ELECTRICAL SYSTEM

LIGHTING SYSTEMLAMPS

CAUTION:Before starting operations on lightingsystem, make sure that the ignitionswitch is to the “ST” position andthe battery ground cable is discon-netted.

Lamp characteristic data, type andelectr ic power are l isted i n the

following table.

Lamps

Front combination lamps :

- low beam and full beam (H4 halogen lamp) 56/60

- front side light 4

- front direction indicator 21

Side direction indicator lamp

Rear combination lamps :

- rear direction indicator

- rear side light

- number plate light

- reversing light

- rear fog light

- rear side and stop light

Warning lamp

Roof lamp

TYPES OF LAMPS

The lamps used for the car are offour types. For removal the follow-ing procedure is recommended.

2. Bayonet lamp - type BTo remove it from lampholder, pressthe bulb, rotate it counterclockwise,then withdraw it.

1. Halogen lamp - type ATo remove i t from lampholder,disconnect connector, then rotateretaining spring being careful not totouch it with naked hands.

Electric power

IWI

3

21

5

5

21

21

S/21

1.2

IO

TYPe

4. Whole glass - type DIt is pressed into lamp holder and toremove it, it is necessary to withdrawlamp out of lampholder.

3. C y l i n d r i c a l l a m p - t y p e CTo remove i t from lampholder,release it from contacts pullingtowards outside of lampholder.

For installation of lamps, reverseorder of removal.

May 1983 40-l 0

ELECTRICAL SYSTEM

COMBINATION SWITCH ASSEMBLY

VIEW FROM M

d5

1 Left lever 5 Connector2 Turning stalk 6 Connector3 COnnector 7 Connector4 Connector 8 Right lever

40-l 1 May 1983

ELECTRICAL SYSTEM

The fOiiOWiIIQ table shows thecorrespondances between positions

of combination switch controls andthe concerned services.

Control

Stalk rotation

Movement parallel

to steering wheel axis

Movement parallelto steering wheel plane

Left lever

Right lever


Control

Movement parallel

to steering wheel plane

Movement parallel to steering

wheel axis

T

1. Removing steering wheel.

2. Unscrew the five securingscrews and remove upper and lowershell covers of steering column(see Group 23 - Steering Wheel andColumn).3. Disconnect connectors @ ofthe combination switch unit.4. Remove combination switchunit by unscrewing the twoscrews 01 securing it to steeringcolumn.If necessary, disassemble combina-tion switch unit separating the ‘CWOlevers.5. For installation reverse order ofremoval.

Position Service enabled

0 - zero position

1 - side ligho

2 - low beams

A

B ID

OFF

S

Position

ON- windscreen washer and/or headlight

wash-wiper with wiping stroke driven

from control unit

OFF - zero position

.

- zero position

- full beam flashing (paired to rotation in

the 0 and 1 positions)

- Headlight change over (paired to rota-

tion in position 2 )

- Right - hand direction indicator

- Neutral position

- Left ” hand direction indicator

Service enabled

- zero position

- windscreen wiper intermittence

- windscreen wiper Ist speed

- windscreen wiper 2nd speed

1 Screw2 Connectors

CHECKS AND INSPECTIONSCheck harness integrity and, by

means of a tester, check electriccontinuity.

May 1983 40-I 2

ELECTRICAL SYSTEM

OUTSIDE LIGHTING

OUTSIDE LIGHTING - FRONT SIDE

May 1983

ELECTRICAL SYSTEM

OUTSIDE LIGHTING - REAR SIDE( f o r t h e 1 2 0 0 - 1 3 5 0 - 1 5 0 0 m o d e l s )

d1

--i,I’

-

May 1983 40-l 4

ELECTRICAL SYSTEM

HEADLIGHT SWITCH

Low beam/full beam light change-over is executed via left lever ofcombination switch (see: Combina-tion Switch Assembly).

DIRECTION LIGHT SWITCH

Operation of direction indicators isexecuted via left lever of combina-tion switch (see: Combination

Switch Assembly).

HAZARD LIGHTS SWITCH

Location

The switch is mounted on upperornament of central console (see:Groupe 66 - Consoles).

Check

Verify switch functioning by check-ing whether continuity betweenterminals occurs in accordance withthe indications provided in table.

REVERSE LIGHT SWITCH

Location

The switch is mounted on gearbox(see: Group 13).

CheckConnect a tester to terminals ofreverse switch and verify the follow-ing resistance values.

When in the OFF position = -aWhen in the ON position = 0 a

STOP LIGHT SWITCH

Location

The switch is mounted on therelevant bracket of pedal assembly.

Check

Connect a tester to terminals of stoplight switch and verify the followingresistance values.

When in the OFF position = maWhen in the ON position = 0 fi

REAR FOG LIGHT SWITCH

Location

The switch is mounted on upperornament of central console (see:Group 66 - Consoles).

Check.

Verify switch functioning by check-ing whether continuity betweenterminal occurs in accordance withthe indications provided in table.

M a y 1 9 8 3 40-16

ELECTRICAL SYSTEM

FRONT COMBINATION LAMPS

R E M O V A L A N DINSTALLATIONWith reference to the exploded viewproceed as follows.1. Operating from engine com-partment inside, disconnect harnessfrom cover 0.2. Remove grille (see: Group 75 -Grille).3. Unscrew the two nuts securingcombination lamps to body.

1 Front combination lamp2 Halogen lamp3 Securing spring4 Supply connector5 C o v e r6 Lamp holder

5. For combination lamp installa-tion, reverse order of removal.6. Adjust luminous beam by fol-lowing the procedures described in“Setting of headlights low beam”.

4. Operating from fender inside,unscrew nut securing combination

lamps to fender itself and re-move it.

Replacement of transparent cov-er @ can be carried out on mountedcombination lamps 0, by operatingfrom engine comparment inside.(1) Rotate lampholder @ counter-clockwise and withdraw it fromtransparent cover IO0.

7 L a m p8 Lampholder9 Lamp

IO Plastic cover11 Headlight wiper clamp

(2) Unscrew the two screws secur-ing transparent cover @J to com-bination lamps 0, then remove it.

40-l 7 May 1983

ELECTRICAL SYSTEM

(3) For installation of transparentcover, reverse order of removal.

LAMP REPLACEMENT

Headlights and front side lights1. Operating from engine com-partment inside, rotate cover 0clockwise, then remove it.

1 Cover

2. Disconnect SuPPlY con-nector 0.3. Rotate securing spring @counterclockwise, and remove it.4. Withdraw halogen lamp @ andreplace it. On reassembly, replace thelamp, make sure the cover is properlypositioned by correct alignmentof the notches.5. To remove headlight lamp @,withdraw lampholder 0, press bulband rotate it counterclockwise.

1 Supply connector2 Halogen lamp3 Securing spring4 Lamp5 Lampholder

6. For installation, reverse order ofremova I.

CAUTION:Do not touch with the hands glass ofheadlight halogen lamp 2 . If thisoccurs, wash the glass.

Front direction indicators

1. Operating from engine com-partment inside, rotate lamp-h o l d e r @ counterclockwise, thenremove it.2. Press lamp bulb @ and rotateit in order to withdraw lamp.3. Replace the lamp and installlampholder 0.

1 Lamp 2 Lampholder

Side direction indicators

1234

1. Operating from fender inside,compress the two springs securingtransparent cover of side directionindicator @ to fender @, thenremove it.2. Withdraw lampholder @ fromdirection indicator 1 _03. Replace lamp @ by pullingthe relevant bulb.4. Install direction indicator byreversing order of removal.

SETTING OF HEADLIGHTSLOW BEAMCarry out the following procedure toadjust headlight low beam.1. Check that tires are inflated atthe right pressure and that car is freefrom any load excepted those ofservice supplies and of one passengerequivalent.2. Position the car and the possibletest equipment on an horizontalplane. If no test equipment is avail-able, place the car inscreen.

front of a clear

3. Move car back of about IO m

(32,8 ft) and switch on low beams.The luminous beam must be incompliance with geometric dimen-sions provided in figure.

Side direction indicatorLampLampholderFender

May 1983 40-18

ELECTRICAL SYSTEM

A = distance of headlight centre centre must be equal to distance Efrom ground between headlight center.

B = height of luminous beamC = IO m (32,8 ft)

The dimensions indicated in thediagram comply with provisions in

Orientation is correct when thefollowing condition occurs:

force in Italy. For other countries,comply with national provisions.

6 = 470 mm (‘l8,5 in)

Distance D between luminous beams

For correction of possible orien-tation errors, from engine compart-ment inside, operate on adjustingscrews of headlights set in evidencein the following figure.

1 Horizontal direction adjustment screw2 Verrical direction adjustment screw

REAR COMBINATION LAMPS

REMOVAL ANDINSTALLATIONWith reference to the exploded view,operate as follows.I. Open back door and lift reartrim.2. Disconnect connector.3 . Unsaew the six nuts securingcombination lamps to body, thenremove combination lamps.

1 Combination lamps2 L a m p3 Lampholder

4. For installation of combinationlamps, reverse order of removal.

LAMP REPLACEMENT

The following procedure is applicableto all lamps and lampholders.

4 0 - 1 9 M a y 1 9 8 3

ELECTRICAL SYSTEM

1. Open back door and lift reartrim.2. Press on lampholder side 0,pull; then remove it.

1 Lamp2 Lampholder

INSIDE LIGHTING1 2 0 0 a n d 1 3 5 0 m o d e l

3. Press bulb of lamp and rotate itin order to remove.4. Replace lamp and refit lamp-holder.5. For identification of lamp loca-tion, refer to diagram of the follow-ing figure.

Diagram refers to the left rearcombination lamp.The right-hand one is specular withrespect to the left-hand.

The rear fog light is present in theleft rear combination lamp only.

1 Rear fag light2 Side light3 Stop and side lights4 Direction indicator5 Reverse light6 Number plate light

PIz hnz--0A l -%

‘=-

0H4

O-Gl

it*Nl

0-J4

May 1983 4 0 - 2 0

ELECTRICAL SYSTEM

1500 a n d 1 6 0 0 Quadrlfogllo m o d e l

Al Battery61 Ignition switchF3 Passenger compartment roof lampF16 Ignition switch lighting lampGl Fusebox

G30 Power window and door lock connectorG86 Passenger compartment roof lamp connectorH4 Roof lamp switch on passenger compartment pillarNlO Passenger compartment roof lamp timer

ROOF LAMP

Lamp replacement

1. By means of proper tool,remove transparent cover, pressureinserted into lampholder.

2. Withdraw and replace the lamp.. 3. For lamp installation, reverseorder of removal.

40-2 1 May 1983

ELECTRICAL SYSTEM

CAUTION:Before starting operations, make surethat the ignition key is to the “ST”position and ground cable is discon-nected.

REMOVAL ANDINSTALLATION1. Unscrew the four screws @

securing cluster @ tobracket @.

support

2. Remove the pressure insertedcover 0, disconnect harness 0,then remove cluster.

LIGHTING AND WARNINGLAMPS REPLACEMENT,. Remove cluster (see: Removaland Installation).2. Rotate lampholder and with-

3. For installation, reverse orderof removal.

draw it; then remove lamp fromlampholder itself.3. Replace lamp with an identicalone then carry out installation byreversing order of removal.

1 Cluster2 Connector53 Cover4 Bracket5 Screw

40-23 M a y 1 9 8 3

ELECTRICAL SYSTEM

ENGINE COOLANT LEVELSENSOR

LocationThe sensor is inset-ted into headertank of cooling system.

Check1. Connect the two ends of testerto sensor connector just as per figure.

2. Check sensor proper function-ing by veri fying the fol lowing:

Float lifted: &Float lowered: 0 a

ELECTRICAL SYSTEM

FUEL LEVEL TRANSMITTER

..Removal and installationFor removal and installation see:Groupe 04 - Supply System.

2. Connect a lamp indicator topins of float plug, as per figure.3. Check device proper function-ing by verifying the following.

Float lifted:

CLUTCH AND BRAKE OIL lamp indicator off

MINIMUM LEVEL Float lowered:

TRANSMITTER lamp indicator on

Check1. Set the ignition key to the MARposition.

40-27 May 1983

ELECTRICAL SYSTEM

WINDSCREEN WASH/WIPER AND HEADLIGHTWASH /WIPER

W I N D S C R E E N W A S H / W I P E R

rI

Im---J

r - -0’PI9

I +3n IL--

r

r--l

Al BatteryBl Ignition switch82 Windscreen wiper control switch83 Windscreen washer and/or headlight

wash/wiper pump control switchGl Fusebox

G85 Front service ConnectOr

L13 Windscreen washer liquid level sensorN7 Trip ComputerN8 Check ControlN14 Windscreen wiper electronic intermittencePI Windscreen wiper motorPI9 Windscreen washer electric pumpCL4 R.H.D. L.H.D. Quadrifoglio model

ELECTRICAL SYSTEM

WINDSCREEN WIPER

1 Motor6 Bush

IO Brush

2 Motor cover7 Cowl top cover

11 Bush

3 Linkage8 Nut

12 Spacer

0 Wiser arm13 Nut

4 Nut5 Spacer


1. Disconnect motor 0 harness.

2. Withdraw brushes

000 f r o m

wiper arms 9 .3. Lift covers of nut @ securing

wiper arms @, unscrew nuts, thenremove wiper arms.

4. Remove cowl top cover 0

(see: Group 75 - Cowl top cover).5. Withdraw bush @) , unscrewnut 8, then remove it togetherwith spacer @ .6. Unscrew the three screws secur-

ing linkage @ to body, then re-move it.

7. Unscrew the three screws secur-

ing motor 0 to linkage @ andnut securing motor shaft to linkage.

8. Remove motor 0 and with-

draw cover @.

9. For windscreen wiper installa-

tion, reverse order of removal.

4 0 - 2 9May 1983

ELECTRICAL SYSTEM


Condition

Windshield wiper does notoperate

Windshield wiper operatingspeed is too slow

Windshield wiper does notstop correctly

Washer fluid does not eject(washer motor operates)

Wiper does not operate inter-mittently but operates at lowand high speeds

Intermittent speed is tooshort for proper wiping

Intermittent speed is too long,for proper wiping

Probable cause

l Burnt fuse

l Loose connection or open circuit

l Improper switch contact

l Foreign material interrupts linkmechanism

l Disconnected rod.

l Seized or rusted arm shaft

l Short circuit of motor armature

l Worn brushes or seized shaft

0 Low source voltage

. Humming of motor

l Faulty auto-stop device

l Faulty wiper motor

Clogged washer nozzle or hose

l Faulty wiper switch

l Faulty wiring

l Faulty intermittence

l Faulty auto-stop device


l Line voltage below 10 volts


Corrective action

Replace fuse

Restore connection

Verify combination switch; (right light);replace, if necessary

Take off foreigti’material

Connect rod.

Replace shaft

Replace motor

Replace brushes

Verify voltage supply

Replace motor

Replace auto-stop device

Replace motor

Free nozzle or hose

Replace combination switch (right lever)

Verify wiring

Replace intermittence

Replace auto-stop device


Restore voltage


May 1983 40-30

ELECTRICAL SYSTEM

Condition

Intermittent speed is erratic

Probable cause

l Faulty wiper switch

l Faulty wiring

. Faulty wiper motor


Corrective action

Replace switch

Verify wiring

Replace motor


40-31 M a y 1983

ELECTRICAL SYSTEM

HEADLIGHT WASH/WIPER

1500 Quadrlfogllo model

I;1

I ! j I 1

Bs

I 1 1 ’ 1 r

! iIIi I1w--B 1

May 7983 4 0 - 3 2

ELECTRICAL SYSTEM

HEADLIGHT WIPER

1500 Quadrlfogllo m o d a l

1 Motor2 Bracket3 Headlight wpsher hose4 . Grille5 Wiper arm6 Nut

REMOVAL ANDINSTALLATIONWith reference to the exploded viewabove proceed as follows.1. Disconnect harness of mo-tor (iJ .2. Lift coversecuring wiper arms @ and 8 ,

of nuts 0 6 and 8 7

unscrew nut and disconnect head-light washer hoses @ and @.3. By means of tool A.3.0602,remove wiper arms @ and @.

7 NutB Wiper arm9 .Headlight washer hose

10 Bracket1 1 M o t o r

5. Unscrew the six screws secur-ing motors @ @toandbracket @ and @ ! then removemotors.

4. Remove grille (see: Group 75 ” 6. For windscreen wiper installa-Grille). tion, reverse order of removal.

4 0 - 3 3 May 1 9 8 3

ELECTRICAL SYSTEM



Page

A.3.0602 Wiper arm puller

40-35 May 1983

ELECTRICAL SYSTEM

HORNSLocationThe horns are mounted inside enginecompartment on support bracketslocated under front combinationlamps.Removal and installation1. Operating from engine com-oartment inside, disconnect hornh a r n e s s 0.

2. Unscrew the nut @ securinghorn 2 to support bracket 0; thenremove the bracket.3. For installation, reverse order ofremoval.

1 Harness2 N u t

3 Bracket

HORN CONTROLPUSHBUTTON Is=3

LocationThe pushbutton is located at centreof steering wheel (see: Group 23 -Steering Wheel and Column).

Check1. Connect ends of tester topushbutton terminal, operating asper figure.2 . Check pushbutton proper func-tioning by verifying the following:

Pushbutton lifted: -&Pushbutton depressed: 0 a

TROUBLE DIAGNOSIS AND CORRECttONS

Condition

Only one side operates

Probable cause

Il Faulty hose

l Loose connector contact

Poor tone quality on one side Tone adjustment not good

Both horn volume reduced l Low battery charge

l Faulty charging system

l Faulty connector contact

-

Both horns do not operate l Wiring cut-out

l Faulty control push button

l Discharged battery

l Both horns faulty

4 0 - 3 7

Corrective action

Replace horn

Restore connection

Adjust tone by operating on the relevantadjusting screw 0

Charge battery or replace

Verify charging system

Rest&e connection

Restore connection

Replace push button

Charge battery

Replace both horns

&fay 7983

ELECTRICAL SYSTEM

4. Dry end of ruling pen to removesilver compounds.5. Once the repair has been carriedout, wait for about 10 minutes, thenverify electric continuity of the wirein object.

6 . By means of a hot air jet, heatthe repaired area for about 20minutes, keeping the orif ice ofheat-gun at about 3 cm (I,2 in) fromsurface. If a heat-gun is not available,let dry for 24 hours.

During test, do not touch’ with thefingers the repaired resistor,

1 Filament 3 Rule2 Interruption 4 Ruling pen

POWER WINDOW1 3 5 0 m o d e l ( I t a l y , o n l y ) and 1 5 0 0 m o d e l

821 Right front power window control switch822 Left front power window control switchGl FuseboxG36 Power window switch cable connector

I1 2 Front power windows relayPI4 Right front power window motorPI 5 Left front power window motor

Al BatteryBl Ignition switchB9 Heated rear window control switch812 Hazard lights control switch

4 0 - 3 9 May 1983

ELECTRICAL SYSTEM

POWER WINDOWS AND DOOR LOCKS1500 Quadrlfogllo model

I I I 1

I I I I

r e--1

M a y 1 9 8 340-4 1

ELECTRICAL SYSTEM

DOOR LOCK CONTROL UNIT

LOCATION

The door lock control unit is locatedinside passenger compartment, in thegear lever console, behind CheckControl and Trip Computer.


1; @wi;ydisc;;;ey;e “,“,:“,I

vant harness.2. Remove control unit @ byunscrewing the screw securing it toTrip Computer 0.For control unit installation, reverseorder of removal.

1 Door lock control unit2 Trip Computer3 Instrument holder4 Check Control

May 1983 40-42

ELECTRICAL SYSTEM

LOCATION

Check Control and Trip Computer

3. For instrument installation, re- used to set in evidence the enabled

verse order of removal. function in order to allow user an

When reading a red led diode is easy identification.

are inserted into a special instrumentholder integrated into gear leverconsole, in centre position, underdashboard.

REMOVAL ANDI N S T A L L A T I O N

1. Withdraw instrument holder 3from console and disconnect therelevant harness.2. Remove Check Control 2 andTrip Computer 1 by unscrewing,for each one, the two securing screwsto instrument holder.

For an easier comprehension of thesymbology used for the two instru-ments, in the following table refer-ence is made to Trip Computer

Indications and the Check Controlsignallings, pairing them to relevantsymbols.

1 Trip Computer 3 instrument ho lder2 Check Control

Trip Computer

1 lstantaneous consumption in L/100 km

2 Medium consumption for the covered distance in L/100 km

starting from zeroing by red Key (Start Key)

3 Fuel consumption in litres since trip start, starting from

zeroing by red Key

4 Medium speed in km/h since trip start, starting from

zeroing by red Key

5 Drive time in h/min since trip start, starting from zeroing

by red Key

6 Time in hoursjmin

Check Control

7

8

9

10

11

12

13

14

Windscreen washer fluid level warning lamp

Engine oil level warning lamp

Engine coolant level warning lamp

Cluster warning lamp

Stop lights warning lamp

Side lights warning lamp

Main red warning lamp

Main green warning lamp

May 1983 40-44

ELECTRICAL SYSTEM

ELECTRIC COMPONENT LOCATIONENGINE COMPARTMENT

1 Passenger compartment roof lamp timer 52 Horns relay 63 Heated rear window relay 74 Headlight wiper relay 8

PASSENGER COMPARTMENT

Front power windows relayFuseboxElectronic device for headlights and flashing changeoverWindscreen wiper electronic intermittence

1 Hazard and direction lights intermittence

40-45 May 1983

ELECTRICAL SYSTEM

HARNESS LAYOUTGENERAL HARNESS

ENGINE COMPARTMENT

1 Engine comparment harness2 Front part and dashboard harness3 Roof lamp harness4 Luggage room harness5 Passenger compartment harness

A3 Alternator with built-in electronic regulatorA8 Ignition coilAl 1 Starter01 Alternator charge warning lampE9 Side direction light lampGl FuseboxG46 Headlight connectorG53 Engine compartment groundG73 Rear service connectorG85 Front service connectorH2 Reverse right switchHI7 Brake fluid min. level control switchL2 Pressure switch for engine oil min. pressure

L5 Thermostatic switch for engine coolant max. temperature warning lampL6 Thermostatic switch for engine cooling electric fanL7 Transmitter for coolant temperature gaugeL17 Odometer pulse generatorMl Cut-off solenoid valveN14 Windscreen wiper electronic intermittenceN18 Electronic device for headlights and flashing changeover0 2 H o r nP2 Engine coaling electric fanP4 Headlight wiper motorPI9 Windscreen washer electric pump01 Air ventilation heater fan

May 1983 40-46

ELECTRICAL SYSTEM

PASSENGER COMPARTMENT AND LUGGAGE ROOM (L.H. DRIVE)

May 1983

ELECTRICAL SYSTEM

DASHBOARD (L.H. DRIVE)

Bl Ignition switch82 Windscreen wiper control switch84 Control switch for headlight, flashing, low beam and full beamB5 Horns control switchB6 Direction lights indicator switchB9 Heated rear window control switchBll Rear fcg light control switchB12 Hazard lights control switch .

40-48

821 Right front power window control switch822 Left front power window control switchC7 Clock

F8 Air ventilation controls lighting lampG5 ConnectorG6 Cluster B connectorG7 Cluster R connectorG86 Passenger compartment roof lamp connectorH3 Stop light switchH13 Choke switchN13 Hazard and direction lights intermittence06 Cigar lighterQ4 Air ventilation heater fan control

May 1983

ELECTRICAL SYSTEM

SWITZERLAND-AUSTRALIA MODEL VARIATIONTACHYMEiRlC CONTROL UNIT-FAST IDLE ELECTROMAGNET

-HAND BRAKE SWITCHTACHYMETRlC CONTROL UNIT - FAST IDLE/ ELECTROMAGNET(For vehicles 1350 - 1500 and 1500 Quadrifoglio models for SWITZERLAND and AUSTRALIA)and HAND BRAKE SWITCH(For 1500 Quadrifoglio vehicles, A USTRA LIA models)

0r - 1

Al BatteryA8 Ignition coilBl Ignition switchB2 Windscreen wiper control switchCl Electronic rev. counter07 Hand brake warning lampGl FuseboxG6 Cluster B connector

HANDBRAKE INDICATORSWITCH(1500 Quadrifoglio)

Check1. Set the ignition key to the MARposition.2. Connect a tester to terminal of

G7 Cluster R connectorG30 Power window and door lock connectorG85 Front service connectorHI Hand brake switchMl Cut-off solenoid valveM4 Idle speed electromagnetN16 Tachymetric control unit

handbrake indimtor as shown infigure.3. The following resistance values.shall be read.

Brake engaged: 0 aBrake disengaged: &

40-49 May 1983

ELECTRICAL SYSTEM

CIRCUIT DIAGRAM

KEY

A l Batter/A3 Alternator with built-in electronic regulatorA5 Ignition distributorA8 Ignition coilAll StarterAl2 Spark plugsBl Ignition switch82 Windscreen wipercontrol switchB3 Windscreen washer and/or headlight wash/wiper pump

control switch84 Control switch for headlight, flashing, low beam and full beamB5 Horns control switchB6 Direction lights indicator switchB9 Heated rear window control switchBll Rear fw light control switch812 Hazard lights control switch821 Right front power window control switch822 Left front power window control switchCl Electronic rev. counterC2 Electronic tachometerC4 Fuel level gaugeC6 Coolant temperature gaugeC7 C lockDl Alternator charge warning lampD2 Direction light warning lampD3 Side light warning lamp04 Full beam warning lampD5 Brake fluid level warning lamp07 Hand brake warning lampD8 Fuel reserve warning lampD9 Choke warning lampDll Engine oil min. pressure warning lampD13 Engine coolant max. temperature warning lampEl Front direction indicator light lampE2 Front side light lampE8 Low beam and full beam lampE9 Side direction light lampEl 1 Rear direction light lampEl3 Tail light lampEl4 Raversa light lampEl5 Stop light lampEl6 Rear fog light lampEl7 Number plate light lampF3 Passenger compartment roof lampF8 Air ventilation controls lighting lampF12 Cluster lighting lampF16 Ignition switch lighting lampF17 Switches lighting lampGl FuseboxHl Handbrake switch

HZ Reverse light switchH3 Stop light switchH4 Roof lamp switch on passenger compartment pillarHI 3 Choke switchH17 Brake fluid min. level control switchH27 Contact switch, on rear door, for heated rear windowI2 Heated rear window relayI3 Horns relayI4 Headlight wiper relay112 Front power windows relay

L2 Pressure switch for engine oil min. pressureL5 Thermostatic switch for engine coolant max.temperature

warning lampL6 Thermostatic switch for engine cooling electric fanL7 Transmitter for coolant temperature gaugeL9 Transmitter for fuel level gaugeL12 Engine oil level indicatorL13 Windscreen washer liquid level sensorL14 Engine coolant level sensorL17 Odometer pulse generatorMl Cut-off solenoid valveM4 Idle speed electromagnetNl Module for electronic ignitionN7 Trip ComputerN8 Check ControlNlO Passenger compartment roof lamp timerNil Door lock control unitN13 Hazard and direction lights intermittenceN14 Windscreen wiper electronic intermiuenceN16 Tachymetric control unitN17 Trip control unitfor fuel flowN18 Electronic device for headlights and flashing changeover01 Heated rear window0 2 H o r n06 Cigar lighterPI Windscreen wiper motorP2 Engine cooling electric fanP4 Headlight wiper motorPI0 Right front dwr lock motorPI 1 Left front door lock motorP12 Right rear door lock motorPI3 Left rear door lock motorP14 Right front power window motorPI5 Left front power window motorP19 Windscreen washer electric pumpP20 Headlight washer electric pumpQl Airventilation heater fanQ4 Air ventilation heater fan controlal L.H.D. 1200 modelUZ L.H.D. - R.H.D. 1350 modelU3 L.H.D. - R.H.D. 1500 modelU4 L.H.D. - R.H.D. 1500 Quadrifoglio model

May 1983 40-50

------------------

II

ELECTRICAL SYSTEM

KEY

Al BatteryA3 Alternator with built-in electronic regulatorA5 ignition distributorA8 Ignition coilAll StarterAl 2 Spark plugsBl Ignition switch82 Windscreen wiper control switch83 Windscreen washer and/or headlight wash/wiper pump

8485B6B9I311812B21822Clc 2c 4C6c7Dl02030405D70809

control switchControl switch for headlight, flashing, low beam and full beamHorns control switchDirection lights indicator switchHeated rear window control switchRear fog light control switchHazard lights control switchRight front power window control switchLeft front power window control switchElectronic rev. counterElectronic tachometerFuel lwel gaugeCoolant temperature gaugeClockAlternator charge warning lampDirection light warning lampSide light warning lampFull beam warning lampBrake fluid level warning lampHand brake warning lampFuel reserve warning lampChoke warning lamp

Dll Engine oil min. pressure warning lamp013 Engine coolant mBy. temperature warning lampEl Front direction indicator light lampE2 Front side light lampES Low beam and full beam lampE9 Side direction light lampEl 1 Rear direction light lampEl3 Tail light lampEl4 Reverse light lampEl5 Stop light lampEl6 Rear fog light lampEl7 Number plate light lampF3 Passenger compartment roof lampF8 Air ventilation controls lighting lampF12 Cluster lighting lampF16 Ignition switch lighting lampF17 Switches lighting lampGl FuseboxHI Handbrake switch

H2 Reverse light switchH3 Stop light switchH4 Roof lamp switch on passenger compartment pillarHI 3 Choke switchHI7 Brake fluid min. level control switchH27 Contact switch, on rear door, for heated rear windowI2 Heated rear window relay

,I3 Horns relay14 Headlight wiper relayI12 Front power windows relayL2 Pressure switch for engine oil min. pressureL5 Thermostatic switch for engine coolant max.temperature

warning lampL6 Thermostatic switch for engine cooling electric fanL7 Transmirter for coolant temperature gaugeL9 Transmitter for fuel level gaugeL12 Engine oil level indicatorL13 Windscreen washer liquid level sensorL14 Engine coolant level sensorL17 Odometer pulse generatorMl Cut-off solenoid valveM4 Idle speed electromagnetNl Module for electronic ignitionN7 Trip ComputerN8 Check ControlNlO Passenger compartment roof lamp timerNil Door lock control unitN13 Hazard and direction lights intermittenceN14 Windscreen wiper electronic intermittenceN16 Tachymetric control unitN17 Trip control unit for fuel flowN18 Electronic device for headlights and flashing changeover010 20 6PIP2P4P I 0PI1PI2PI3PI4PI5PI9P20Cl1Q4aia2a3a4

Heated rear windowHornCigar lighterWindscreen wiper motorEngine cooling electric fanHeadlight wiper motorRight front door lock motorLeft front door lock motorRight rear door lock motorLeft rear door lock motorRight front power window motorLeft front power window motorWindscreen washer electric pumpHeadlight washer electric pumpAir ventilation heater fanAir ventilation heater fan controlL.H.D. 1200 modelL.H.D. - R.H.D. 1350 modelL.H.D. - R.H.D. 1500 modelL.H.D. - R.H.D. 1500 Quadrifoglio model

M a y 1 9 8 3 40-53

BODY-SHEET METAL PANELS

CONTENTS

GENERAL INFORMATION., . . . . . . . .49-2

Identification codes . . . . . . . . . . . . . .49-2

Lifting points. . . . . . . . . . . . . . . . . . .49-3Wheel alignment. . . . . . . . . . . . . . . . .49-3

BODY COMPONENT PARTS . . . . . . . . .49-5

Body components . . . . . . . . . . . . . . . 49-5Under body components . . . . . . . . . ,49-6

BODY CONSTRUCTION . . . . . . . . . . . .49-7Body construction . . . . . . . . . . . . . . .49-7

BODY SEALING . . . . . . . . . . . . . . . . . . .49-9

Description. . . . . . . . . . . . . . . . . . . . .49-9BODY ALIGNMENT . . . . . . . . . . . . . . . .49-11

Measurement operations . . . . . . . . . .49-l 1Measurement points. . . . . . . . . . . . . .49-l 2

CAUTIONS FOR THE OPERATORS . . .49-14Safety rules . . . . . . . . . . . . . . . . . . . .49-14Body and outer components

protections. . . . . . . . . . . . . . . . . . . . .49-l 4

Cautions during replacement

operations . . . . . . . . . . . . . . . . . . . . .49-l 5

Cautions during welding operations . .49-l 5

REPLACEMENT OPERATIONS . . . . . . .49-20

How to read this chapter . . . . . . . . . .49-20

Symbology . . . . . . . . . . . . . . . . . . . . .49-21

Removal and installation

procedures . . . . . . . . . . . . . . . . . . . . .49-22

Radiator core support . . . . . . . . . . . .49-29

Hoodledge panel with core

support removed . . . . . . . . . . . . . . . .4g-31

Hoodledge panel with radiator core

support removed (Partial

replacement) . . . . . . . . . . . . . . . . . . .49-33

Front side member. . . . . . . . . . . . . . .49-35Central pillar . . . . . . . . . . . . . . . . . . . .49-37

Outer side member. . . . . . . . . . . . . . .49-39Outer side member (Partial

replacement) . . . . . . . . . . . . . . . . . . .49-41

Rear fender . . . . . . . . . . . . . . . . . . . .49-43Drip with rear fender removed. . . . . .49-45

Lower rear panel . . . . . . . . . . . . . . . .49-46Upper rear panel . . . . . . . . . . . . . . . . 49-47

Rear part of rear floor with rear fender

and rear panel removed . . . . . . . . . . .49-49

Rear side member with rear panel

and rear floor removed. . . . . . . . . . . .49-51Roof panel. . . . . . . . . . . . . . . . . . . . . 49-52

M a y 1 9 8 3

BODY -SHEET METAL PANELS

GENERAL INFORMAi-ION

IDENTIFICATION DATA

Identification andcertification label Chanis No.

Identification andcertification label

Identification and-certification label Chassis no.

See Group 00 - Identification Data (according to CEE/ISO standard specifications)

See Group 00 - Identification Data

May 1983 4 9 - 2

B O D Y - S H E E T M E T A L P A N E L S

LIFTING POINTS

Front towing eyeand jack seat

Rear towing eye

Jack and safety stands 1. Front axle and suspension

rWARNING:a. After lifting the car by means of hydraulic jack,

provide to support car weight by means of safety

Toe-out mm M - H =4+1

(in) M-.H =0.16*0.04

stands. Haif toe-zlut mm L = ‘12 lv-- 2 f 0.5

b. Before lifting car rear (front) side place wheel chocks (in) L=1/2M -0.08f0.02

by positioning them at front (rear) wheels. Toe-out angle a=lof

Securely position hydraulic jack and safety stands in thepoints identified in figure.

Rim diameter

Camber angle

mm

(in)0=340

0= 13.39fl=-295’f30’

WHEEL ALIGNMENTCaster angle y= l”f30’

Max steering angle 6 = 3350’

CAUTION:The technicians assigned to the repair and replacement

2. Rear axle and suspension

operations of sheet panels, shall always take into account,content of the remaining part of the “Workshop Manual”in order always to maintain original quality and func-tioning conditions of car as a whole. As restoration ofcar correct alignment is of particular importance, in thefollowing part are provided the data relevant to geometryof both front and rear suspensions. For any furtherinformation, refer to the specific Groups.

Toe-in angle U=O”+25’

Camber angle p=O”+25’

Wheel alignment is measured with cBr under nominalheight (see: Group 00 - Wheel alignment).

4 9 - 3 M a y 1 9 8 3


BODY CONSTRUCTION

BODY CONSTRIJCTION

4 9 - 7 M a y 1 9 8 3


BODY SEALING

DESCRIPTION

The following figures, show the body areas which aresealed by Manufacturer.The scalings applied to these areas, must be smooth andfree from scratches or gaps.

Take care not to apply too much sealing and not toallow other unaffected parts to come in contact with thesealing.

Body components sealing

Paint seal, after priming or painting, and then sleek bymeans of a brush along all sheet joints in order to remove

possible sealing faults.

ICIR: Paraflex Alpha 3M8531 IE8536/E

Alternative: part. no. 3522-00014

Sealant for bolted jointsSealant for joints between panels assembled by bolting.

3M - Autosealer 8573E - part. no. 3522-00045

49-9 M a y 1 9 8 3


View from I

Detail M

View from L

BODY ALIGNMENT

MEASUREMENT OPERATIONS

Method of measurement operation. When a tram tracking gauge is used, adjust pointers

(A) and (B) to equal lenghts as shown in the follow-ing figure.Check pointers and gauge itself in order to make surethat no clearance is present.

. When a measuring tape is used, verify there is noelongation, twisting or bending.

If, during measurement qperations, tape interfere withone or more parts of car body, accurate measurement ofdistance and length will not be possible.

4 9 - 1 1 May 1983

BODY - SHEET METAL PANELS

MEASUREMENT POINTS

M a y 1 9 8 3 49-12


May 1983


2 ..

.

Outer parts protectionWhen removing external parts (hood, back door,moldings, finishings) it is necessary to protect bodysurfaces with clothes, protection tape or othermaterials, in order not to damage or scratch vehiclebody.The scratched painted surfaces must be repaired: evena slight scratch may cause corrosion.

CAUTIONS DURINGREPLACEME-NT OPERATIONS

Use genuine spare parts.

. It is recommended always to use genuine spare parts.This allows perfect repair and restoration of vehicleoriginal functioning.

CAUTIONS DURING WELDINGOPERATIONS

Spot welding 150°1. Spot welderBefore starting welding operations, carry out the follow-ing checks in order to obtain welding sufficient strenght:(1) Welder arm adjustmenta) Keep the arm as short as possible in order to obtain

welding maximum pressure.b) Tighten arm and tips securely so as they do not get

loose during soldering operations.

D= Electrode end diametert =Sh;thickny, ; ~

Spot welder a/m

Arm minimumlenght

IArm different

length

Align both electrod-

Maladjustedelectrodelength

CORRECT INCORRECT

(3) Electrode end diameterIt is necessary to carefully verify diameter af electrodeends in order to obtain the required welding strength.Before starting working, make sure that end diameter (D)has a value proportional to sheet thickness.Remove burnt and foreign matters from electrode ends.

D=Zt i-3 (mm)

2. Condition and preparation of panels to be soldered

If the surface of the parts to be welded presents gap, paintfilm, rust or dust, this prevents welding current flow, thusreducing soldering area and, as consequence, strengthof welding spot.Before starting welding, verify conditions of the parts tobe welded, carrying out proper corrections.(1) Clearance between the parts to be welded.Presence of any clearance between surfaces to be welded,causes reduction of current flow, The welding thusobtained, results to be insufficient and poor in strength,Before carrying out soldering, match the surfaces and,when necessary, tighten them by means of a clamp.

(2) Electrode alignmentAlign ends of upper and lower electrodes. A misalignmentof electrodes generates insufficient pressure of solderingpoints and, as consequence, an insufficient strength ofpoints themselves.

49-15 M a y 1 9 8 3


INCORRECT INCORRECT CORRECT

(2) Welding of metal surfaces.Prepare the surfaces to be welded, removing all impuritiesand foreign matters (paint, dust, rust) in order to obtainperfect welding.

(3) Anti-corrosion procedure applicable to all metalsurfaces.Coat the surface to be+ welded high conductivityanti-corrosion agent. It must be applyed to end ofsurface to be welded, also.

Preliminary operation Apply anti-corrosion agentto the whole surface, endincluded.

3. Cautions during spot welding(I) Spot welding selectionUse the direct welding method (for the parts this methodcan not be applied to, use the MIG welding method).

(2) Electrode installment.Operate such as sheet forms a tight angle with electrodes.if not so, current flow will be low and the obtainedwelding streng.ht insufficient.(3) Welding of three or more overlapped sheets. Inthe areas where three or more sheets are overlapped,spot welding must be repeated.

In casa three or more overlappedsheets ara welded, repeat weldingtwice.

(4) Number of spot welding points.Generally, efficiency of spot welders available in theRepair Shop is lower than efficiency of spot welders usedat the Factory. As consequence, the number of spotwelding points performed at the Service Shop should beincreased by 20 ” 30% with respect to weldings performedat the Factory.(5) Minimum welding pitch.The minimum welding pitch is function of thicknessof sheet to be welded. Generally, the values providedin the following table, should be observed.

ThicknB (t) Minimum pitch (I)mm (in) mm (in)

0.6 IO.0241

0.8 (0.031)

1.0 (0.039)

1.2 (0.047)

1.6 (0.063J

1.8 (0.071)

10 (0.39) or more

12 (0.47) or mare18 (0.71) or more

20 (0.79) or more

27 (1.06) or more

31 (1.22) or mom

1 I I

M a y 1 9 8 3


01

f 1 CORRECT

It must form an opening ofabout 3 mm dia., when stressing

i

INCORRECT

t

(2) Test to be carried out after welding, by means ofchisel and hammer.. Insert tip of a chisel between the welded sheets and

slightly tap on chisel until, between sheets, it isobtained a 3 to 4 mm clearance (0.12 to 0.16 in); if,on the welded part, no strain is present, test result isthen positive.

. If sheets thickness is not equal, clearance betweensheets must be limited to 1.5 to 2 (0.059 to 0.079in).Take into account that the above value is only areference one.

. The mentioned clearance changes according taposition of welding spots, flange length, weldinginclination and other factors.DO never exceed this limits in order not to causedetachment of welding points.

. After test, make sure that the strained part is

Reference value: 3 to 4 mm(0.12 to 0.16 in)

Slightly tap by meansof a hammer

Reference value: 1.5 to 2.0 mm(0.059 to 0.079 in)

Slightly tap by meansof a hammer

MIG welding1. Conditions of panel to be welded.By means of belt sander or wire brush, remove anyforeign matter from surface.Paint films, rust or oils present on sheet surface, causesdecrease of welding strength, thus generating blow holes.

2. Cautions during welding operations.

(II Plug welding (of pre established holes)a) Make a hole, having 6 to 6 mm diameter (0.20

to 0.24 in) on one of the two sheets to be welded,then match the two sheets and clamp them.

b) Position the torch at right angle with respect tosheet, then fill metal into the hole.Each time welding is stopped, on the surface anoxide film generates which causes blow holes. If thisoccurs, remove oxide by means of a wire brush.

c) Make sure that welding between upper and lowersheet is perfect.

Plug welding Panel edge

I Butt weldiirg

r Point to be weldad

SEC. A-A

(2) Butt welding.a) By means of intermittent weld, tack the two surfaces

to be welded in order to prevent strains and align thetwo surfaces, then, fill in the spaces by placing smallwelding beads.

Mav 1983 49-18

Part around the hole

-.


REPLACEMENT OPERATIONS

HOW TO READ THIS CHAPTER

The formulation of the present part of the manual isuniform for all the replacement operations. For its struc-ture, refer to the following example.

:I) HOODLEDQE PANEL WITH RADIATOR CORE SUPPORT REMOVEDcarry c4lyII rwl~mml rmr R.dl.LM Em. swplrt km, bm ,,nm”,d,

II)(Iv) REMINDER WHEN REM<

$u#lsl bl”~ - BY rm.“l 01 .iT SW, cut.- .nd. b” m*anl 0‘ .nr dir

In detail:(1) “HOODLEDGE. PANEL WITH RADIATOR CORE

SUPPORT REMOVED”In the title it is indicated the element to be removed(hoodledge) specifying, if required, the operativecondition (in this case, radiator on core supportremoved). If the element is not in the requiredconditions, it is necessary, to execute preliminaryremoval of the other components; in the present case,it is necessary to remove the radiator core support,referring to the specific replacement procedures.

The parts Tepresented by chain line, set in evidence thecomponents which must result to be removed or forwhich it is required the preliminary removal, accordinglyto step (I 1.

(III)PARTS TO BE WELDEDA list is provided relevant to the components whichare to be welded using the methods indicated in step(II).

(II) “SERVICE JOINT”Any information concerning the welding operationsto be carried out is shown in the figure indicating thewelding method and the spot numbers, together withaccurate location of spots on the elements to bejoined.

Example: a l 3 -Welding spot number

LL

Welding type (spot welding:see simbology on page 2 1)

Parts to be welded

(IV)REM~NDER WHEN REM~V~NG/INSTALLINGIndication is provided, relevant to the main opera-tions to be carried out, with special care in identifica-tion of the areas concerned in the cut operations,selection of the equipments to be used and definitionof welding methods to be adopted.

M a y 1 9 8 3 4 9 - 2 0

BODY -. SHEET METAL PANELSSYMBOLOGYCUTTING AND WELDING/BRAZINGOPERATIONSThe symbology used for the cutting and welding/brazingoperations is shown in the following figures.

ed by means of air

Cutting performed by meansmyhTr air chisel

. .

Spot welding

l l l l Spot welding of two overlapped sheets@I @I@@ Spot welding of three overlapped sheets

.the value in parenthesis 1 1indicates the number of weld spots

Spot welder

CO2 arc welding

n n n n MIG plug weld

m MIG seam weld/point weld

.. Brazing

May 1983


Welding - brazing

Sealing


PROCEDURES

COMPONENT REMOVAL

(1) Make sure that all the damaged parts have beendetected, by measuring the installation main dimensions.Refer to ‘“Body Alignment” drawing.

Tools required:. Centering gauge. Tracking gauge. Convex rulel Rack-and-lever jack or car lift

(2) With a body-frame repair system, carry out drawoperations, depending on deformation condition. Reuseof the reclaimable parts must be performed in accordancewith the figures contained in “Body Alignment”.

Caution during operation:. Carefully secure drawing chains to body and equip-

ment, so as to prevent accidental release duringoperation execution.

. Apply draw stress in the direction opposite tocollision.

(3) Cut-off damaged parts.

Tools required:. Air saw. Air chisel

(4) If welding spots are not visible, remove paint bymeans of rotary wire brush.

Tools required:. Rotary wire brush

(5) Punch all the welding spots in order to make center-ing of a drill.

Tools required:. Hammerl Center punch

M a y 1 9 8 3 4 9 - 2 2 ---.


Caution during operation. Punch deeply in the center of each, welding spot. A

non-centered punch does not allow complete cut ofnugget. Besides, a shallow marked hole location doesnot allow a reliable drive of drill.

. As a rule, punching must be executed from sides ofthe components that are to be removed.

(6) Remove welding spots by means of a spot cutter oran air drill.

Tools required:. Spot cutter. Air drill

Caution during operation:. Use a drill speed of about 1000 r.p.m. in order to

obtain the best results.

Cautions during operation:. Take care not to drill mating parts. In case holes have

been made, plug them making use of gas or MIG plugwelding.Presence of holes, decreases strength of the concernedcomponent, besides, it may generate water leakage.

. When, for new components, are used holes alreadydrilled in welded parts (just as per those of the spotwelding) make use of a drilling machine having smalldiameter drill (below 8 mm (0.31.in)) and completewelding as soon as possible.

III I - Hole must have a diametern 0.31 in1n I’Ill ‘i below 8 mr

-I

flJ!lJ1

?

:i

E.g.: replace outer side memberleaving central pillar in its original position.

(7) By means of a chisel remove the remaining spotwelding parts.

Tools required:. Chisel. Hammer

PREPARATION FOR MATING PARTSINSTALLATION(1) By means of a sander, grind sheet in correspondencewith welding spots.

Tools required:. Air sander. Disc sander

Cautions when grinding. Take care not to cut much on base metal: this may

generate decrease of sheet thickness and, then,welding strength.

I CORRECT ’ INCORRECT

49-23 May 1983


l Carefully remove iron powder from the surfaceswhich have been grinded and from surrounding areas.Presence of iron powder, causes decrease of weldingefficacy and can also generate corrosion,

(2) By means of a hammer and dolly correct deformedareas. ’

Tools required:. Hammerl DOllY

Cautions during operation:. Check against presence of even the smallest defor-

mations, in particular, in the inner panels wherethey are hard to be found. Infact, if they are notremoved, they can cause a strength decrease due tostress concentration.

Carefully check meting parts of each pillar

(3) Remove paint from welding edges.

Tools required:. Belt sander. Disc sander

(4) Apply primer to edges of new components andof body panels which are to be welded.

Before welding apply conductive antirust paint on edgesof all sheet parts which are to be assembled.

Recommended paint:Part. No. 3540-44401SAVIU: Zincovid No. 7949SCHRAM LACK: Extrinom PunktschweifarbeGLASURIT: Glassomax 7 F 4625 (red color) *

* To be used with catalystGlassomax Harter 965-7/l in the proportion 1 :I0(part. No. 3541-20003).

Panels must be welded within 15 minutes of the paintapplication (air drying time of paint film).

The film thickness after drying must be 0.005 to0.025 mm. (2 to 9.8) 10s4 in.

May 1983 49-24


PREPARATION FOR NEW COMPONENTINSTALLATION(1) If a partial replacement is to be carried out, it isnecessary to maintain an overlapping tolerance of about50 mm (1.97 in) during cut of non-usable sheets, in orderto have a sufficient mating surface.

Tools required:. Air saw. Hack saw. Tracking gauge. Convex rule (or equivalent)

It is recommanded always to use genuine spare parts. Thisensures a perfect repair and restoration of vehicle func-tioning.

(2) MIG plug weld.This method must be used for those areas which cannot be reached by spot welder. To carry out this opera-tion, drill, in the welding spots, making holes having 5 to6 mm. (0.20 to 0.24 in) dia.

Tools required:. Puncher. Air drill

Holes must have 5 to 6 mm(0.20 to 0.24 in) dia

(3) Remove paint from components to be welded.

Tools required:. Belt sander. Disc sander

Cautions during operation:. Remove paint from both sides of components that

are to be welded, such as the surfaces to be spotwelded, spot welding rims and edges of surfaces to bebutt welded.The remaining paint, prevents current flow into spotweldings, with consequent poor strength of spot. Itcan also generate depressions in the plug MIG weld-ing.

(4) Apply primer to component and body surfaceswhich are to be spot welded.

Tools required:. Wire brush. Conductive anti-rust paint

INSTALLATION(1) New service parts temporary installation.

Tools required:. Vise pliers. Convex rule. Tracking gauge (sight). Centering gauge. Port power. Jack. Spot welder. Mig welder

49-25 May 1983


Cautions during operation:. Position components as per figures provided in “Body

Alignment”. Into body compartments, install themovable parts (i.e. windscreen, doors, hood, back-door) in order to carry out check of clearances,grades and parallelism. If necessary, adjust sheetsuntil correct alignment is obtained.

. Clamp parts to be welded by means of pliers andsome welding spot.

(2) ExecuTion of the required weldings.Carry out welding complying with specifications providedin “Cautions during Welding”.

Tools required:l Spot welder. M IG welder. Autogenous welder

(3) Grind MIG welding by means of a sander machine.

Tools required:. Air sander .. Cl isc sander

CORRECT INCORRECT

Cautions during operation:. Take care .not to grind excessively on spot weldings:

it may generate decrease of sheet thickness and,consequently, welding strength.

. Remove iron powder from grinded surfaces andsurrounding areas.Presence of iron powder, causes decrease of weldingefficacy and can also generate corrosion.

(4) After welding execution, remove clamps used forsecuring edges and remove possible dinging.

May 1983 49-26


(5) Apply anti-corrosion agent to the welded compo-nents.(6) Apply sealer to joints.This operation must be carried out carefully in order toprevent corrosion in the welded joints.Refer to figures provided in “Body Sealing”.

(7) For under body protection, apply a coat having 4 mm(0.16 in) thickness:

Antidrum: part. No. 3523 + 00001Alternatives: 3M

Body Plast 8874 EBody Schutz 8864 EWI Grey protective acrylic 854751

m Area to he protected

49-27 May 1983


May 1983 49-28


RADIATOR CORE SUPPORT

Parts to be welded

a. Radiator core support and engine support lower crossmember

b. Radiator core support and hoodledge panel upper

pati

c. Radiator core support and hoodledge panel upper

Par-td. Radiator core support and engine support lower cross

membere. Radiator core support and hoodledge panel

REMINDER WHEN REMOVING. By means of air saw, cut along line A.

REMINDER WHEN INSTALLING. By means of clamps, temporarily secure new radiator

core support, then adjust it.

4 9 - 2 9 May 1983


. Install parts temporarilyl Check and adjust clearances, grades and parallelisms.

May 1983 49-30


HOODLEDGE PANEL WITH RADIATOR CORE SUPPORT REMOVEDCarry out replacement after Radiator Core Support has been removed.

) Front

Parts to be welded

a. Upper hoodledge assembly and lower hoodledgeb. Lower hoodledge assembly and dashboard lower

sheetc. Upper hoodledge assembly and dashboard lower

sheetd. Lower hoodledge assembly and side membere. Lower hoodledge assembly and side memberf. Lower hoodledge assembly and front side memberg. Upper hoodledge assembly and engine upper cross

member

REMINDER WHEN REMOVING. By means of air saw, cut according to lines A, B, D

and, by means of air chisel, cut according to line C.

h. Upper hoodledge assembly and engine upper crossmember

i. Hoodledge assembly and engine upper cross member(spring seat cap reinforcement)

1. Hoodledge assembly and hoodledge side reinforce-ment

m. Hoodledge assembly, hoodledge side reinforcementand engine upper cross member

n. Hoodledge assembly, hoodledge side reinforcementand engine upper cross member

49- 31 May 1983


R EM I N DE R W HE N I N S TA L L I N G

. When are removed welding spots of the three over- g Install together radiator core support and hoodledge

lapped sheets drill the whole (welding spots are panel; then verify alignment dimensions concerning

identified by dimension line shown in the figure). hoodledge panel. Refer to drawings provided in“Body Alignment”.

. Carry out, from both sides, MIG plug welding ofdrilled sheets.

MIG welding

M a y 1 9 8 3 49-32


HOODLEDGE PANEL WITH RADIATOR CORE SUPPORT REMOVED(Partial Replacement)

Carry out partial replacement after Radiator Core Support has been removed.

Service joints

Parts to be welded

a. Upper part hoodledge and lower part hoodlege

REMINDER WHEN REMOVING. By means of air saw, cut according to lines A and B.

REMINDER WHEN INSTALLINGPrecaution when cutting the spare half hoodledge panell Cut spare half hoodledge panel al igned with

non-replaced panel part.

Overlappingtolerance

4 9 - 3 3 M a y 1 9 8 3


Dimension check and fender temporaneuous installationL Install together radiator core support, half hoodledge

panel and body.0 Check alignment dimensions referring to drawings

provided in “Body Alignment”.

May 1983 49-34


FRONT SIDE MEMBER WITH HOODLEDGE PANEL REMOVED

Carry out replacement after Hoodledge Panel has been removed.

Service ioints

-

Parts to be welded

a. Plate and replaced side memberb. Plate and present side member

REMINDER WHEN REMOVING REMINDER WHEN INSTALLING. By means of air saw, cut according to line A in figure, Precaution when cutting spare side member.

in correspondence with the hole located on side l Cut spare side member aligned with n&-replaced sidemember. member part.

4 9 - 3 5 May 1983


CENTRAL PILLAR

Service joints

SECTION A-A

Parts to be welded

a. Pillar and pillar inner reinforcement C. Outer pillar and inner pillarb. Outer pillar and inner pillar d. Inner pillar and roof panel side member

REMLNDER WHEN REMOVING. Unscrew the two screws securing rib to roof panel

inner side member.. BY means of air saw, cut according to lines A and B,

shown in figure.

l -Remove paint in correspondence with the fourwelding spots of pillar reinforcement lower part atabout 115 mm (4.52 in) from lower edge of outerside member (see sect. A-A).Punch the four welding spots and remove the rein-forcement pat-t.

. By means of disc sander carry out grinding of contin-.uous welding joining central floor side member @to inner central pillar @ _

1

1 Reinforcement2 Body side ring

3 Central floor side member4 Inner central pillar

4 9 - 3 7 M a y 1 9 8 3


REMINDER WHEN INSTALLINGPrecaution when cutting spare pillar

. By means of clamps, temporarily secure central pillar.Check component alignment.

.Cut spare pillar aligned with the upper and lower part

After continuous welding of central pillar, carry out.

of non-replaced pillar part.tinning.

. Temporarily secure both front and rear doors.

. Check and adjust clearance, grades and parallelism.

===T===Overlapping 7tolerance

=FI

Overlappingtolerance

I

May 1983 49-38


OUTER SIDE MEMBERService joints

a. Outer side member, front side member and inner c. Outer side member and closing inner central pillar

front pillar d. Outer side member and inner wheelarch

b. Outer side member, diaphragm and central floor side e. Outer side member and outer wheelarch

member f. Outer side member and central pillar reinforcement

Parts to be welded

REMINDER WHEN REMOVING. By means of air chisel, cut according to line A shown

in figure.

. Remove paint in correspondence with the fourwelding spots of pillar reinforcement lower part atabout 115 mm (4.52 in) from lower edge of outerside member (see section A-A).Punch the four welding spots.

l By means of a drilling machine, remove welding spotsof the 3-layered sheet joints.

49-39 M a y 1 9 8 3


REMINDER WHEN INSTALLING

Precaution during cutting of outer side member. Cut outer side member aligned with non-replaced

panel part

Overlappinetolerance

l The continuous welding areas of outer side memberto central, front and rear pillar, must be tinned.

I

Welding indications. Use the MIG welding method to weld the three

overlapped sheets along the whole perimeter fromboth sides.

. Apply anti-corrosion agent to boxed part inside.

May 1983 49-40



Precaution when cutting outer side memberl Cut outer side member aligned with non-replaced

panels

Welding indicationl Use MIG welding method to weld the three over-

lapped sheets along the whole perimeter from bothsides.

nMIG welding

. The continuous welding areas of outer side memberto central, front and rear pillar, must be tinned.

. Apply anti-corrosion agent to boxed part inside.

May 1983 49-42

BODY --SHEET METAL PANELS

.d REAR FENDERService joints

b

Parts to be welded

a. Fender and outer wheelarch e. Fender and floor

b. Fender and inner wheelarch f. Fender and drip

C. Fender and inner fender reinforcement g. Fender and upper rear panel

d. Fender and outer wheelarch h. Fender and upper rear panel

REMINDER WHEN REMOVING. By means of air chisel, cut the area shown in figure.

Take care not to cut frame of rear fender.


Precaution when cutting spare fenderl Cut spare fender aligned with non-replaced panel

part.

49-43 May 1983

BODY -- SHEET METAL PANELS

Fender temporaneous installation. By means of clamps, temporarily secure rear fender.

. The fender area of continuous welding to roofpanel side member, must be tinned.

Sealer application. Apply sealer to wheelarch outer side.

. Temporarily secure the adjacent components: doorand backdoor. Check clearances, grades and parallel-ism.

May 1983 49-44


DRIP WITH REAR FENDER REMOVEDCarry out replacement after Rear Fender has been removed.

Service joints

Parts to be weldeda. Drip and rear fender inner frameb. Drip and rear panel,

REMINDER WHEN REMOVING. By means of air saw cut according to lines A and B

shown in figure.

Take care not to cut fender frame.


Caution when cutting spare dripl Cut spare drip aligned with the non-replaced drip

part.

4 9 - 4 5 M a y 1 9 8 3


LOWER REAR PANEL

Service joints

Parts to be weldeda. Cross member and rear panelb. Cross member and floorc. Cross member and side member

REMINDER WHEN REMOVINGl By means of a saw, cut areas A and B taking care not l Punch junction points of lower rear panel to rear

to cut central area, mentioned in the figure, in ordernot to cut floor in correspondence with spare wheelcompartment.

floor of spare wheel area.

Precaution during welding. For the spot welding, make use of a brass wire.

I+1Centml area

M a y 1 9 8 3 4 9 - 4 6


UPPER REAR PANEL

Service joints

Parts to be weldeda. Rear panel and dripb. Rear panel and outer fenderC. Rear panel and outer fenderd. Rear panel and floor

REMINDER WHEN REMOVING. BY means of air saw, cut according to line A.

REMINDER WHEN INSTALLINGl By means of clamps, temporarily secure the upper

rear panel.

4 9 - 4 7 M a y 1 9 8 3


. Temporarily secure backdoor and check clearances,grades and parallellisms.

Precaution during welding.

Check correct positioning and alignment of bumperto rear panel.

For the spot welding, make use of a brass wire.

May 1983 49-48


REAR PART OF REAR FLOOR WITH REAR FENDER AND REAR PANEL

Carry out replacement after .Rear Fender and both Lower and Upper Rear Panel have been removed.

Service joints

:

1-sF

-4~ e -6mb

REMOVED

Parts to be weldeda. Rear floor and rear side memberb. Rear floor and rear side memberC. Rear floor and central cross member

d. Rear floor, rear side member and inner rear wheelarche. Rear floor and rear seat cross memberf. -Rear floor and outer fender

REMINDER WHEN REMOVING. By means of air saw, cut according to line A.

. By means of a drilling machine, remove welding spotsfrom the S-layered sheets joints.

4 9 - 4 9 May 1983


REMINDER WHEN INSTALLINGSecure rear floor temporarily and carry out markingalong side member and cross member from floorunderside.This easy drilling operation of the MIG welded spots.In order to obtain the best welding result, make useof spot welder as far as possible.Carry out holes for the MIG welding in the rear floorwhere spot welder can not be used.In rear floor installation, temporarily secure fenderand rear panel.Check installation dimensions in accordance withdrawings provided in “Body Alignment”.With the components temporarily secured, carry outtemporaneous MIG weldings in some points of rearfloor. . Apply sealant to non-replaced surfaces of rear wheel-

arch and of floor, in accordance with “Body Sealing”.. Apply anti-corrosion agent to weldings under floor,

then apply primer.

M a y 1 9 8 3 49-50


REMINDER WHEN 4NSTALLINGl After temporaneous securing of side member to

rear floor, carefully check dimensions provided in“Body Alignment”.

May 1983 49-52


REMINDER WHEN INSTALLING. Before carrying out welding, apply the adhesive to l Apply sealant to the areas indicated in “Body

joints between roof and central rib. Sealing”.. Carry out tinning in the areas between roof and rear

fender, which are continuous welded.

May 1983 49-54

DOORS

CONTENTS

FRONT DOOR . . . . , . . . . . , _ . . . . . , M 55-2Door assembly . . . . . , _ . . . . . , . . . . 55-3Internal finishing panels . . . . . . , . . 55-3

Window regulator devices and

glasses . ” _ . . . . n . . . , . . . . . , , . . . . 55-3Door locks and handles . . , . . . . . . . 55-4Door mirror 1 . . . . . . . . . . : . . . . . . . 55-4Moldings and seals . . ..,.....,,.. 55-4

REAR DOOR . . . . . . . . . , . . . . . . . . . . 55-6Door assembly. . . _ d . . . . , . . . . . . , 55-7

Internal finishing panels . . . . . . . . . 55-7

Fixed glasses . . . e . . . . . . . . . . . . 1 _ 55-7Window regulator devices and

glasses . . . . . . . . . . . . _ . . . . . . _ _ . . 55-7Door locks and handles . . . . . . . . . . 55-8Moldings and seals . . . . . . . . . . . . . . 55-8

SERVICE DATA AND

SPECIFICATIONS. m . . ~ ~. . . m ~. . _ _ . . 55-9Tightening torques . . . . . . . . _ . . . . 55-9

May 1983

DOORS

FRONT DOOR

1 Door2 Door lock device3 Lock block clamp plate4 Lock block5 Handle6 Molding and weatherstrip7 Molding8 Molding9 Glass velvet seal with trim

1 0 Glass1 1 Door mirror1 2 Ring nut1 3 Rubber1 4 Hinge

@II* 1 3 5 21( 1 . 3 6 + 2 . 29 . 8 3 + 1 5 . 9 )

15 Tie rod16 Hinge17 Window regulator device18 Panel lower clamps19 Seal2 0 Sealing screen21 Upper trim and weatherstrip2 2 Door lock control2 3 Panel24 Window regulator handle2 5 Arm rest2627

Power window switch (1500 and 1500 Quadrifoglio models)Power door locks device (1500 Cluadrifoglio model)

May 1983 55-2

DOORS

DOOR ASSEMBLY

REMOVAL ANDINSTALLATIONWith reference to exploded viewproceed as follows:1. Disconnect door from tie rodand f rom h inges @ and @ b yunscrewing the six screws, thenremove it.la . Only for the 1500 and 1500Quadrifoglio models.Disconnect harness and then proceedas per step 1.

2. For door installation reverseorder of removal and tighten screwssecuring .hinges t o d o o r t o r h eprescribed torque.

@ : Tightening torqueScrews securing hinges to door

13 G-21 Ndm(I .36 + 2.2 kg-m9.83 + 15.9 ft4b)

INTERNAL FINISHINGPANELS

Cover end of the tool used forremoving plastic rivets in order notto damage or scratch the body.

REMOVAL ANDINSTALLATION1. Lift ornament of arm rest @and unscrew the three securing

screws, then remove it.2. Remove ornament covering thedoor securing screws, then removewindow regulator handle @ .3. Remove plastic rivets securingpanel @ to door. Remove panelby bending it.4. Remove plastic rivets securingupper trim @ to door.5 . Remove hook o f door lockcontrol rod. then remove uppert r i m @) ,

6. For upper trim and panelinstallation, reverse order of removal.

WINDOW REGULATORDEVICES ANDGLASSES

REMOVAL ANDINSTALLATION1. R e m o v e p a n e l @I uppertrim @I and sealing screen @ .2. Lower glass @j) c o m p l e t e l y ,unscrew the two nuts securingwindow regulator device @ toglass, then remove by rotating it.

3. Unscrew the five nuts securingwindow regulator @ to door, thenremove it.

3a. Only for 1500 and 1500 Quadri-foglio modelsDisconnect harness of windowregulator motor, unscrew the fivenuts securing power window @to door, then remove it.

4. Install window regulator andglass by reversing order of removal.

5 5 - 3 May 1983

DOORS

DOOR LOCKSAND HANDLES

REMOVAL ANDINSTALLATION1. Remove paneltrim @I andscreen @ .2. Lift glass @J

@I uppermove sealing

completely inorder to avoid damage.3. Remove plastic fasteners secur-ing levers to door.

4. 1500 Quadrifoglio model-Release connecting rod betweenlock @ and door lock electricdevice 0 . To remove it, if neces-sary, disconnect harness, and un-screw the two nuts securing it todoor.

5. Release connecting rod betweenlock block @ and lock 0.

6. Withdraw clamp plate of lockblock @ by means of proper tooland remove lock block @.

7. Unscrew the three screws secur-ing lock @ to door then removelock.8. Unscrew the two nuts securinghandle @to door, then removehand le.

9. Install handle and lock byreversing order of removal.10. Verify proper functioning ofdoor opening control and, if neces-sary, loosen the three screws securingdoor lock clamp and move it untilperfect closing is obtained.

DOOR MIRROR

REMOVAL ANDINSTALLATION1. Remove panel @ and uppertrim @J _2. Withdraw rubber @I and un-screw the two screws securing mir-ror @I to door.3. Unscrew ring nut 1

O@and

remove door mirror 11 .4. Install door mirror by reversingorder of removal.

UOLDINGS ANDSEALS

Cover end of the tool used torremoving moldings in order not todamage or scratch the body.

REMOVAL ANDINSTALLATION1. Operating as per figure, removemolding with weatherstrip @.

May 1983 5 5 - 4

DOORS

2. Remove molding 8 .3. Remove panel 8 and uppertrim with weatherstrip @ .4. Remove door mirror 0 .5. Remove molding 7 .6. Remove glass 0 and glassvelvet with trim 8.

8

7. Reposition moldings and sealsby reversing order 05 removal.8. With reference to the followingfigure take care to secure glass velvetseal on clamp @ of glass guide 0located inside the door.

1 Glass guide2 Glass velvet seal clamp

CAUTION:Apply proper grease to hinges, tierod and door lock device.

55-5 May 1983

DOORS

REAR DOOR

1 Door2 Spacer3 Ooor lock device4 Rubbers5 Handle6 Fixed glass7 Melding8 Fixed glass guide9 Molding

IO Glass velvet seal with trim11 Glass12 Molding and weatherstrip13 Door lock control

14 Hinge16 Window regulator device16 Hinge17 Panel lower clamp18 Seal19 Sealing screen20 Upper trim and weatherstrip21 Door lock control22 Window regulator handle23 Arm rest24 Panel25 Door lock electric device (1500 Duadrifoglio model)

3 N -m(kg+nftw

May 1983 55-6

DOORS

DOOR ASSEMBLY

REMOVAL ANDINSTALLATIONWith reference to exploded viewproceed as follows:1. Unscrew the four screws secur-i n g h i n g e s @ and I@ t o d o o rand remove it.la . Only for the 1500 and 1500Quadrifoglio models.Disconnect harness and then proceedas per step 1.

2. For door installation reverseorder of removal, tighten screwssecuring hinges to door to theprescribed torque:

0: Tightening torqueScrews securing hinges to door

13+21 N - m(1.36 + 2.2 kgam9.83 f 15.9 ft.lb)

INTERNAL FINISHING

PANELS

Cover end of the tool used forremoving plastic rivets in order notto damage or scratch the body.

REMOVAL ANDINSTALLATION1. Lift ornament of armrest @and unscrew the three securingscrews, then remove it.

2. Remove ornament covering thedoor securing screw, then removewindow regulator handle @I _3. Remove plastic rivets securingpanel @ to door. Remove panelby bending it.4. Remove plastic rivets securingupper trim @ todoor.5 . Remove hook o f door lockcontrol rod, then remove uppert r i m @ .

6. For upper trim and panelinstallation, reverse order of removal.

FIXED GLASSES


1. Remove panel @ , uppertrim

8

and lower completelyglass 11 .2. Unscrew the screw securingfixed glass guide 8 to door, move8sealing screen 19 and recoverspacer 0.3. Unscrew the screw securingfixed glass guide @ to door frame.4. Slightly detach the glass velvetseal @I in correspondence withfixed glass guide @ and removeguide.5. Remove fixed glass.6. Install fixed glass by reversingorder of removal.

5 5 - 7

WINDOW REGULATORDEVICES AND

GLASSES


1. Remove panel I@ , uppertrim @ and sealing screen 19 .

82. Lower completely glass 11and windscreen the two nuts securingwindow regulator device to glass.

3. Unscrew the three nuts securingwindow regulator @ to door andremove it from lower side by liftingglass 0 .

4. Remove fixed glass guide @and fixed glass @.5. Remove glass 0 .6. Install glass and window re-gulator by reversing order of re-moval.

May 1983

DOORS

DOOR LOCKSAND HANDLES


1. Remove paneltrim @ andscreen @ .2. Lift glass @)

@f uppermove sealing

completely inorder not to damage it.3. Release d o o r l o c k c o n t r o lrod @) from door lock 0.

4. Unscrew from door the doorlock control rod @ securing screwand remove it.

5. Release from door the dooropening control rod.

6 . Only for 1500 Quadr i fog l iomodelRelease connecting rod betweenlock @ and door lock electricdevice @ _ To remove it, if neces-sary, disconnect harness and unscrewthe two nuts securing it to door.

MOLDINGS A N D

SEALS

7. Unscrew the three screws secur-ing lock @ to door, then removelock.8. Unscrew the two nuts securinghandle @ to door, then removehandle.

9. Ins ta l l hand le and lock byreversing order of removal.IO. Verify proper functioning ofdoor opening control and, if neces-sary, loosen the three securing screwsof lock clamp and move it .untilperfect closing is obtained.

Cover end of the tool used forremoving moldings in order not todamage or scratch body.


1. Operating as per figure, removemolding with weatherstr ip @ .

2. Remove molding @ and @.3. Remove panel @ and uppertrim with weatherstrip @ .4. Remove fixed glass-guide 8 ,

8fixed glass @ and glass 11 .6. Remove glass velvet seal witht r im @ .

M a y 1 9 8 3 5 5 - 8

DOORS

6. Reposition molclings and seal byreversing order of removal.7. With reference to the followingfigure, take care to secure glass velvetseal on clamp @ of glass guide @located inside the door.

CAUTION:Apply proper grease to hinges anddoor lock device.

1 Glass guide2 Glass velvet seal clamp


TIGHTENING TORQUES

ItemN-m kg.m ft-lb

Screws securing hinges to front door 1 3 4 2 1 1.36 + 2.2 9.83 f 15.9

Screws securing hinges to rear doorI

13+21I

1.36 + 2.2I

9.83 f 15.9

55-9 M a y 1 9 8 3

HOODS

HOOD POSITIONADJUSTMENTLoosen the four screws securinghinges to hood and move hoodforward, backward and side to sideuntil correct position is obtained.

CAUTION:. During installation of hood

lock @ make sure that striker

rod is positioned in the center ofhood lock slit by operating onthe two screws 0. Then,temporarily tighten the lock.

1 Screws 2 Hood lock device

. With the hood lock temporarilytightened to body, verify thathood bumper 0, located onhood 1 come in contact with8body 3 ; if not so, properlychange hood bumper heightby screwing or-unscrewing them.

1 Hood2 Hood bumper

3 B o d y

l Fix hood lock by tighteningsecuring screws.

. Verify proper functioning ofhood lock opening control.

. Lubricate hood lock mechanismwith proper grease.

REPLACEMENT OF HOOD OPENING CONTROL CABLE

CAUTION:In case of breakage of hood openingcontrol cable, it is possible to openthe hood by pulling the nylon-madeemergency cable @, lowted in the,passenger compartment inside.

1. Cut the cable in proximity tohood lock device @ and loosenscrew of sheath supporting brack-e t @.2. Operating from vehicle inside,withdraw cable and sheath of hoodopening control lever 0.3. Insert the new cable with sheathand secure it to hood openingcontrol lever.

1 Cable2 Hood lock device3 Cable retaining ring

4 Bracket5 Hood opening control6 Nylon-made emergency cable

5 6 - 3 May 1983

HOODS

4. Operat ing f rom eng ine com-partment inside, insert cable 0 intoeyelet of hood lock @ and securecable end to cable retaining ring 0.5. Ver i fy funct ion ing o f hoodopening control.

6 . I f n e c e s s a r y , a d j u s t s h e a t h oil letting it slide into sheath.position by operating on special .bracket @.

Do not bend excessively cablesheath in engine compartment in

C A U T I O N :order to prevent opening stressincrease.

. Lubricate the cable with suitable

BACKDOOR

1 Backdoor2 Backdoor trim3 Hinge4 Shook absorber6 Seal6 Movable shelf

Vibration-damper strikerSealBackdoor lock deviceShock absorberHingeSupport

13 Vibration damper striker1 4 Badge16 Label16 Electric contactS17 Backdoor striker

REMOVAL AND . Provide a support for backdoor

INSTALLATION to be used on removal fromW ith reference to exploded view

shock absorbers.above proceed as follows:

Before removal or i n s t a l l a t i o n , l Release the two cables sup-1. By means of a screwdriver drill,

proceed as fol lows: porting shelf under rear window.remove the two rings securing rods of

. Place a cloth or other padding shock absorbers @ and @I and

on backdoor corners in order to For removal and installation ofwithdraw rods from their seat.

avoid damaging or scratching backdoor, two operators are revehicle body. quired.

May 1983 56-4

HOODS

REPLACEMENT OF BACKDOOR OPENINGCONTROL CABLE

1. Cut cable @) in proximity tobackdoor lock device @ and loosen

screw of bracket @ sheath securing.

1 Cable2 Backdoor lock device3 Cable retaining ring

4 Bracket5 Backdoor opening control

2. Operating from vehicle inside,withdraw cable and sheath frombackdoor opening control lever 0.3. Insert new cable with sheath andsecure i t t o backdoor o p e n i n gcontrol lever.4. Operating from luggage room,insert cable 1 into eyelet of back0door lock device @ and securecable end on cable retaining ring @ _5. Veri fy proper functioning ofbackdoor opening control.6 . I f necessary , ad jus t shea thposition operating on special brack-et @.

CAUTION:. Lubricate the cable with proper

oil letting it slide into sheath.. Do not bend excessively cable

sheath in the luggage room, inorder to prevent opening stressincrease.

M a y 1 9 8 3 5 6 - 6

INTERNAL TRIMMING

TRIM

ROOF TRIM

123456789

1011

RoofTapsSun screenSun screenPassenger handlePassender handleRoof lampPassenger handleInside mirror supportRoof lampInside mirror


Be careful not to stain roof.

With reference to exploded viewabove proceed as follows:1. Open protection of screws secur-ing passenger h a n d l e s 0, @and @ to roof panel, unscrew themand remove handles,

2. By means of proper tool, removetaps 0.3. Disconnect harness and removeroof lamps @ and @I .4. Remove inside mirror @) inorder to gain access to the three

screws securing mirror support @.to roof nanel and remove it.

5 . Remove sun screens 0and @.6. Remove weatherstrip of doorsand of backdoor in contact withroof; move upper part of frontpillar trim.7. Remove roof trim @ andwithdraw i t f rom backdoor c o m -partment.8. For installation, reverse order ofremoval.

C A U T I O N :For installation, it is recommendedto position roof trim starting fromrear side and then use a cord toreposition windshield seal in its place(see : Group 75 - W i n d s h i e l d -Installation).

1 Roof trim 4 Cord2 Front righr 5 Windshield

pillar 6 Body3 Windshield seal

May 1983 6 6 - 2

INTERNAL TRIMMING

FLOOR TRIM

INTERNAL TRIMMING


With reference to exploded viewabove proceed as follows:

1. R e m o v e r e a r s e a t @, f r o n tseats 0, rear console @, speedlevel console @ and safety beltanchors @I and 0 (see therelevant paragraphs).2. Unscrew the fourteen screwssecuring kick plate @ to body andremove them.3. By means of proper tool, with-draw plastic rivet securing to bodythe accelerator pedal end of trav-el 0; then remove it,

4 . R e m o v e s e a l s o f f r o n t d o o r material trim @ .compartments in the part where they 7. install floor trim by reversingcover floor trim and remove the order of removal. After installingadhesive tape strips securing trim to handbrake cables, adjust i t bybody. following procedures described in5. Unscrew nut and lock nut of Group 00 - Maintenance of Mechanicparking brake @ adjustment fork Components and Body.and withdraw the two cables frombracket 0.

6 . R e m o v e f l o o r t r i m b y with-drawing it from parking brake and, ifnecessary, remove soundproofing

CENTRAL PILLAR TRIM AND FRONT SAFETY BELTS

1 Door opening seal2 Door opening seal3 Central pillar trim4 Safety belt5 Safety belr anchor on tunnel6 Central pillar trim cover

5

p::

a*27 f 4 3a*27 f 4 3(2.8 + 4.4(2.8 + 4 . 42 0 . 2 5 f 3 1 . 8 )2 0 . 2 5 f 3 1 . 8 )


With reference to exploded view and @ in the part where they cover

above, proceed as follows: central pillar trim 0.

1. Move front seat completely 3. Lift protection of screw securingforward. safety belt @ suppot~, unscrew it2. Remove door opening seals @ and remove the support.

4. After removing protection, un-screw the screw securing safetybelt @ anchor bracket to body.

May 1983 6 6 - 4

INTERNAL TRIMMING

5. By means of proper tool, removeplastic rivet securing cover @ totrim @ and remove it.6. Remove pillar trim @ bylifting it.7. Unscrew the screw securingsafety belt @ retractor and removeit.

8. After removing protection, un-screw the screw securing safety beltanchor 5 on tunnel and remove it.0

9. -Install safety belt and pillar trimby reversing order of removal. All theanchor safety belt screws, must betightened to the prescribed torque.

@ : Tightening torqueSafety belt anchor screws

27 + 43 N.m(2,s + 4,4 kg-m20.25 + 31.8 ft-lb)

CAUTION:If the vehicle is collided or over-turned, replace the en t i re be l tassembly regardless of nature ofaccident.

FIXED PART TRIMOF SHELF UNDERREAR WINDOW

1 Fixed part trim of shelf under fearwindow

2 Movable shelf hinge3 Seat back clamping device4 Seat back fixed part

REMOVAL ANDINSTALLATIONWith reference to the exploded viewabove proceed as follows:1. Remove movable shelf underrear window.2. Unscrew screw securing seatback fixed part @ to body, lift seatback and remove it.

3. Unscrew the screw securing tobody hinge @ of movable shelf,and remove hinge.4. Unscrew the two screws securingto body the seat back clampingsdevice @ and remove it.5. By means of proper tool, wirh-draw the two plastic rivets andunscrew the two screws securingto body, trim @ of fixed part ofshelf under rear window, thenremove trim.

6. Install trim by reversing order ofremoval.

6 6 - 5 May 1983

INTERNAL TRIMMING

REAR PILLAR TRIM


1 Back door seal 3 Plastic cap2 Rear pillar trim 4 Door opening seal

1. Remove door opening seal @in the part where it covers trim 0.

2. Detach plastic cap @ andremove pillar trim 0.

3. Install trim by reversing order ofremoval.

LUGGAGE ROOM SIDE TRIM

1 Luggage room side trim2 Fixed part trim of shelf under rear

window3 Movable shelf hinge4 Seat‘back clamping device5 Seat back fixed part


1. Remove seat back clampingdevice @, seat back fixed part @and trim of fixed part shelf underrear window @ (see: Trim of fixedpart shelf under rear window).

2 . By means of proper tool, removeplastic rivets securing side trim tobody, then remove it.

3. Install side trim by reversingorder of removal.

M a y 1 9 8 3 6 6 - 6

INTERNAL TRIMMING


Take care not to stain seat and seatbadk upholstery.

With reference to the above explodedview proceed as follows:1. Move seat completely forwardand unscrew the two rear screwss e c u r i n g g u i d e s @ and 0 t ofloor.

2. Move seat completely backwardand unscrew the two front screwss e c u r i n g g u i d e s @ and I@ t ofloor.

3. Remove seat together withguides, from car.4. If necessary, remove guides @and 0 from seat.(1) By means of proper tool, releasethe seat turnover control lever @from guides.

(2) Remove guides by unscrewingthe four securing screws to seat @.

(3) Install guides and control leverby reversing order of removal andtightening screws to the prescribedtorque.

@ : Tightening torqueScrews securing guides to seat

1 7 f 2 0 N.m(1.8 + 2.1 kg-m13.0 + 15.2 ft-lb)

5. If necessary, remove seat backadjustment device @ , hinge ~ 0,and seat back 0.(1) Li f t cover @ of sea t backadjustment device @ .( 2 ) K e e p i n g k n o b @ sti l l , bymeans of proper plier, rotate counter-clockwise the plate securing knob;then remove it.

( 3 ) R e m o v e p l a s t i c t r i m s @a n d @ .(4) Unscrew the four screws secur-ing to seat @ the seat back adjust-ment dev ice @J and hinge 0;then remove seatback 0. 1

e

(5) Remove the four screws securingtrim @ to seat back @ up-holstery.(6) Lift clamps securing seat backupholstery, turn it inside out and liftit until protections @ and @ ofseat back adjustment device @Isecuring screws and of hinge @ areuncovered.

(7) Remove plastic protections @and @I and unscrew the fourscrews securing to seatback t h eseatback adjstment device and hinge;then remove them.

M a y 1 9 8 3 66-8

INTERNAL TRIMMING

(8) For installment reverse order ofremoval. Tighten the screws ofseatback adjustment device and ofhinge to the prescribed torque.

REAR SEATS

1 Seat2 Seat back fixed part3 Seat back4 Shelf under rear window fixed part5 Seat back clamping device6 Luggage room and seat back trim7 Seat back8 Seat back hinge

@ : Tightening torqueSecuring screws of seat backadjustment device and of hinge

17 + 29 N-m(1.8 + 3 kg-m13 + 21.7 ft.lb)

6. If necessary, remove headrest byoperating on knurled part as shownin figure.

7. Install seat on car by reversingorder of removal and tighteningscrews securing seat guides to floor,to the prescribed torque.

@ : Tightening torqueScrews securing seat guides tofloor

IO+11 N-m(1.1 + 1.2 kg-m8 + 8.7 ftdlb)

6 6 - 9 May 7983

INTERNAL TRIMMING


Take care not to stain seat and seatback upholstery.1. Lift and remove seat.2. Unscrew the screw securing tobody @ the seat back fixedp a r t @ then l i f t seat back andremove it.

REAR CONSOLE

1 Seat back fixed part2 Seat back3 Body4 Door compartment seal

3. By means of proper tool, with-draw plastic rivets securing luggageroom upholstery to sea t back .

CONSOLES

1 Rubber bellows 3 Ashtray2 Console

4 . Unscrew nut secur ing sea tback @ to body @ and remove it.

1 Seat back2 Kick plate3 Door compartment seal4 B o d y

5. Carry out same procedure forremoval of the other seat back.6. Install seat backs and seat, byreversing order of removal.

REMOVAL ANDINSTALLATION1. Remove rubber bellows locatedon parking brake.2. Remove ashtray, which is pres-sure secured.3. Unscrew the screw securingconsole and remove it by moving itfirst forward in order to withdrawit from clamp located on f loortunnel.

M a y 1 9 8 3

4. Install console by reversing orderof removal.

6 6 - 1 0

INTERNAL TRIMMING

CE:NTRAL CONSOLE

M a y 1 9 8 3 6 6 - 1 2

INTERNAL TRIMMING


CAUTION:. Disconnect battery ground

cable.. Before removing the com-

ponents fitted with harness,make sure that relevant con-nections have been discon-nected.

With reference to exploded viewabove proceed as follows:

1. Remove by pulling, knobs @and @ of heater control assembly.2. Detach finisher @I and discon-nect harness of clock @ , lighterseat @ and lamp 0 .3. Remove finisher @I .4. If necessary, remove lighterseat @ by unscrewing ringnut @ and withdrawing bush @and ornament @ .

5. By means of proper tool, removefinisher 0.

l/r ,-E==ilh-6. Disconnect harness of

s w i t c h e s 0, @, @ a n d @:then remove finisher 0.

i. Unscrew the four screws secur-ing heater control assembly @ toconsole 0.

8. Remove the four screws securingconsole @ to dahsboard.

9. Remove console 0 b e i n gcareful during lamp @ and harnessremoval.10. Install console and its com-ponents, by reversing order ofremoval.

66-13 May 1983

INTERNAL TRIMMING

DASHBOARD

May 1983 66-14

INTERNAL TRIMMING


CAUTION:. Remove battery ground cable.. Before removing the compo-

nents fitted with harness, makesure that relevant connectionshave been disconnected.

With reference to explbded viewabove proceed as follows:1. Remove central console (see:Central Console).2 . Remove s tee r ing whee l andcolumn shell covers (see: Group 23 -Steering Wheel and Column).3. Remove cluster 0 .(1) Unscrew the four screws secur-ing cluster 0 to support brack-et@. -

Low view

5. By means of proper tool, removeornaments @ and @ .6. By means of proper tool, removefinisher @ of duct @ and unscrewthe two screws securing dash-board @ to body.

7. Unscrew the seven screws secur-ing dahsboard @ and @ to body.

/I \CAUTION:

(2) Open cover @ pressure in-set-ted, disconnect harness; thenremove cluster 0 .4. Operating as per figure, removespring securing center ventilationduc t @ control cable to heatercontrol assembly.

To remove the whole dashboard, twooperators are required.

8. R e m o v e the whole dash-board @ and @.9. If necessary, disassemble dash-board components @ and @.(1) By means of a drilling machinefitted with suitable drill, countersinkthe four rivets securing upper dash-board @ to lower dashboard @.

66-15 May 1983

INTERNAL TRIMMING


TIGHTENING TORQUE

Unit

Item

CENTRAL PILLAR TRIM AND

SAFETY BELTS

Safety belt anchor screws

FRONT SEATS

Screws securing guides to seat

Securing sraws of seat back adjustment

device and of hinge

Screws securing seat guides to floor

N-m kg-m ft.lb

27 + 43I

2 . 8 + 4 . 4I

2 0 . 2 5 + 3 1 . 8

17 + 20 1.8 + 2.1 13 f 15.2

17 + 29 1.8 +. 3 13 + 21.7

10 + 11 1.1 + 1.2 8 + 8.7

66- l 7 May 1983

EXTERNAL TRIMMING

CONTENTS

FRONT BUMPER . . . . . . . . . . . . . . . . . 75-2 G LASSES . . . . . . . . . . . . . . . . . . . . . . . 75-7REAR BUMPER . . . . . . . . . . . . . . . . . . 75-3 Windscreen . . . . . . . . . . . . . . . . . . . 75-7DRIP COVER MOLDING . . . . . . . . . . . 75-4 Rear window . . . . . . . . . . . . . . . . . . 75-9GRiLLE . . . . . . . . . . . . . . . . . . . . . . . . 75-5 SPECIAL SERVICE TOOLS . . . . . . . . . 75-l 1COWL TOP COVER . . . . . . . . . . . . . . . 75-6

May 1983

EXTERNAL TRIMMING

FRONT BUMPER.

1 Bumper2 Bracket3 Bracket

REMOVAL ANDINSTALLATIONWith reference to exploded viewabove proceed as follows:1. If present, disconnect fog

light @ and @ harness.2. Operating from engine com-partment inside, disconnect harnessof the two electromagnetic horns,unscrew the nut securing each hornto b racke t , and remove horns.

4 Fog light5 fog light

3. Unscrew the four screws secur-ing brackets @ and @ to sills.

4. Unscrew the two screws securingbumper to fenders.

5. Remove bumper and, if neces-sary, disassemble fog lights.6. Connect bumper to body byreversing order of removal.

May 1983 75-2

EXTERNAL TRIMMING

REAR BUMPER

1 Bumper2 Bracket3 Bracket

REMOVAL ANDINSTALLATIONW ith reference to exploded viewabove proceed as follows:1. Lift luggage room upholsteryand rear trim.2. Unscrew the four screws secur-ing bumper brackets @ and @ tobrackets @ and @.

3. Unscrew the two screws securingbumper @ to body.

4 Bracket6 Nuts6 Bracket

\ 6. Install bumper, by reversingorder of removal.

4. Remove bumper.5. If necessary, unscrew the eightscrews securing brackets @ and @)to rear floor.

75-3 May 1983

EXTERNAL TRIMMING

GRILLE

1 Badge2 Gr i l l e

REMOVAL ANDINSTALLATIONWith reference to exploded viewabove proceed as follows:1. Open hood completely removingit from stay.2. By means of a magnetic screw-driver, unscrew screw @ securinggrille @ to body.3. Remove gri l le, by means ofsuitable wooden tool.

3 H o o d4 Screw

4. Install grille by reversing orderof removal.

CAUTION:. Be careful not to exert excessive

force during operations, as grilleis made of plastic.

. Take care to keep oil away fromgrille.

75-5 M a y 1 9 8 3

EXTERNAL TRIMMING

COWL TOP COVER

1 cowl top cover2 Windscreen seal3 Plastic nut screw4 Seal rubber

With reference to exploded viewabove proceed as follows:1. Open hood and remove seal @.2. Lift protections of nuts securingwiper arms @, unscrew the relevantscrews; then remove wiper arms.3. By means of proper tool, removethe five springs securing cowl topcover 0 to body.

5 Windscreen washer pipings6 Windscreen wiper arms7 Sprayers

Ii

1I

\\

\I

4. Unscrew the two screws, pro-tected by a cover, securing cowl topcover @ to body; then lift cowl.5. Disconnect windscreen washerp ip ings ($ separating t h e m f r o msprayers @ which are pressureinserted into cowl top cover, thenremove cowl top cover.6. Install cowl top cover by revers-ing order of removal.

M a y 1 9 8 3 7566

EXTERNAL TRIMMING

REMOVALWith reference to exploded view remove, by means of proper toolabove proceed as follows:1 . Remove w iper a rms @ a n d

ornament 0.

move cowl top cover @ forward3. Remove door opening seal @in the part where it covers pillar

(see: Cowl-Top Cover). trim 0.2. Operating from vehicle inside, 4. By means of proper tool, remove

pi l lar t r im 0, then remove it.5. Operating as per the followingfigure, set end of tool A.9.0051 outof every 10 cm (4 in), starting fromcentre of windscreen upper rim;between body and windscreen seat.

6. Careful ly pul l upper part ofwindscreen, remove it from body,then remove it completely.

INSTALLATION

For installation, two operators arerequired.

CAUTION:By means of silicone, lubricate rim ofwindscreen weatherstrip in order toallow an easy insertion of weather-strip on body.

1. Into weatherstrip rim 0, inserttwo cords (A and B) arranged as perfigure in order to allow repositioningof weatherstrip @ on body.

May 1983

EXTERNAL TRIMMING

2. Rest windscreen on lower side ofito seat into body and verify it isproperly centered with weather-strip @ mounted on lower side,only.3. Slowly pull first cord startingfrom upper rim and follow position-ing of weatherstrip rim by slightlytapping, with the hand, on wind-screen from outside.4. Repear same operation withsecond cord until complete installa-tion of windscreen.5. Carry out installation of pillartrim, of door compartment seal andof ornament, by reversing order ofremoval.6. Install cowl top cover and wiperarms.

1 Roof trim2 Windscreen seal weatherstrip34 Right Cord front pillar

5 6 Windscreen Body

REAR WINDOW

1 Rear window2 Rear window

weatherstrip

7 5 - 9

3 Backdoor4 Movable shelf

M a y 1 9 8 3

EXTERNAL TRIMMING

REMOVAL under rear window.With reference to exploded view 2. Disconnect electric cables ofabove proceed as follows: heated rear window.

1. Open back door and release the 3. Operating as per the followingtwo cables supporting shelf @ figure, set end of tool A-9.0051 out

of every 10 cm (4 in), starting fromcenter of rear window upper rim,between back door @ sheet andrear window weatherstrip seal 0.

INSTALLATIONCAUTION:Do not damages filaments of heatedrear window with tool A.9.0051.

For installation; two operators arerequired.

4. Carefully pull upper part of rearwindow, release it from back doorand remove.

CAUTION:By means of silicone, lubricate rim ofrear window weatherstrip in order to

allow an easy insertion of weather-strip on body.

1. Into seal rim @ inset-t twocords (A and B) arranged as perfigure in order to allow repositioningof weatherstrip on back door.

May 1983

AIR VENTILATION

CONTENTS

WIRING DIAGRAM . . . . . . . . . . . . . . . 80-2 Heater fan switch . . . . . . . . . . . _ _ . 80-5AIR VENTILATION UNIT a. .,. . . , . . . 80-3 TROUBLE DIAGNOSIS AND

Removal and installation . . . . . . . . . 80-4 CORRECTIONS . . . . . . . . . . . . . . . _. . 80-5

c:May 1983

HEATER

.-

WIRING DIAGRAM-~

111213141

I I,i,i 1I 1 G1,5

G1.5

A l BatteryEl Ignition switch84 Control for headlight, flashing, low beam and full beamF8 Air ventilation control lampG I FuseboxQl Air ventilation heater fanQ4 Air ventilation heater fan control

(IV - Low speed)(2V - High speed)

r iIIBI@II M I---d

May 1983 8 0 - 2

HEATER

AIR VENTILATION UNIT

23456789

101112131415

Air ventilation unit shell coversHeater fanDoorAir ventilation unit controlsDoorAir ventilation unit shell coversHeater coreDoorOuter air duct frameOuter air ductIncoming air intake nozzleCenter ventilation ductAir ventilation unitEngine compartment cross memberLiquid delivery pipings

80-3 May 1983

HEATER


CAUTION:. Remove battery ground cable.. Before removing components

fitted with harness, make surethe relevant connections havebeen disconnected.

. Be careful when removing airventilation unit pipings, other-wise liquid leakages from heatercore may occur.

With reference to exploded viewabove proceed as follows:1. Remove lower finisher of centralconsole and unscrew the four screwssecuring air ventilation unit con-trols @ to console (see Group 66 -Central Console).2. Unscrew the four nuts securingair vent i lat ion unit @) to body.

3. Operating from engine com-partment inside, disconnect harnessof heater fan 0.4. By means of two terminals,clamp liquide delivery pipings @to air ventilation unit 0, in orderto prevent leakages.

5. Loosen metal clamps securingpipings @ to air ventilation unit;then remove pipings.

6. Unscrew the two screws securingf rame @ of ourer air duct @ toair ventilation unit; then removeboth.

7. Carefully withdraw air ventila-tion unit and air ventilation unitcontrols a.8. If necessary, disassemble airventilation unit in order to gainaccess to its inner components.(I) Operating as per figure, removethe eight springs keeping togethershell covers 0 and @ of airventilation unit.

(2) Remove or cut seals.(3) Separate the two shel l cov-ers 0 and @.(4) If necessary, with reference toexploded view above, release controlcab les o f doors @ and @ b yoperating with suitable wrench onthe screw securing levers to doorhinges as shown in figure.

Door hingeLeverDoor control cableScrew

(5) If required, disassemble com-ponents of a ir vent i lat ion unitcontrols operating as per figure.

9. If necessary, operate on airventilation unit components presentin the dashboard by fol lowingthe indications provided in Group 66- Dashboard.10. Install air ventilation unit byreversing order of removal.

May 1983 80-4

HEATER

HEATER FAN SWITCH LOCATIONCAUTION:. .After restoring hydraulic con-

nection, it is necessary to top up E lI I I

header tank of engine coolingsystem.

. Lubricate air ventilation unitcontrol cables by means ofproper oil.

The switch is located in the lowerornament of central console (see:Group 66 - Consoles).

CHECK

Check switch proper functioning byverifying that continuity betweenterminals occurs in compliance withthe indications provided in table.


Condition

Insufficient heating performance(No heated air flow to ducts)

Insufficient air flow to floor

Insufficient defrosting perfor-mance (Cold air to ducts)

Insufficient air flow to defroster(Refer to: Group 66 - Dashboard)

Control lever drags

Noise from blower motor

Probable cause

b Cooling water temperature too low

D Heater care plugged

l Insufficient cooling water level

I Malfunctioning air mix door

l Blower motor speed too lo w

l Malfunctioning air floor door

l Malfunctioning door control

Refer to “No heated air flow to ducts”

l Blower motor speed too low

l Malfunctioning air main duct door

l Malfunctioning door central

l Bad cable sliding

l Control cable bent excessively

l . Air intake door not operateproperly

l Loose bolt in blower motor

? Broken blower blade(s)

Corrective action

Check thermostat: replace if necessary

Clean heater

Refill

Check door and adjust

Check blower motor and:-- restore poor connections- replace blower motor if necessary


Check control and adjust

Check blower motor and:- restore poor connections- replace blower motor if necessary


Check door control and adjust

Adjust

Correct

Check and adjust

Check and tighten

Replace blower

80-S May 1983

alfa romeo 33: Руководства по ремонту и обслуживанию

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