WORKSH Oe ATTN Zea VERSION WITH CATALYTIC CONVERTOR DIREZIONE ASSISTENZA TECNICA (Bz, Romeo Hp aezaso0200000 December 1087FORWORD This publication Is for vehictes equipped with catalytic convertor, Lamibde sonsor and fuel vapour emis- sion control system. The manual complements the basic workshop manuals [ALFA 75] and petrol engines. In addition to specific topics related to the model in question, procedures that have been modified with respect to the basi¢ version, are included in this manual, Slight changes, however, have anly been men- toned end should he referred t0 in the basic text, These signs indicate thet the corresponding group (see quick Paar rova00000 Te Ro tera ito) of to bask: mama! shouts be refered 0 for PAI46700000000 petrol engines —p GR. ‘aii fopios not expressly deat with in this menu. PAAZ2B000000 W December 19874422800000000 QUICK REFERENCE INDEX COMPLETE CAR. GR. 00 | ENGINE MAIN MECHANICAL UNIT @R. Ot ENGINE FUEL SYSTEM GR. 04 ENGINE tGNITION, STARTER, GR. 0s ENGINE COOLING SYSTEM GR. 07 Decombsr 1987COMPLETE CAR CONTENTS GENERAL VIEWS 00-3 Dimansions . 00-3 ‘Weights ano loads . 00-4 ‘Wheels and tires .. - 00-4 IDENTIFICATION DATA . IDENTIFICATION LABELS Position of labels . Vehicle identification codes an 088 INSTRUCTIONS FOR PRE-DELIVERY INSPECTION MAINTENANCE, VEHICLE MAINTENANCE SCHEDULE ... 00-10 FLUIDS AND LUBRICANTS: SCHEDULE DIAGRAM RECOMMENDED FUEL AND - O12 LUBRICANTS sevsnoe OOF Fual 00-13 Fiuids and lubricants ........ 00-13 APPROXIMATE REFILL CAPACITIES ENGINE MAINTENANCE Engine main mechanical unit . ‘Changing of oil and oil fiker - Check of lubrication system tightness ....... OOS Tightening of eylinder head nuts ...... 00-15 Check and adjustment of valve clearances Check of timing chain tension and setting of timing .. Checking and restoring ot ‘00d working order of the timing variator .. Adjustment of tension and replacement of alternator drive belt. Adjustment of tension and replacement of power steering pump drive bett Adjustment of tensione and replacement of air conditioner compressor drive belt 900-16 00-15 0045 00-16 00-19 00-21 ‘Cylinder compression test .. Fual system .. ons OOS, Cheok and adjustment of the accelerator 00-25 Check of fual system pressure and lighiness of system ‘Trouble diagnosis procedure for the checking of the tightness of fuel injection system Check of the tightness of the fuel vapour emission: evaporation} system heck the tightness of the ait intako system downstream trom the air flow gauge - .. 0027 Checking, cleaning an¢ replacement of the fuel filter Replacement of the fuel thier ... ‘Check of the Idle r.p.m. ‘Check of exhaust emissions (CO) with the engine running on idle Exhaust system _. Replacement of the Lambda seneor 00-76 00-26 0027 0028 00-28 0029 and the catalyser .. 90.29 Engine Ignition 90-30 Check of . 00.20 Check, cleaning andiar replacement cof me spark plugs: firing order... 00-30 Engine cooling ... 00-30 Check of antifreeze mixture tevel and cooling system fightness check .. ELECTRICAL CHECKS USING THE TROUBLE DIAGNOSIS TESTING INSTRUMENT 0 FAULT FINDING IGNITION AND INJECTION WIRING. DIAGRAM (MOTRONIC MLé.1) TECHNICAL DATA AND SPECIFICATIONS . SPECIAL SERVICE TOOLS .. (*) SEE WORKSHOP WANUAL- G2 FEiieSex221 — GR, 00 prazesnncooan December 1907COMPLETE CAR GENERAL VIEWS DIMENSIONS Unt: roe Binenwiore | : " ~ ener | won ; (Arce 28 | || sao] ae | | | in cereependenco wih pound om civng whoo! cur aa, wn ut soaring tock 00-3 Docomber 1987COMPLETE CAR WEIGHTS AND LOADS Moae!| Welotns ond londe as wo ght alowed oo 19 Ker agp a 970 Canrying eapacty a 28 Fro 0 Max slowed giose weight po hs ose weit vo fo 0 ax toring GEE met eo 1200 ax vocal ead an tow hook a o Feo 2 Seating capacy eer z WHEELS AND TYRES ode! ims and tres me | sng” O ovata” a Tebelese es 19560 whe x te kK . P 20 rong sreasare Des 3 x ze e P 22 A Front Ps ‘The wheel mits mus be Vphtened 10a frgue of $8 Hem 10 ham) Docember 1987 IN: With reduced fea! and normal apcce CC: AL lord ane gh apoed Op 280 a 00-4 (9) Rime wet 4 securng sere 18) Ritsu 5 eonureg screws (2) Pressure measured on cod 4 pas2807000000COMPLETE CAR IDENTIFICATION DATA wet my ome wi mi Tonia arte “0 - ieee label | Tee ec wo toe Tyee appro Wo Tene uae Cre tn} ‘ot ogee waz eao _somngannan Boor on rer rah ce ten Sort No, ‘ot uppene cc01 301 regulars the enaineidkag rom caus: ing rogue reacige, ©. Start the engine; wth ino engine on Idle, using the prassure gauge, check that 00-26 {he reeding is equal to the recommended value: Fuel pressurs’ rea + 3256 KPa 28 = 4.2 bar; 2.9 + 9.9 kglomh 6. Recoanet the hore G)to the sine take tor (7). Yn nc ongine on da the {uel prasaute should Tale apcesitely (0.5 bar and ren iow agtin wen the 2 cobitor trey wave @ oponed. Wt doesnot cur £683 fr ponte teak fom the vaowun hase G) 2. Chek tghindes of aptarn oopng th procate galge oon facia ard wih teenie ord, ho ‘te eae mode cporenea hm preasreregdatr (8) nl prenere (aloe oA bor ie Yad ore tha te preture doe et ered ti aha) 1. te presi a bar coos at tho fel tem bes ard unions dock pratt aks he preted sche of bar and rotate a encour tect ie endorthe ebon no! toa pnp ‘TROUBLE DIAGNOSIS PROCEDURE FOR THE CHECKING OF THE TIGHTNESS OF THE FUEL INJECTION SYSTEM “The procedure is 19 be carried cut at Intervals indicated in tno Veni meintenance schedules and in the enc8 ofthe folowing eymptams: = Small of petrol = Visee signs of leaks tom the unions. ‘and connections o! the aystern ‘he pceaible causes are: = Petrol leaks fromthe components the ‘unions and the comections of the system ‘paz2ascoo0000COMPLETE CAR eee Carry out the proved coserbod in he preceding paragraph forthe heck ofthe {ual aya preseurer and the sek of the el te Spread in parr: 1 Moko swe of Mo ptosence of fre {ighig equine in the workshop 30 25 to be abo 10 workin conations of max iam safety, D._ Run ine engine to nom ring temperaiue, Sion the igriton ot <4. trspect visa the components and none ofthe we! esiom eo us 19 esta tha origin ofthe teak. Check he atta syste (conneting ‘bes, unions, component) ur an aust gas enter (NOIR system) 4. Tho pontor of the analyeor wt react im the sc of the cone of the fo ‘The analyser test must be camiod out slowly #0 80 to allaw tor the slow reaponse time of the instrument. 2. Following the tcatien of the ieak by ‘meana of ne procedure indicated in pnts 4. andlor @, eliminate tha ea by replac- Ing ho datectnve components ofthe syste for by suitably Hattenirg the loose clips. 1. Oncompletion ofthe prscesing ope {ion star the engine, let the engin ole ter 2 ew minutes and thon sate the ignition ofl |. Repent ine est desoribad in poinis c. ‘nd din order to chock tne exactness of the diagnasis and the elfectiveness.ol the ropait. 1. On completion of the procedure described in poinisa. to. cary ova oad test of al las! 90 minules, folowed by & final sdeck te enoute the coroct working fordar of the systarn. CHECK OF THE TIGHTNESS OF THE FUEL VAPOUR EMISSION (EVAPORATION) SYSTEM ‘The procedure described below must De. ‘carried out when checking tis huel-xysem. pressure and in the preaenc cf the smot ot patra ae2ea90000000 “Th probable cause iz plowsby of vapour Frora the tubes. unions or parts of the sysiem, PROCEDURE «As ‘8. Discowneet the mune connecting the ‘vapour clanner and the feel tenk and con ‘ngct 10 9 compressed a soutee, wth pressure gauge batwesn Ihe seurzo of ‘comoroesed air ana the tube. 1b, Pressuroe the system with compress (99 ale unit @ oreseure of: 0.025 bar (2.99 kPa; 0.0265 kglern; 254 mn HO) je oblained and close the system. his value carol be wached, open the ‘eompressed air exuteo anc eneck the fighiness of the system with an HC anelyeer of 2 -Sn00p> leak detecto) fc. Measure the fall im oresoure in the _syetam (tis rust Not be Hors than: 0.00126 ber (0.125 KPa: 0.00127 mgfern2; 12.7 mm #0} ater 10 minutes) 4 {taRar 10 minutos the fall n prossure is greater ban tho epociied value, toeato the leaks by amearlng the fubes ard unions sith soapy water ar by using the ~Sncope inthe cane af leaks coming trom the ‘et app, replace the cap feat of al ‘if aflerrep'acing the cep tho tightness of ‘the systom Is rented, th meansthat he ‘cop nes dotectve. if the tightnoss ie oat rwslored replace the fier pipe. 12, Replace the part that ere thought 19 be detwetive andor adequately tighten loage pipe eine ete hh. Repeal the operations b. and 6. 19 check the coneeness of the ciagnosis, ALTERNATIVE PROCEDURE « “To be cared out wth he fuel tank al ast 314 fat, f8. Disconnect he tube comesting the ‘vapour closner and tha tual tark anc con- rect Ib a compressed air soures, wih a pressure geuge haween the source of ‘compressed air and the tube. 00-27 fb. Prassuise tho ster biowing Bo- _2ane into tho vapour breather tbl uth 2 pressive In ootained oat: 0.036 bar (2.49 RPE 0.0255 kom’ 254 mm HO} © Chacko the exteence of propane leaks tom the bina, wire or porate tater cy ing HC probe sens Core rect fan HE anatoor. Repair the Heat (or ighten the ip clas. ita i sutson. f Rageet operations. and: to check tho conernace of ihe cagnoet CHECK THE TIGHTNESS OF THE AIH INTAKE ‘SYSTEMS DOWNSTREAM FROM THE AIRFLOW GAUGE Inordero detect the existence ot alrleaks ‘nroughou! (ha entee air intake sysiem, Oe G Dx Or @ © O# O» @e @ © Gh eaee ee oF repaes win, — \wnimvoten no orosooafen the woubie dagreds nevunend. check ‘or he Dramance of 12 eae ont. Factors of the pune ‘TEST Ne. 187 December 1087 ves. FRoplooe pap tats rer mocteniag -—- I 00-54 '»a«29000000000COMPLETE CAR TEST No. 13.7 — CHECK CONNECTION PIN'8 ELECTRONIC CONTROL UNIT 9 Sat munimate tor 20:V 5. Sch iron of “= Dfseonnect wing atte muse com tt Place tre Teet prods sesoes pin & multiple connector end ground ard (ado zoe enon on the moter No, | Sechtor the causo tine erin cain NP ) geteciceis conse unk mutts connec: ‘erm the weg Test mo. 14 padz9eq00c0000 00-55 December 1987COMPLETE CAR eee TESTS TO BE CARRIED OUT WITH THE ENGINE RUNNING TEST No. 14 — CHECK POSITIVE HALF WAVE OF THE INDUCTIVE SENSOR wore: “Te contnutyeneck mo be carte ok wh te mtiote oo or fr eednoe, {he ercn etched Opa he wou gris system cncornecind, ‘Ghee Mat withthe engine running ‘on ke th rultmatrreing sek ‘meen 260 n¥ and 2 V. | NO_a| cwargapbaneentnepronc ubmetand XO ed ser tne corect ga. |—+| ‘Speed ap tne wonine wed chock tat Po sangor 1 205 mm ‘abe eresace, no. |W fo vno fa keto ae, hack tnt | a) es (Check tho wing soiuty bower: pn 28 Moone decor contd wit | yo, frutipt connecter) anapn 1 eam. FM o rapaace wing. |—» ane comnactor 813). yin 22 Mooie eleowort sod unt Iuliplecernecor and pin 2.2m. se ee connection ves Rooke thes. poor. \enaceeiay check the senahg system, December 1997 00-56 PAg25800000000COMPLETE CAR ‘TEST No. 15 — CHECK THE NEGATVE HALF WAVE OF THE INDUCTIVE SENSOR + Sm engi, Sale (7 besion 12. 1 Seemutmate fa 20 9 8 be Check thet wit the engine wunnina are test NO. heck te a ee Make si mat the pradous est ND. 14 ‘saan 280 mV and 2V. Spend te engine wp and enact that tha valve read ts oqul lo or greater shan the previous wave. TERT Ha. 38 ‘PAgZ9B00000000 00-57 Docenter 1987COMPLETE CAR TEST No. 16 — CHECK OF CURRENT TO ELECTRIC FUEL INJECTORS wore: “Tho ooninaiy choca to be cri ou Stat engin. ‘wh enters ex Oh ering 1 Sacto) poation 19, ‘te inlion woh a ond no Ue {Ske () poaton agrosis wate dscomected. 12 Suen) poston 1 1S Ser ratinete or 2VES. operate the sccelraor stecting Disconnoc the eectc tel inecion con cf ard rapid sccoertions ned power aj ana chee mg eo | hack he the maxima rowngs on uty erwoor Ni ‘tho cmukimeter ove 350 ri 240 AV 1 37 eoay S126 and pin ot pach ane. [Pane wry, — (un ine engi temperate ester {5c hie iectr commer than 50°C}. “pr 14 Maton siecrore conta! vn ukide corrmctor (81) and in 2 of (eon elec Tae net canner Check Fe eteionrate deere eter | oy pone oy enackrg ina icivevana al | NO! eeslace dfocve latte te tects |] We on [218 08m) yes. ¥ ves apiece the Motronisscerorto cont un TEST Wo. 17 December 1967 00-58 PARZ?B90000000TEST No. 17 —~ CHECK FI COMPLETE CAR UEL INJECTION TIME te ‘militar vane of tere 2somv. nore: temperate the valine are grat Wn the engine at normal unalog teniperstors aoe on Ice, rood ® nd NO. Rosca the Mouonic eects cont Whi the engine cold and ow eared ves tence t icrensa, (Check for fun! encchanact wit c= Dtleration by eperntog stort sary bumtzon the coset ad cach Jeg tat he reading on the mutiemetar NO, Replace the Morrone wma contd rece bution $ on the trouble ‘ogroals nerument und heck or ‘so increaue In tanalon or te ves. i ble aagncete icitument and check ora ara increase inthe elie Hen me. {tke extra temperature ie grate ‘an 10°, pres tion oF te wou NO | reptace he stone tector coro! TEST No. 18COMPLETE CAR TEST No. 18 — CHECK ACTUATOR COIL A AND COIL B Nore: Tn conta cack 9 tobe cared ov. ‘hn mutretr st or ar rec ‘Re grmion eweed of andre rue sbegnesls sytem dcorneded, ‘Read wtension comsaponding tthe (cage rpm. on te multietr eg: wey Ho | isconnactood A nodule corns ane {HOw repeat pe prececing pcceaue cing ‘Be tonaon val ax encoded, [YES ot option monde aetempdy and col A ves. (contin) Decernber 1987 Wen ne ition sults on, the coll ‘module dseonnocied andthe mule miter VES. check the prosece of +12 berween the (gowid on he Sing mpi et (130) and pn t moaue conreta OV bowen the gun onthe ting sparen covet and pe 4 mee oct + OV between the ground on the eng poten cover ard pe 3 CELI Check ting conte fe NOTE) bat. weer pit Motion cian contol ‘Grtenstnle conocer (and pn 2 cll, 2X mole connect. | M2 | ropiace rte weg vesCOMPLETE CAR ves. ‘Sa men (1) 9 pogtten 1 ane cnet, {hr tm provious tension lowe. Diacomnsc x88 mode connector an poet ho preci povodire chet ‘fertaon vate ae spect, [YES aol pepiaes mevtutanesrnny an eal @ | —ey TEST Ho. 8 paees@00002000 ‘Yn the gion ewtonad of, co module deconanctedand the ultimate {ot lor 20V Fs, check foe binant f= 12 Vbecwoan em ng ojatam cover groune(GTS"}anapA {roa conrme: OV between the ground on che tag tern covet nd pin 4 rodule ce ecto, DV betwee tha ound onthe ning inatem ove! pnd pin 2 module con ‘crac tha wing cominuty {608 NOTE) ‘tween in 19 Metonic alecrons oon ‘rune mugue commecsa’ (1) an pS 2 cel module cornet (4 [NO al rehace roaie wing. ves Peplace Merle electric ona ue 00-61 December 1987COMPLETE CAR TEST No, 19 — CHECK IGNITION ADVANCE 1 Bratt ont. {Selector 6) passion 17. owen Him posuen 2. Set munnmerfor2V ES ‘aplace Meteonic letra coma ut ves TEST mo. 20 December 1987 00-62 -PA#29800000000TEST No. 20 — CHEGK FUNCTIONING OF CONSTANT IDLE ACTUATOR COMPLETE CAR ith ne oogineutaig en i, ens ect ne ladon oa heck that hoes an ineroased in he foam note: the ange star Purina. check te bunerty Reconnaet the conser and cnsck That te ie tbs. 2 venue ‘hees ar bos. Mand | NO_, | Popace const ite acme 29) an vest No. 2 Pa422600000000 00-63 Gecernine 1967COMPLETE CAR TEST No. 21 — CHECK FUNCTIONING OF ELECTRONIC CONTROL UNIT I the engine running at between ‘The continuky chechis tobe srried out $000 arc 1500 rm. press ater su re mutates settor One asngs, Ne. 2 of De toute cana tho lvion swihed of end re Woe srmert ‘agnosis sytem cssonnwciet be Daconnet ne bcttomagnet he er hack thet ine mio waver | yo | ing vant and. ppg porat oto | NO | Replace aac ekg Someries momettary Ta IP the [a essere hese. chk hal "| var . ocean We enone tone oe. [= emove the seins Stée ans Si20.| Hy Chek ae Src centnaty bons: [8 replace wing. “pnt pve obtaay Stara coma “| fonotletngvetae below Boa -pouna ning ees cve [Ot33) ‘Tstcomecter on ding valor ack ware -De 3D hans of ley BYE arp 87 ane of tay S128, Proce weg —| ves Je 1 Fatt the rfaye Ste ond $124, owen emave flay $122 and chose conrad Relpiion ana sat teenie, | wo | poememnpinencue anny Sic at ves ‘Check tal wher baton £ of te WON IE in 31 Moirerse electronic gontiel unit ‘Sagres warvert i pened any pn owns oes Sikes ected |e epice oy Sie arg, 4 ete ves ‘mana to Maton t Paphce fe tn 90. Pt ig nr preset (1) epics 1 vmstmae| |_| epics me Mone crane ca ane nine nna oe pn otowed by hung. v8 TEST hi. 22 December 1987 00-64 . PAA23600000000COMPLETE CAR ‘TEST No. 22 — CHECK OF CONNEGTIONS TO CONDITIONER (IF FITTED! + sometr (7) pasts 8 + Bot matin for 20 VF. nove: ‘Ther contnaty chuck et cand out te titer eter Ont cotage. ‘he git enced of at the tout lage ofc deeenneced ' (conmmvesy paazesconcoode ‘Sep 0 eng, owt ofthe igion and dace! te Wotrrke slr ane ‘canto unt enstple connecter (81 and fhe hing cometton Ge, Gheok me wing eortinity katwean pn ‘2a Mononis ecto coal unt mal ‘one pm conection see gate [BO replace wing l= ‘Chesk ning coreruy Bower “pew geonnactin Gi23a body de fomale) avd in 12 cornocton OAS ‘atbeert sew Cana. ‘pet onnention Gite ale anc eon Siieet otal NO__ | Ronice wing and nocesery replace ‘coedbener corral 00-65 Decemcer 1987COMPLETE CAR ves + senvera (771 poste 70 1 Wu he compressor rating ra ‘pe compressa natn operation, rod OY on tte mollmatar. Check that te ongie pa. dows nt ele th sting ato. ves TEST Ne, 28 412 Von tne mutooene. [HO | conve unit maple conrecte sed tne NO! peste wing. No Sing sornectan bossa. ‘Sheek the wing only between pin ‘Zeetoone contra ut mule cone” tox a Bin 3 connection 2190e engine ‘ace ena) 1 @ lo 0 ne commen ca [- esa nagar te ‘Sconmerton G188e (ema and 4 | yo ‘erecton G28, NO a! euace wit, ven COMECTON omCOMPLETE CAR ‘TEST No, 2% — CHECK THE SETTINGS FOR THE DIFFERENT MARKETS. NOTE: The netting In carried oUt by mean of the connection, using the appropriate connector (83, of a device In the form ‘of a relay with a casing of a differant colour, ‘+ Munineer 200 Ohi F8 {Disconmecr eregatve omit he beater ‘= Direonmeet a multe comecte of {he inelocs 1.0198 rm te Oe {rave conva' ont. ‘+ paconwectie ngatvessmintot te | er . = Batch lon ot | [ . on ‘ih te soutorie con! unk mance ee carae aes teense, connate are Te ag thing cos he rultiratar on amen of NO | deemectireneoartewter 27 | O_o asa sing, — ‘esetangtr he raat nquealon ca er ent) ont muneie Cemecty end gra Sane [OF HLEDIS RO poi obcone cinta ent mai weet | eel cea, Sect ant grand 2 pn. and aiecbonecomrtunt RENE | OCTANE ‘natye scores 7 [lesen ‘cack na haw 1 comasty tne essa | ternal g7 ef the baoo a he ootog 00h seven ea rune | recsanes | Rescs tes ihe ts tan ‘oom’ [teore ves Bear wt _[Seran tereon (enon! feta |e ‘esred n_ | eure [emer ‘eats the rap mech vice, ee [ 0) ves + Aacommas! he mae eowect 31 Ferman Lanse tte eon seeroni con ves TWBT Ne. 8 ‘P8423800000000 00-67 December 1987COMPLETE CAR TEST No. 24 — CHECK LAMBDA SENSOR: 1 race ne werproct oe muzmexerin the OLTs sockets of te toute agrees inners. sMatneter2¥ B 1 Samer (i pon 22. nore: The Sonny tek tobe cared th he matinee et tor Oran reed, {he ipnton sid off art ou dteghone sytem scared. ‘Str song a ehaek not wih regard to ibe rpm. range, tbe | 49 ree wg siden co wit ‘mutlap cenntctr aseonnacied ad te Jemaoe abso ated of check athe ‘ending on ine mairear fale bat. Mel rasan f cantruy bovwoon piv 24 Pepicn wig. +—+ een 100 m¥ and. '¥ appIOE ecrorie ceavol UNL URIoe connecter inamery. ‘Shs tara senso commer wing ee. ves Paplace lmbta soneos. ves ’ ‘TEST No. 28 December 1987 00-68 P46 25809000000COMPLETE CAR TEST No. 25 — CHECK FUEL VAPOUR CONTROL SOLENOID VALVE ACTUATOR note: Tre comury ene 02 cared xe smth te moldaster ser Ohm seadngs, (on the pls of the soled vale. Accolente tbe enping wilh short ce borate and aheck for he ‘momentaneots recipe f+ 12 Vou ‘he multimeter with gual ae caleraton). *trineter 209 FS. Sie te wi. {he gntie sttohea of anc he wn figheab sytem scorer. Places ten procs ofr mute Disconnect the Huard wre Horn tha NO, | soot vane. YAR negation yn MARCHA rr, oakon ono orn panenaa of 4°20 Bowron th bused wee ano ground no__| Paploame wing oorusan na clot | MO! valve Bhuoed mie and pin BE Ging aba ray base 8170. ‘TEST Mo. 26 ‘paazesoqoco00e Disconnect the brown xe fom the folnoldvabe and ceconnect fe eae: None coal ut mpi conneeo ‘Crk ohe chet cominuty bowen it ‘96 lecttni onl ut ateete 2 ‘eccr and a browne soenok abe Eo repiace ming. piace he Matonie secre contre 00-69 December 1987COMPLETE CAR TEST No. 26 — CHECK POWER SUPPLY TO THE LAMBDA SENSOR PREHEATING RESISTANCE. ote: “Te cant creck ete cae out ‘Westbe watlmaer tft Ot ding, = Mtinnter 20 F.8. Sune egire ‘he ipnion owed ofl rd is Wout ‘Sagnosie ysam dacornecte, Dieconnect bo fl pup rely S1200R8 Ploce he teat prod ofthe muti {he rca sorter realy eno? the Jt aide of te vehicle and sacute = teving varios acs (a) trom mma autably teapatve comecoronfontegitade IRIs ft neceaaary drain aff or suck of evince fa oul uaing a syinge, the Fu trom tare = deca tol most power eunply G8 anccsconect the beso the er 5, Diaconnect the accelerator control leads @) from the respecte cine VO Roesng guap. cane ectre: 2. Tum forwards) the accolraiorconre] —— aerator power aupry lead @3 and cam right round and wide out the pawt of warring ight oa (2) orn terminal . the ecocterator cable (23) inserted in the bord 8) ited on te fet side of ne Fina operations nd of ve cam (08 deal erqine concanment (eve deta, *(L8OSEN, on bath ses, bat da Kot b Fomvetne aera caxeitom — — power suppy ude @Q anc exgtng MOM re seeye Gat sees the ue tha suppor bracket GB extectng i fom teoa@drontre tener mooi). 98 part at tha angio mountings othe ‘below (200 detal ted on ihe right sie of the rear cover —_—-mslal cheat of the body ices detail. (ooo cera By ©. Unscrew the two sorews 2) that — lorie concer comes(@lana(@® sea te uover vat of te heat vd) stusied on the rer pat ofthe aan ERMA OAQNG Mount (see deal 5) take manfol remove ne 2996 C0" rar tna flowing stepe ef the precede, pariment protection (see deta Tater to the figura Wiaw of the ander pan. of the vehiete in questian. ‘8 Disconnection of electric ac 2, Datomeet the following dloctic loads, WARNING: Temoving hem tom the pat ince: ‘each the elect leeds trom anys — igh tension toad (0) from the front Ean separate trem from the engine 49, Draining off off spovk eu sgtion cot 20 m0 rot to obsinut its removal {if requlted, aceoring tothe = figh tersion lad rom the pear cperaions to be cated out) spa plugs igtion eit Raise votcts on hyaraute — mmmum and mmimumy aoosieratee b Unscrew testa Jondain of he butterty switch tad G3) ftom the fonaine of, Serw plug Back on won te respect swtoh (068 Sota Ey opetaion (a tnished = pomorsuply lead G3) from te cone tant ide regu actuator; = ground toads GB) of the injection Siem from Oe Ag% side ol he 11. Removal of exhavat tube cries head corer f.Unoerew he serous and romave the — engine i presute nici od eat shield rm theta scar box fromthe seaar fed on heart de othe engine Hock cee deal Mt By Rarowe the fur ruts which washers — coolant onpaatireeeniot ead @) connecting eo eatatoe ance Dox fromthe sersotfitedon height pat 7, Removal ol compresir and ofthe ext lab tothe axes cof ne iiake mand (coo cota My, siecondtloner tasted of te engine. = caviar: ompeaite indicator ed). Working tom boreal the vel, c._Loosen the nut (4 tha cks the pipe trom senesr on rear pan of cyinder remove ine wo bois thal eacina te at cap(S)oomecing te cata large fhe (oe eta th; condtnot compressor eupoon bracket exhsial tbing oO ra ena @)ioee — manimum coor fenparaire ware @ tote engine Hare deat 4, inal eed @) from inermoconact —_b.omovethe compreesorcine bet. ——_«d._ Remove me bats (9) securing the cnvat pan of cfince bea fme tad c. Move the compransar ot right_catnylesleacor bx tothe bracket(6) at »: Gide Of the vehicle and cocure it suitably. tne end of the fhywheel housing Dell. December 1987 01-4 ‘PA 20600000000ENGINE MAIN MECHANICAL UNIT Unio the catalytic stlencer box 3) from tho elanic susp singe (@) (00 cust 8) {.Umhock tho cea! engine tno elastic spor rings an ere the con plete exhaust tbe rm the rea gh fi Parove tbe two. soon (2) thet Secure ne lower parc heat had ted on the Wet engine moaning, oad remove the shes Gi). 12, Removes of he propeller shat 2. rove the four screws and remove tne upper heat stied Gi) of he atencer box. , Remove the central eres pleco (3 unscrewing the serews (3 seausing ita ne bos Sip oll tne protest boot (2) ond Unscrew and rameve the bolt (coher tegibe gow selector 10948 (88 dal ©, 11s fo to be necessary, unsere the crows (3 sccurag ne gear iver suppan @ and move it 0 a 10 fiat the feroval fhe prapetor chat (ove deal), 4. Unserew the nts 7 and cemove he pane @@)prcocing he Hyahea! (se texnt 5. {tn the goat over neal and te ring the propeller shatt @}) approariatoly, cumeraw ateeatay the nts 3) and the ote @) hat cones tne shah 1a he fhywhest end the cluch lrk respectively {o2e ootas 0 270 F}. t Unsci the bro screws @) ond ‘tocomrac the sts (23 of tho rea engine mounting fom the body Gee det 6) 9. Unceraa tne emo nu @9) anc cacon- Cache cnt supp Gate progr shat from tho bedy (99 aa 1. Unsezew the six srews GB socuring tt rua ere pve 29) te boy and remove i (200 cota 8). 4. sie the rar axe wth colurneps Jack equiapoa wit erao A.2.0075 anc sip the propel: shat of rom the clutch fer. ‘Paazaeqqo00000 Lower the jack and remove the pro poli shai 18 Fit operations a Fila eultable lever on the rear engine: tmausng 20 2 feta the operate othe removel the engine. Unocrew we rearcve tie lower sem ing nas ote Ste ongine mountings Gi (ese cual. awe he tervl tt srt romove the upper sci of the a ngina mourtnos @) (ae ha Fake tho Ayo ER again 4. Alan th engins te te iting get, tate wntar sdeguere eis and rome ‘itr Ro cine empatinent roe ing twin te leer tached foe ear ee matting. ‘CAUTION: Hinocessary disconnect the contra eps plug leads and remave the spark plugs thomeeives. 01-5 December 1987ENGINE MAIN MECHANICAL UNIT REFITTING 1a the floor of the vehicle to the the progeller shatt and the roar engine spectied tormus. mounting is equal to te specied distance, fb FF tne dietance 1 not equal to tral specited, vary accordingly the length of the Forthe flowing steps ofthe procedure Tater tothe tgure View ofthe under (7): Tighoning 137 eae ae eee ot ager ie Seba ene Srmnenrcomnme 1 iy noe ore SE im Bea es ‘engne mounting. Sr ntchtie eagne to wb tog BF the sud @ ofthe var arine poar and using a hoist, 161 it tall gentsy into mounting | the body oy means of the two: Recap comprined, rencrering —Sefows by th wonnousing ove. © Rate Nyt petctn panel B®) c. Centro the engine in the engine com- —_‘fighfoning the bots {19}. periment ragtng ton tha tir ss mound etR the eat elect vod (by fings and ating sure hae ne hele or medre ot he bo tgmcong Riot tows onsale ae signet bath be oe tue ene rte moun eros! I rn a0 fay igen en See eee C)rrateningioeve vedy sn at Hon bon iene tegen oe Ragone whut ad eon and ty re rrr ‘igen ne rats @) securing te loner pat te eee 1 Soeee ‘of the olastic mountings to the body (eee 2, Rear engine mourting deat or both sides ©. Pte conta eos pace (3 tthe 1 pamote in manowung wrt aetna ee ‘he rear engine rouirg 1 Toten, to the specie forme. the screun @Bsocuring he geai box atsemdly 4. Refining of the axhausi tube super cis cnce 1 te By Paton ta ota stnear on - wre coats wpm rg astern popter stan)" econ 8 Carvout he rt of he erelte Eero saeuing the oer ruse ssp hg at propelar shelby reversing heros tre body connost fo the rar loath 6) wet eocrbodatetep 12. sPomoval- kg yes tate tigtorirg te cut ot opps dip). Te account the following 0+ 45Kgm Tighten tne noi (7) nat seeuros ike oo atomte ie mt Bushing ofthe pre- cntaic sencerbax(3)to the bracket @) felix shai and he spherical entng s+ Chocc that tho distanne Ax potweon at tn end of the hare! Rousing ba Of tho roa ot wih 6 Om ot ISECO MOLYKOTE BR? ores 1 nocoasary use te rare grease 10 greene the fyanoel of the engine. Distance Ar bebrecn the prooeter — From ng 19 dime tock tha propeller ‘shaft and the rear engine mounting shal. preening using te method which eft 10 be met suite andres uly arene nus @ ond ine bors G3) of te elastc ints to the epocifiod tighlaning torque: B= tttrng oe mere ing toe pater tat tn re Mirae uch a wT oe _ Seen WARRING When reiting use new setblocting as, — Tights the nuts @ securtng he cn teat suppor 23 0 ne propa shah Dvcomber 1967ENGINE MAIN MECHANICAL UNIT 9 Fetiting of the accelerator contrat = Tighton the fiting 10 tne eect seat it propety tora, cane ©. Fulvighienmenuawen vasren(Z) — Wi tte engin rftng completed, Reconnect the acceler cable pre {at ecura te eaaye srcor tx tothe slat theenghe end lop up ne recee-——_eoadngmte ree oe a dest fernauel marvel cle engine sad kine vol nt ie vel stabs tia sReeovae sep 5. pe clo @) tohtening he ut = With tne ering rutiog tum teste rane cataheeelencar von bs ing whe puting on afew locks, tariering the respecive serena, both lot enn. eno op up the recencite tho tAX-rforreemat, 10, laces! connections Forthetolloingetensintne procedure — Rel me reervor Hr cap. Restore the sloctscal comecions pro: refer to the Figure View of the engine ceading nthe rare ord Ya se FD- compartment of ie vehi In question. clin sRemovae a step 8. 5, Rofiting of the air-conditioner Compressor 44. Fine operations a. Reve we lower trace of te ae RACODREC the sano rake vaccum 4. Rattting of nerve stenting pump conditioner comorensor 3 tthe engine tbe CZ)to the iting onthe sar Brake, i Toctennecewoneccns men) Gath aa ene char ante b. Pastan etter Dn tscamoet feniome support andtigmienthe screws elatve bots. snontand sscure vt olive mun. atime compressor dive ben Ging brachat. cores the baery Bb. Fi ow crve pen GB) on the pufley, .c, Restarethecorreettension othe com- teint, move the bel tensioner puiley GD) upwarts pressor dive bell and tighten the nat. © For filing and checks reler to the Adenine spaced tension i escned and paragrcan -Engie meianencee— Group ‘hen tighon the sergwe agcurma the bat Load to be appli to the mide = tensioner piey. ur tthe bons 4 Release the engine tood, suppor Pome ets and re-atach ine hinge securing bots on Load to be applied to the mide bot aides ot une varie part of th bet: Camber: P at47 = 2948 (15 = 30 hg) Few: mm Camber: 4. Wascontectas na tube tings > F-1omm the compreser and rel wi Freon . Meperetions have boen carted cut on the seno steering system restore the system to proper working order operating a fallow: Reconnect the bes fo he san st99F- ing purnp observing the toloning tightening torques: 8, Rafting of radiator Aft the radiator togather mth ihe electro. fan and then reccriect the tubwe of the ‘cooing aystom., proceeding inthe reverse twang rues eet ected ont OW enturn tune (iting on servo steering eum Ming 45 + 50m {48.3 + 6.1 kara) (Of dettvery tube ‘ting on servo 7. Felting of the sir fitter steering pump Mting Fat the al ter anc then tecammect the 28: 31m fir foe fubce, proceoaing in the teverse (2.9 + 3.2 kgm ‘order total duserbed Removal al stop 2 = Rent tne resercir GB wih the spec tid hed (ACIP ATF EXRON 8 v1297: DEXRON FLUID 11297 ‘nig conpsoay = Onthe pure fans cron ibo fing 6. FL euppty ester, curing the oll turn tube from the Rastora the ful supply system proceeding Dump reservoir unl the Mid comea In the Fevereo order to inal described In (ut and unt ll the siris expelled. «Removal ot stop 4. Paeg9g00000700 01-7 December 1967ENGINE MAIN MECHANICAL UNTT VIEW OF ENGINE COMPARTMENT [_2f=itme=-3)ENGINE MAIN MECHANICAL UNIT ‘PAKR300000000, 01-9 December 1847ENGINE MAIN MECHANICAL UNIT 2, Fae doar eye, grog lot 38. Engine al preceueineator ead ener bad inden romrare war 20. Ting and vm. sense ood, 14, Engh grou iad 42 Conngevn tt mnumom prepare ‘warn lap lad 48, Miarum o! love warn tmp one ‘44 Timing vv eas 46, Beotic ful njectr pomer supply leads 48, Atornatar poner suppty leads 27, aera warning amp le ‘28 Terminal bears 49, cater meter poner apety iets 60, Stator motor leeromagnet excteton fone 1 watery 48. Contng mato trate thee 51, Str setor 2 Sarva taka vacium he 38 Does [52 Atcondidonar compressor ir few gauge lena 0. Ema an atvatng aad ‘8% Comareasr art bon 44 Mm pan, 08 vEpoo TUD6 21. Beebo ‘an power sup lead 54, Gon tense culey a p.m. by pace ube 22, Pasiotr securing ero pra drive oat 6. Atrnho duct socunng ip 23. Aasilor arn secutng serena 2. Nr imake duct Bb Ful reluen tbe pam BA make duct scaring op 25, Feel russe regulator 58. Sow sloenaa stem Au resent 8. Ai ler sorer 26, Foal ler ie 38, Se engine mouring upper seourg 10. AN ior contnoar cure ie 27. Puls ampar scree 1 her container 28, Accelerator contra cable 5. Hm hil ancuring scr 12. he swowtag 20, Suppan tence SL. Hact ants gat mourn 18. Coco ctr me 90, Freet spat pig Saiion ce toad 62 Pye ate “V Covtantdavay ase 21, Pear spk pag ton cal ead 2 Arar 18, Cooler return ube 22. Deed 84. Ful vapour rooyaing tbe 16. Pain fer lobe 88, Acclerabr butety wih 25 Lance sense reusonee cotnecioe 17, Pacis beta ube 24, lel region acta ead 50, Lanta sonsr connecter Dacemer 1987 1-10 (pa23800000008ENGINE MAIN MECHANICAL UNIT WEW OF THE UNDER PART (, SE TTE=E=-3) & [o]ENGINE WAIN MECHANICAL UNIT 1. Ol ranage 99 2 Mine we ashen t sac fe cae ye alenso bor to he out rand 2. Gaeyte stoner bo snhauel bo 4. Pe ap mat 5 Pipe clo 18 Rear engh of estat hbo 7. Bot far spewing eat stoner box to enact 1. SyppOR bracket tor catayte Dox aunauet ‘ube 6, Ela singe 10. Heal sted soci scores 11, Hea eld an lek meunng 12. Cena cosspoce securing sows 12. Cantal erneepiace 14, Proce bot 5 Seeunng hot December 1967 16, Goat setae 98 117. Support senurng serows 18. Goat over support 1. Fynteelprlectve pane! oecurog bots 18, Fsbeet protective ans 21, Propoler sat . 2. Nuss sacri Fortean jo 23, Bots secng rear sate ent 24 Semis sgeung 208 25, Rea engne mourving 28. Nu seeung propeter anak cont capper 27, Pepeler shalt cara! suppart 26, Screws secur row ose eco 28, Ron cross piecw £2, Seo engre moaning per securing 130, Sie engine mounting lower sourng screws seme 3. Gata stent box nant stds Kowa) 21. Side engine mounting 24, Calayle stance 2x nea hel pe) 01-12 PAAZ2E0000000ENGINE MAIN MECHANICAL UNIT TECHNICAL DATA TECHNICAL FEATURES OF ENGINE Engine 2000) wey) Crate Oe 4 suche eye Nunber of eyinaers ‘inte Nunbedng of xhnders OSS, Bae — Sroke mn Baas plc capacity ont ‘082 Combustion chamber ont 55 Compreeion rato in Poner DN ‘Mamm wen ar ue) sts7o0 = 6800 rem, “Feu Dm em) rT) A200 rem TES (8) 10000, wea (9) 40019. eatin average pean weet (1) _ a” vr emo ROM 6 Oasane vequrere Seve 2) @ Engi ol proseue (3) ‘Mex ante 12m we 943.69 Meinum at exmum rpm, 4s (ba: fen) 33.19 043,351 Maden a minimum co. A 4 OORT AAT 3 ABC AS #6 O)Amimon rom {2} Ditvenco berwoon the Octane Research Metiea Nutee! ana te Cstane Method Number (9) Vanes to be memured wih engine at Renal uesing temperature {0 at OC} ‘PAK23800000000 01-13 December 1987ENGINE FUEL SYSTEM CONTENTS DESCRIPTION Functional desoription Diagram of Motronic ML4.1 fuel system ... Wiring and maln components of Motronic ML4.1 system .. Important information of @ general nature... AIR INTAKE SYSTEM COMPONENTS OF THE AIR (NTAKE SYSTEM .. Air fitter Air flow gauge and temperature sensor ‘Complete accelerator butterfly housing Minimum and maximum accelerator buttertly opening switch .. Constant Idle regulation actuator Air intake box . FUEL DELIVERY AND GAS VAPOUR cece OF Fuel supply tubing ‘Compensation valve Fuel! fiter .. . Main fuel pump nn Fuel pressure regulator Hammering damper Electric fuel injectors .. Fuel vapour trap .... Air inlet valve .. Carbon cleans? Fuel vapour flow control solenoid valve ce ee OB Paszs600000000 04-1 P.M. AND TIMING SENSOR IGNITION AND FUEL INJECTION ELECTRONIC CONTROL UNIT (MOTRONIC) a MAP SWITCHING DEVICE .. 4.24 EXHAUST SYSTEM .... 04.25 Manitolds, catalyser and silencers ..... 04-26 Rubber suppor .. Lambda sensor SETTING AND ADJUSTMENTS Setting of accelerator butterfly (flow rate) : Setting of the accelerator butterfly switch ‘Adjustment of the accelerator COMOL reece ‘Check of fuel delivery pressure and tightness of system Trouble diagnosis procedure for checking the tightness of the tue! injection fuel feed system ... Check of tightnoss of fuel vapour ‘emission (evaporative) system Check of tightness of the air intake system downstieam from the ait flow gauge ‘Check of the idle running ‘Check of exhaust emission (CO) on idle TECHNICAL DATA AND SPECIFICATIONS ... Technical data Checks and adjustments General specifications ..... SPECIAL SERVICE TOOLS 04-29 04-31 04-31 04-92 04-32 04-33 December 1987ENGINE FUEL SYSTEM FUNCTIONAL DESCRIPTION “The ois cunpod inthe fue inortae passing tought pute dempor()ard the er. coma rom he eran. spgene tema re “Tho preanure repussiot (78) regulates the pressure of ho ful ine tel couot tube (a8 a fureion of the pressure treasured tear iriate box(@) neue way a8 10 malta the cifornce ba tween the fl pronnue anc the reese inthe air otake box constant ‘When eu pres exceeds the man im epocitad ane 087, ne posaure ‘equator causes the rtum ofthe axcees {vot mo rl ta, tn os way the quant of fel injected dendsexcluey on rw ineaien imo, ‘wich i cided bythe secre contrat ‘ont @ by means oft nol a snore fleaighed 10 meant. Ye data. which characte th unatoning of 0 ongine “Tete data ote pm. one Ad, Bat tery tension, engine temperature etc. “The cuantiy of akan ina measured by ‘moar tow gauge (2) which has tha uno- tion of avartyng te ow at accon- soquenty sending asia tothe dactorse ctv un TR eee caging of tho sl Injected ¢ determine on the bas of is sions Insgo tho a fom gougn, eros 2 can- sor(@)whien meer terete oF tho ly aken ia Te e0000 foraanas 8 signlto tne electeic conta unt anane Unt Js thus able ro semper the jc tion bre acerdng othe van in he air weigh = fe! weight ratio. The engine ‘ompert.r bs measured by ‘he speci endorsed wt tho so ‘ing pat Inmeraed nthe coolant hie. From hea ow gauge) ears there dut(@)arainen acta te scenery biter nousnn @) Aton @)is tt on fo oesoraorbut terly rousing and. # conabts of tietoswienet. One ot thats Ie ne rinirum opening eich wie Kamion figrai nen te 20g of ery fron 09" (complet elsed) andthe die the maximum opering such, December 1987 DESCRIPTION (ASE ‘ic turianesaokinal wen ne opening angle o the buttery is greater an 60° ‘The signa eat toto electron: cont Unit ay those wo ricraswtchos permit roepentvoy a command 1 out INe Wel supply duting engine deceleration vihonever tne senate of Buterty cts fo and p.m. greeter than 1080 eve Fevogrised, are the conto of the tut envickment dung accoteration when, on aspect aquest engine power he ait ftw gauge sige! excoods a preaetormin fd increment and cornneneds, nol onthe ‘wal infetion 1 met the now requirement tnt an adn! ncraase fo rnch thor quired ¢.p.m. rapidly. ‘Tha constant tle ectuatr (7) fitted in be which bypasses he ascelerter it- tory housing, With he buterly closed or sip open ta sacton artne passage of {he actiatordterines a tow of which Janet conoid bythe accobrator but Dy command rn the crn control “Tho apace romthe socaoratr batt Iy hung into thar iniaks box @ and {nen trough te rina marnotd(@) m0 the cytes During old stating. ho aoc cortrot uni contol the grin advance and te ingcton tne. “eigen sdvanesdapercisoxcusvly on therm, andthe engine temperature. “The isto te ctorined by a vale programed inl the electronic carol uit and exrocted seceding lnprace ofthe it takan in he engine temperature, {ho batty leelon snd tho #2. The sensor designed to. measure the ‘ongires.p 1. ad me engine ming ‘tthe Inductive type and functions by theans ofthe vada nite magnetic els ‘genera bythe passage of he teeth ot tho cog wht (panic wheal fect onthe ‘ive she. of the encine. “The ignition acvarce a dotermmed by & rap programa int the electronic con- {a Unk fanctoning on te Basis othe 1pm. and te engine bad. “Tre value reo obtained a opumiced 96 {uresion of fe ar itake ter peralre and te engine temperature. Wve value thes opt ised ces greatly ‘fom tho valle abtaned fom the pro rammed map tn ijcton tine i ne 04-2 crossed Ye guaranive a auflent margin from the soar ok it. The cam shal (ar inske ss easroed with an electromechenical-nydrautic 1ype ‘ming varitor ([3), whichis able to modity tho alr inake Ging (advance) 8 tat & roster quart of ii takon in. The regan of teil nang 8 con- totes dutng al taaee of faretoning by means of he consan actor CP} Whom the engin ia runing on id te functon of te actuators t ring th reel panto the nominal pan. by ing on the accoator bor by pa. sovellas comating Ya ds rurnngot te erative, he actustar(P)alo nts 8 an ac- Girl airbox and rgatfor ean Genng ster. pades600000000ENGINE FUEL SYSTEM DIAGRAM OF MOTRONIC ML4.1 FUEL SYSTEM (Z#=i=5=5) ©9 eo OO im rue. ama Moen vaca FUEL VAPOUR {EVAPORATIVE} Paazse000c0000 04-3 - December 1987ENGINE FUEL SYSTEM eee 1 Ae er 2 i ow am 2. Ai ake tempeteture sens AA aka ht 5 Accalerar bata rousing 6 niu ana maximum oocolraoe tadtarty opening exten 7 Gonetan ide radon actuate 1 Arius box 8. rte asd 10 Fae take 1, Atalay ae pump {2 Main wot pum 13. Fun! er 14 Hamman damper 15, Fl alia hbo 16. Fu ores rage 1, Beatie fat Iypetone 8. Egno coclan aperture soneer 10, Timing vaitor 20, Rpm, ard heing oaneor 21. Ol apoor tap 22. Fron spark phign gn serbusor £2, Peas spark plugs pron itibutr eed 25, eat spark ge 28, Fron epak page ion f 1, Cel 8 power modulo "2, Fat sow prs lon oo (con ay 19. Col & power mode 90, IgaB0n ane tut aca acronis cone rt (tone) 31. ut cum rtay 2, Relay wih ie 2. ung varator ay 34, Main etay 236, Fuel apour ing ese 36. it ve {eomparacion web) 2. Sena vave 38 Caton caniar 28 Orewoy ve 40, Fuk vopous ow cont olen (wating FUEL VAPOUR EMISSION CONTROL SYSTEM ‘Thoton vapours aranatng Wom hen are cle, tronch spec bing, 2 0ep (nen rian me spec dog paris the umolihe pel concenaat tone pera tam. “Toprovert he vapours om escaping tothe amoxphere the tank ted wa tesla cop. “The Wt vapours which donot comes inh tap poce oto per ng ot ‘rap end, pssing trough he vapor brat bing end re one Nay ve, rach the act carton tw on cnnaen @. “The vapour flow is controlled by asokencid weve GD whch opens (or 060) 00 to Sentai rote em Ine onal ut (tone) 9. Fre vec proses ess than a preset ‘ae eg the eget ning oF nil) te solenad ave enon sed fond doen 00 port the vepa Tow rier he vapour cane. Unaer nomal engine tictoning con ‘irs the apa ow gana ates 19 spor coenar en aborted the o- reed cabon. Here, dun tae fen of te preuredtowee ering ete, tre carton le washed Bo cure of ‘ait whieh Nows through tha filter iteolt by: mmeane ofa vate G@). Inthe ewachinge ation, the pewol vapours ‘and the aimeephetia air mixed tagother, are comicied dio to the affect of tho: ‘vacuum pressure, 16 the aie falako box ‘xtra thery are aided 0 the mbaure. “There are tw conetitiora inthe aysen ‘he fist is located atthe exit of te tel vapour ep (dlamencr 3 ru; the secon ‘fee batween the vapour oleaner and the ait intake marifold (ameter 1 mn) 1, stor the stopping of the engine, tne (pressure in the gic vapour tmp toned 1 Fall, due to atop in tomporature, a com pensation valve @9, positioned in the ‘vapour breathnor tubing, vetwoon the wap, and th fier. pormits the entrance of at ‘oapheric alr and maintains the pressure in the rap equal to the extemal at ragptierie povssur.ENGINE FUEL SYSTEM WIRING AND MAIN COMPONENTS OF THE MOTRONIC ML4.1 SYSTEM @ tin % Wee ® @ ) 7 Batary 38 Aelay te oa 2. Front apark plug igntion ei 10 oar epee plugs 10. Tig vatlor ay {oot 8) 11 Teng veraor 2 Main iy 3, Power mode {col B) 12. Beers Wal noctow 21. ch ng connection 4: Rea spark plugs iin cil 18. nave cootantiompersture sensor 22 lon ard fc iocfon sfeie {coi 14 Goole ee roulaton actuate ntl nt thavonk) 1. Powarwoouta fod A) 18. Minium end raxinum accolraior 28, Conmecior for sot wouble agnosis 18. Rips. ane tog sensor ‘oping etn . 2A Lara nance 7. Fro pact plage ignten astute 16. AY fom gRU96 end sr este temparire 75. Lara sare cammectra 28. Rear Epa pigs ition erator saneat 28. Mover electron conte unt nag 9, From part phage 7 Fuel pump ony ering oes December 1987 046 . PAEPSOON00000ENGINE FUEL SYSTEM IMPORTANT INFORMATION OF A GENERAL NATURE ‘+ Mever alaconnect the battary with {se engine running or In any case ‘with the Ignition switehed on (ste ‘ing hey Inthe position ser (coe ‘Go click). Fallure to observe this ‘precaution wil rit insettous and: permanent aemage to the electatcal ‘components and the electronics of ‘the electron sont} eyetem, © Before stating the engine, make cure ‘athe terminate of tho banery are tut ty tohtened Do not use a wapid chargers to stan, the engine, 1 Comptlely disconnect the battery orm ‘the eystom before recharging it ‘+ Donotstarsheenghneif the electrical ‘connections are Interrupted or oom ponents have bean removed. ‘+ Dencteorneet any low o high tention paint to ground or interrupt any cor ecdons while the engine is running. ‘© Remove the electronic contro unit ‘whan axseiting paintwork in turace. ‘at temperatures of moro than 80°, (© When titieg seseasonas on the vehi ‘le tisalwnys acbsable to disconnect the electronic corto uit and proce ‘to check the functioning of the ac- ‘cesscriae wth the control unit discon- noted. ‘The connection of leds tthe connec ‘tons af he alectronte contol system for accessories is very strongly nat eeqramondod. + Bofors carrying out any operation on ‘to various componens ofthe system, make sure that ttere ere no connec: ‘are dleconnected, dips loosened oF {tubes torn or visibly obatncted. (= Never connect of score the ela ‘real ohups rom ee conductors othe ‘tectonic contol unit with the gation ‘swhehod on. |= Do not connect the high ar low tere ‘iore cables 19 ear in oror to toat ‘them under any circumstances. ‘+ Make sure that tha connectors of the screened leads ara cotrectly con ected. '* Make sure thet the ignition system is functioning etfcionty by checking the par plugs and checking that tho slatnytor sap Ie not damp or eracke ‘04, thatthe loads between the cel and ‘he datioutors and between the dis fbutore ang tne spark pluge are cor paezynqo990000 rectly connected and thatthe ineule- ‘Hon does not present taeas of buen. tng or anrasions +) When replacing fuses, remove bre Power supply fn (Bsearnoet me o- lal). Ifa usa burns repeatedly, seek ‘the caus ofthe short circu, Novor cepace a fuse with piace of wr. Hin imperative tat burnt tunes be replaced wih fuses of the same amperage. TEMPERATURE OF THE CATALYTIC SILENCER BOX ‘A100 high temparauure of the caealyic silencer box during driving can cause damage 10 the alumina menokh thus reducing fs transformation capacky and damage he contaher or tne vehicls reeuting in a risk offre. ‘The eogine phenomena thal can cause ‘overheating of the catalytic silencer box = Carbon deposits onthe apark plage ot ‘on ox mace cyindsrs, — Fuel pump detoctiva o fue ter doa 2d (tal pressure too low) — Fuel inootors datectve. — Air iter sanridge very diy. — Accotrator contra) eystem net get and adjusted correctly. = Engine and related components nA st and adjusted tc the manufacturers specified sardavds. — Leaks inthe exhaust tubing upetresm: from tne exhaual gas sensor. —Pronaure requlstor rot functioning. — Bettany enon roo fow or recharging Grou cateotive). “The artang esndhions net oun cause averheaing of the slencar box are: = Too tbe tual inthe tank, = Overioading of the engine for long Patieds, tor exam, when iravetingat ‘msimam speed, when boning a relet oF climbing of tan — Traveling downhill with the engine ewnened oft. PRECAUTIONS TO BE TAKEN WITH VEHICLES FITTED WITH CATALYTIC SILENCER BOX = Use only unleaded petrol 04-7 ‘wold whowing the petrol tank to becom empty. Do net run tho engine with one of tho spark plugs disconnected and never ‘connect the spark plugs to ground. Do nal overaad tne engine tor prong fod periods. Pay particuur attention when towing oF olmbing for long periods, Do net tum tha engine oft when de Ing dowr hill First sop the vehicle and then stop the engine. Do rot park on oF nese infemmabla mater al such as cry grass, pec soak (64 ground, dry teaver, rusbich of. Never emipar with the exhaust anise ‘sion conte oyename itl trbidcen by law. ‘Cary.out the risintenance operadone ‘8 desoried nthe instruction booket. Parteet engine mantenance is tun: ‘damental to the conservalon of tha ‘cetlytesloncer box. Dovember 1987ENGINE FUEL SYSTEM AIR INTAKE SYSTEM tanuwwoevaal sunceva tana OA and aw E ‘pacza000c00000 December 1987ENGINE FUEL SYSTEM AIR INTAKE SYSTEM COMPONENTS Pas2asoo000000 04-9 December 1587ENGINE FUEL SYSTEM AIR FILTER REMOVAL operating as foo 4. Daconnedt te comevtar(3) tom he sr foe gage 2._Dacennee he fing tee tom the ar take due + Tubetorterceycingctolvepour at peak rm + Bypase ube or conetare le ego: in @). 3. Lecter the seoung otp @) and conned te ake dt tom re oo- neat butety tesing @) “© Looten ine sooving ae G7) and revo the ai take diet @)hon ihe ait tow gs $8. Unhookike lou song ei an he air er ecver Band remove wrayer “with Ihe air flow gauge. Also remove the Mar sterara 1. Connecter 2 av tom guage 2. Peek pin i vapour iacyting tbe 2. Fer deren! 1pa423800006000 6. receseay unsere the three mute @ that secure the er ter cmaines 16 tho nogy and remove n 10, Secures nuts 19a fe eotanar INSPECTION AND ADJUSTMENT. 4. Clean the fiter elamant thoraughiy ‘owing commpresaod afr rough K at fo pressure, If necessary repiace the titer senent. REFITTING Proceed tothe cfiting ofthe air iter by reversing the order of removal NOTE: ‘When pastioning the titer element in Athy comteinar, be sure thatthe arom, ne dieating the upper port, i ‘upwards, AIR FLOW GAUGE AND TEMPERATURE SENSOR ELECTRICAL CHECKS Floer to tha paregraph -Eletriea choke ff tie Group of. REMOVAL 4. Remove the ais tier assemily (som paragraph «Ar titer - Remeva) 2. Unscrew the fou serous GQ) thet ‘cura 216 sir Row gauge (2) 10 te fer 8. aow Cw sow gauge (3) the relatve guakets @) and remove The okt Stange (5) fom tho ter cover (3) 2. A tw gauge sacwreg eens 2. Aso age 1. Br fit cover 04-11 Oscember 1987INSPECTION AND ADJUSTMENT Poss on he butters ofthe ak Row gauge ‘and check that Il uinafroely without aticke Ing oF eatching ane at 1s No Seared OF din. necessary, clean the irtamal auras of the sir low gauge wih a dry oth REFITTING 1. Ratntha ai ow gouge by rove. sing te order of eave Replace the gaskars (4). ‘WARNING: ‘Pay particular atgntion to the tighten, ing of the fittings 00 48 to prevent air {rom being taken In other than through the ther, 2 Whan the ale low gauge ax baen rae ‘ted, carry out the check and adusiment, Hf necessary, af the axhaus! CO percentage (oe perograch Gelinas anc suitmert) COMPLETE ACCELERATOR BUTTERFLY ASSEMBLY AND HOUSING REMOVAL Remove the completo sccelerator butte Jy houshg ard assembly procceding as tetows: Dacernter 1987 ENGINE FUEL SYSTEM 1. Discuss henagatieeminal he bout 2. Remove the aiitrtooether withthe ai How gage andthe eave a aka uct eco paragieoh Ai thee-Romnval 3. emove the stop sng) disconnect the nconeatar concen (2)and age tack the shestng G) from the relative suppor. 1. sup ng 2. Acclarmtr eam eae 3 Stemming 4 Dheconnect to connector (2) ram ie acoolceto: butey miamum and mex imum opening emo 4, Sniten connec 5. Actor bert minimum and smaxtmam paring swt 5 Uncrowe eu secur arene @) remove the aceterator housing (7) and Tororo Io gaske and he abelrtor cable spon 04-12 6, Pccmbratr otwty Peusrg secuing 7, eer butery hounng 5, Recebraer cable euppert, 5. Lacten tne pe ospe ans atsconnect the folowing tubes Irom the sccelersior feuverty housing + tubs(@)lor ihe delivery of coolent rom the acodacator butety howsag the header tank 4+ b2(()oc the setvery of coolant om the eccolorator butiorty housing othe cinder head. 70. Tub lr to detwaty ct aosiem fem ihe ‘ccatraior terry hovang ¥e he (cr eed paazaeo0000000ENGINE FUEL SYSTEM . cateto mmo sate atectied connections ~=—- CONSTANT IDLE waren correct tft anew ska betmacn the + Maltin the theo @) and @ Leet ater cata ee, REGULATION above the Jevel of the header tank yt totese ACTUATOR ene momo tise to tkten econ v0 the tose of coolant. Hnesessary,caryoutineseningotinees- «ELECTRICAL CHECKS ‘+ D9 not taenpar witn tne acceler ‘cetertor bulterty assernbly (ace paragraph tothe paragray ‘e butterfly easembly adjustenents. -Soting and adjustment). re wee paragraph «Electrical checkse ‘= Prigite eat to re oink box 80 0 1 0 prevent any foreign matter thom entering, REMOVAL 4. Disconnect the connector 7. 2 Laoaen ine pipe clip and eieconnact Removal of the accelerator butterfly ACCELERATOR ‘the constant idle regulation by-peee tube aaasminy swton BUTTERFLY MAXIMUM 1 Urew the wo seo @) ord AND MINIMUM OPENING ©, Utomw ho seoung sro tne ip remove the accelerator butt anima @ that nots the seatrto the nia and naxium opening smich (2) SWITCH tox. 4, Remmave the actuator (@))complete wits ELECTRICAL CHECKS al. oferta paragraph ecicalcheckes of Group 00, REPLACEMENT 1. Disognnoct th connector (3 of ne switch) ® 2 Unnctow the two. scroms (6) and temove the ach 1. Swch securing sens 2 crenata bateety ina ae maximum opening eaten 1. Aacebtelar butorty hous, Retiting ef aceeierstar buttertly. 2 bree uke scembly sete Sch Proceed to the reiting ofthe azcotarator “+ Conetant ale regulton setuaor buttery assembly smtchby raversina the order of removal and then adjust It as deseo te praraon et ar ; perirnna siustment Proceed othe refitting ol the constant idle 1. Sertch connectar “regulation actustor by reversing the order 2 Aino Sat naman ad citer ana pena gra anton 3. Switch securing sommes. (0 the folowing: +) Thappe ctp(@) must be wal ohen- REFITTING 8d (0 prevent The leakage of air. Proceedioine retingstnecampleeac «8. Flanewanithandarocesdwoihose- + Th connector (1) must be pushed tiemartieay monger mnanny Saget ae pamguphaearg ena” Spay ooo ea on 8 brine no cue erenera rainy joann, ae Pacpse0odoag9e 04-13 December 1967ENGINE FUEL SYSTEM AIR INTAKE BOX REMOVAL rece tothe remeva ofthe iia box parting as fotows: 1. Disooaroc the battery forminale. 2. Pane the for ogee wih the intr goupe ane to oko sir intake ‘duct [see paragraph «Air iter - Removals). | Rmeve te actor buted hou: ing ia peregranh wCometoe accelerator unary bourng and sab -Romovan. 4. Loosen the ple chp and daconneet tne aene-brakevacuyrntube(7)fom ihe sir rake box. +1. Senmoaraee vaouum Noe 5. Disconnect ne vacuum Le forthe pressure reguetor(2)are! he ul vapour rocyeing be @) em thea ial to 6. Loasen the pipe clip and disconmoct ‘he pooh pra el vapour rocjetng tbe Gem the ot wooo ap, TC Urocrow fee scrow securing the lp ene remove boot vapour s29 (6) tre air te Bo 8. Unscrow ne exw @) ma score the a intake box fo the aupport 2. Vacum be fore fet pease regulator 1, Fool vovewt rocyng tba 4 Peak ro. of pour reeling tbo 5 ot 1 OF vapour op Lense tha pipe efp and disconnect the peta turn tage (2) om he Ma peste roar 10. Loewen the pipe cba 7 sewing he susoer connectors ((3 of te al Inet ratilold fo the ai axe box 7. Peat ret tubo 8. Foal pressure ropultoe 11, Pos cles 12 Pabber exmecters paazseo0000000ENGINE FUEL SYSTEM 11. Remove the i itt bow ‘tncrnang ton heer comers UF te a et anal 138. ret marion INSPECTION AND ADJUSTMENT 4. Clean the inside of he ar intake box {tmoroughly, by blowing compressed irr toit REFITTING Proceed oie eng! he a naka ba brewing the omer remove snd oah- ing parca eteon io te clawing 2 The ip cea (J enouingtbe oer carnoctrs (3 lo tho ai take bax trust be Ugniened wel soa o wld try leshege of 1 nocesary rplace the ruber core noctora(@ bebresn the aint ba tre te dr net mano + Fa new geste betwoon the se- caleatorbutertyhoisingend heir intake bo. 04-15, Dacemoer 1987ENGINE FUEL SYSTEM FUEL AND FUEL VAPOUR SYSTEM wf ory S100 Levey! einseert wed Ch ‘qr ornenie pn “th tcp Samar “Us, ‘gr LonROP Pd “Ob Bug nes ng “8 fund wr“ vans 2 ‘und pecwuny “9 a uopesueciog *3 reo end“ any 0) S094 aya kd aazaacoo00000 04-16 Docambor 1087ENGINE FUEL SYSTEM ‘CAUTION: lofore replacing the components ofthe fuel eystem the following must be scru- pulouely observed: (2 Make sure that auitable safety equip ‘een ie extinguishera Be.) avalanhe jn the workshop, 1B, Oleconnect the graund terminal of ‘the battery. ©. Place the fuel taken trom the fuel ‘tank in a auiteble contalner wit a sate y WARNING: After having refitted the componente of ‘te tuel eyetem, cheek tne tightness of ‘the system to a pressure of 4 bar. FUEL TANK REMOVAL 1. Set tha vohice on a tydaute 1m, remena iha cap ae sick the as rom ‘he font using ¢ uted pump. 2. Remove the tning of he Moor ofthe luggage compartment, mew ase rene ing of te wall ofthe comaartment (ight de) ard romave tw con of tho Wet va ouge. 3. Disconost te comecors (7) art @) ‘and then wit the connector om We acd pasasgo oxicingit tom Soneah the vehicle. 4. Laosen ine op nd detach he cout ino @)hom thotark thou damaging he ruber gasket under the couping. pa t2x602000000 1. inmate fal pup connector 2 Fier det ‘3. Gouptrg connactng the ina ote tank “¢ Fal lvl cage connmctor Fal evel guige 5 Pals the whe ono ana acon recta ubes(1) and) hom the ange 1. Fant ot te 2. immoteed bc pump 8. Fel detvery tude 6. Support the tank on a column ype {8ok, uneoraw the Innes screws securing ‘he tank tothe bocy and remeve i 7. Wagoesaary, divide the tank inte te ‘various component gerts. 0417 INSPECTION AND ADJUSTMENT Gheck that te tank ¥ nol cracked oF ielormed. replace if necessary REFITTING 1. Fitthe tek anthe vehicle proceeding lnvtre reverse order to net lowed echo removal and paying pertcularattenisn to ‘he corract postaning of te uber gasket ‘between the tank ard the floor of tne lug (9096 compartmert where the ile ‘ler lipe meots the tank FUEL LEVEL GAUGE REPLACEMENT 1. ave ho ting o th toot of the \ggage eorperment 2, Remove te tel vt gauge covet 2) and claconnet te connector @). 1. Fue ret gauge cornector 2 Fuel eve! gauge Decemoee 1987ENGINE FUEL SYSTEM 9. Using# sultant too}, urn tha et ov ‘98.99 sntbclockuioe and exroctit rom the ‘uel Cank wih the rolelive gasket OO 4 Replace the gasket betore tina the |e Iavel gauge on tho tank. AUXILIARY FUEL PUMP AND GAUZE-TYPE FILTER REPLACEMENT 1. Sel the vorila on w pyerouks remove thelr cap are ck el om the ek ving 8 avtate pump. 2. Unthetinng other othe bggege cempariment, dsornec to renored foal pump comectr sid Woah he las lod postage ond ere hom terest the venice 2 ae he vee on the hye it and decanraet ho taboo (Aad tom sre farge @) Dcember 1987 1 Peat ctu ate 2. inmoreed tet pure ange 28, Foo! tray tas 4. Using special service fool A.S.0197, turn the Immérsad fuel pump Range ari ‘lockwiae and extrac tne assembly ror ‘he tank with the relative gaskel Low e a 6. Replace the gasket before fiting the: fmmorsod fut purnp ascomy. Proceed 10 refit using Ine special savin col A6.0107. 0418 FUEL SYSTEM TUBING REMOVAL WARMING: ‘The tubing of the fust system should on- 10 removed if absohvely necuveary. 1. Set the vehicle on a hydraulic fit 2. Remove the vel ilercap and using ‘suitable pump suck Ihe uel ror he fark 8. Laceen the pipe eps af the tubes 1o bbe sernoved, ‘WARNING: Plug the onde ofthe tubes to prevent the eatrance of foreign matter during diamesemdly {both gid and exible ‘bing 4. moxder to remove the bing locatec ‘onthe Hoo insize te passenger camaart: men, fret remove the Ing of te aor on ‘te right side. INSPECTION AND ADJUSTMENT 1. Chack thatthe Hexibfe tubes are not ‘oraus or defective in any way. Rplace ay detective tubing. 2. Chock thal tne right tubes are neither clogged nor dented and that they do not ‘show signe of oxlssion, REFITTING Ft the tubing with caro by operating in {he teverae order fo that followed for the. removal paying atigniton to the tioning warning, WARNING: &.afttine plpe clipe on the junctions of the system with oare. Do net over Lighten tha pipe cllpe so ag to avo damaging the tubing, 1. Nelther band not twat the rigid tub Ing white rafting thoes on ine venicte, ©, The tubing located inside the vehi lo Rust be incarted in the ratative tube feueaages aa far as the red reterence banda merked on each tube. i Start the engine and check that there ata no leaks from the junctions. «22800000000ENGINE FUEL SYSTEM ‘COMPENSATOR VALVE REPLACEMENT 4, Remove the bring of the floor ot the luggage compartment 2, Daconnent the fing breather 1ube ‘wih the attached compensation vale, INSPECTION AND ADJUSTMENT 4, Glowajet of airinothe valve fom the ‘ing on the petrol niet se. ‘Considerable meictonce shoud be fot and ‘a certain quantty of al should come cut of tho fing on the almosphere sida. 2. law at of wr inlo the vale fro the ‘ong on the almospners cide. “The jet of ar should come straight out of ‘ho ting on tha petrol nt side witout any resistance being fal. 3. tthe cemperwcaion valve dows 00 pre ‘ent the above desorbed charscenstcs, ‘then It must De replaced. REFITTING When teliting the compensation valve, oho caret Bethe ight way round, In tne ‘rscton of ils functioning. FUEL FILTER REPLACEMENT 2. Opersing an banesh the vehicle pion to tunes (1) and (3) Loosen the ibe chp and detach he tubes (1) ana (2) tor the ar €. Leoken the aupnot lp G) end temove hot <2. Flt te oe staking are to 00 thal ne ao samp on ta casing ot Siar beng i tho dracon o! to hn delivery, Whoa he tring comme, evove the sabe ginchers fam the fel delery subi. ‘Paezs800000000 1. Fal to 2. Fae flee 3 Fao! cuit woo 4 Fae sigpon at MAIN FUEL PUMP REPLACEMENT 1. Sect wehicle ona bya and ehaconnect tho negatve terminal ot the ttn. 2. Weiting trom uonesth tw vhicie sconnoct te pump power sup la (1) 3. Pinch he utes (2) nd (3) unscrawe the nat et te pare cin OS loosen the pipe clips (Band (7) and then ceoennact io taser) and (3) vor te pump 4. Loogen tne lp B) and remove the pomp 1. Fuel sume power euppy mds 2. fuel camp init be Fuel camp aucet we 4. easing mot 5. Pump supg0" do 5. FA the now puma by reversing te cxder of romeval and paying parle a tention tine tonto: + The placement camp is supe in ened packaging, tis win gree fire alana nth he ie tings coe <3 wit epectal uae ‘en fengitisne neces 9 en ye Take car not rover te conection othe par supy ted (0) + Taper te toning sowing compo: nent to Ihe spacified torque: = Nu ter oing of pump secuteg lp @): teers tee FUEL PRESSURE REGULATOR REPLACEMENT 1. era tno ai ier (ete parngragh 2. Untasten the securing pring cp and rome tha vaio (1). 3. Check thatthe valva i in coreet work fr by blowing compressed ai into shout be acta to aes only in the direction indica by the ariow If the valve i not tuncienfing oorracty replace it 4. Cary out the refiting byreversing the ‘order of roma reoeingto ne preceding igure for the correct positioning of the va CARBON CANISTER REMOVAL AND REFITTING Working om beneath the ve remove the ecron (3) and dilodge he earn ‘canter (2) fom ts novsing. 2 Lower thn conker mordorto bean} tog acoso evapo inat and ost tines, Devoonec the bing and comowe the cain. 2 Crack atthe one-way vane @) end the wasting aie Aare carrot wore ing oe. 4 Gary ou te retina by evoringe ‘2¢d0r of the removed. 2. Secu som £. Carvon canine 3, One-way vee 1 wasreag ave 04-22 FUEL VAPOUR FLOW CONTROL SOLENOID VALVE ELECTRICAL CHECK ‘Checiethe clout coninuty ofthe sclaroid vale a3 described inthe paragraph -E-0o- ‘cal checks with the use cf the trouble ‘dusgnosis inetrument- ot z1e Group 00. REMOVAL AND REFITTING 1. igonneet the fu! vapour eying {ube (F}eoming fom the carbon ela 2. Disconnect the fv0!vaacurreyoing ‘ue (2) that provides the inte to the air tntake Dex 41 Disconrac the poner supey connec: tore G@)t0 te eaercis van 4) Unacrew ihe serens (6) hat secure the solonci vive 1 the body 5. Pomove te soenald vane @) 1. Fad vapor rcycting tbe Yn thn eatbon char) 2. Fug vapour eecyetng tae tote sir ina 008) 3, Power eepy comectars ‘4 Securing sew 5. Scloood wake 5. Garry out the reftting af te salen atv by reversing the onda ofthe removal. Paazgasc000000ENGINE FUEL SYSTEM TIMING AND R.P.M. SENSOR 8. Raft a new timing and r.m. senor by reversing wre ore’ of removal and tak ing cere to obsorve the ‘ollowing Fting specications: © ramove the protection fora te mow ‘sensor belo fing. 4 Fitthe news timing and rp.m. sensor ving hand pressure only. Do not use -zmaliet and do not ake the sansot “Tighten the sensor securing eorew to ‘he following tightening torqus (the ‘Seren must bo parbally mictoaneap- suleted). INSPECTION AND: ADJUSTMENT Rater to paragrapn -Eloctrical checks» of, the Group 00. ‘REPLACEMENT For whe repacement ofthe ting end Sum, reneor proceed a ous: 4 Disconnect theming and 9.00 sorisad (3) om te thing connacton 2) susie oF the le side valance pane ot ‘ angine comparman Bein tase vem O.8 kgm ‘| Postion the magnete pote of he fn Ing anc p.m. sensor In such a way ‘hats dsones rom tho phone whoot {cogged wheel] fells within the _spectind valua. H = dietance ot uming and r.pum. ean ‘sor from the phonic wheet: 06 +15 mm 4. Thing ane pom. sense oad 2. Connection 2. Remora the scree (@)and exact tha ‘ining v9.in. sonaot (4) trom ita suopont wore: Ia advisable not ioremove the apport @Q othe tring and pom, santo PRA 23800000000 04-23 December 1987ENGINE FUEL SYSTEM IGNITION AND FUEL INJECTION ELECTRONIC CONTROL UNIT (MOTRONIC) INSPECTION AND ADJUSTMENT ‘Rater tothe paragiaph - Ing and check that thay ace rat damaged ‘and that they nether present cracks nor tracas ol conosion 2. Inapoct the rubboe ringe and supports and repiace them H they presant signs of ceracke, porosity oF saing. REFITTING Carry out the reiting of he indust sdarants by reversing the order of the removal and takeng ino. account the folowing Apply R. GORI Never Sez 0° BOSCH 5.964 000,105 grote tothe thoes ol the Lambea tensor ard secure it (0 the catalytic sloncar using a sured spener. 1 Phnew goshets)berween = args af tho exnaust mento} andthe orinder hac. ©. Ussnowsottocang ate (D0 secure tha xnav mandaldsto ho cinder haa. paazse0c000000ENGINE FUEL SYSTEM 4. Postion tn exhaust tabeonte eet suppone (39 ond @) anc ensure the conta suncar Connect ths carta stnoer te Rout be to re rer wero. {Fx the fot endo of he cata slloncer othe exhaust anit fog seme gasbts @) @. Shake the xhauttublog atte 9 98 {> eat prope 1 Tightan af me sacuing Bote ane cea. 1 Coaneet the Laide sensor connec: tom inthe engine cxparnmert J Oncomplton efit, check at The rer support ns are able towing freely and ar ro under tonto, x itn te engine running, cack tal ‘hare wo no leaks of enhaut peas ftom oF the tubing and that the whole system «3 not excessively noisy, RUBBER SUPPORTS REPLACEMENT 1. Raise the vec on 2 yeu 2 Uneara tolowor bon rcovte the small plate (@) and the space 4. Unesrew he bon (2) ane remeve me sesport(1) with re reaver ite) and ne spacer. 5. Bat ascureg exhaust ret te PER 4. Forth sing supports, proceed by simp: ty releasing she suppor fom the books. Paszaaooooco00 4 Hnecenory,unerow te at and rece the rer ook Cary out tho roeting by reversing me ‘crder of tho removal making ewe that on ‘competion ofthe Rng he suppor are ake {ning freely and ae not under tension, 4 bat 2, eat nook 3. Bast ng 44 Sloncer- Rw semen LAMBDA SENSOR INSPECTION AND ADJUSTMENT Rotor to the paragraph »Elecical checker cof tha Group 00, REMOVAL AND REFITTING 1. Sat he vehicle ona nyt i 2. Wong tome ange compare, Tamora re eo person and dconnect thw conmetre (| ard(2)o ihe Ua sensor vin. 3. Working ftom beneath the vehicle, emeva the lower protection ofthe catahtc storeae @) 3. Camp chance protection 4, Remove te tama sensor @) and ‘era wing wing tabs senna, & On refiting apply B, GOR Never Soez ‘or BOSCH 5.964,060.105 grease to the (tread of the Lambe sender 6 Using sutable spanner tthe Lamb 18a genscr in ne catalysar éghtening «10 a torque of: 0.8 + 0.6 Hm (8 + 6 kgm) 1. Repeston ho wting ing «wth te rate lps atc connecting the connec: tors (3) anc 8 Rell te ceatayc siencsr @) Protection of the December 1987ENGINE FUEL SYSTEM SETTINGS AND ADJUSTMENTS SETTING OF ACCELERATOR BUTTERFLY (Flow rate) (Check. ighnes of he ncabrzor bu tary cst te How mater operating a2 tol 1. Dasonneat ne connector) tom to se ow gauge 2. Disconnect he folowing tubing rom the ar ako duct: 4 Paakcepim. oll vapour reoytng tbe ‘© Constana (dle regulation by-pass tubo 8. Leosen be dip @) ac decorrnet he ax na st (rote acolo bu tery pousing 4. Leoten Rot (7)and mora teatt iat ont(6) eal tow gage (2) 5 Unfasen ihe four epg cp excut- ing the ait ei caver (B) and remove tageter wih tne ar tow guage ‘Ago remove the filter element ©. Pier ebrnant December 1967 8, Place te butter G.2.0085 of the flow meter against the opening of tha ac ‘eleratorbuttenty housing. 7. Measure the flow of airtrough the ac- ‘calerazor bunerfly housing and check that ‘the value falls within the specified valves. ‘Accelerator buttery blow-by with buttery inthe slosed position (Soler flow meter: 240 + 260.07 W acale 8, 1 a flow rate doos not al win the pected tts, jet sre ntl the crret wus obiina 8. Ff the disconnected components by reversing the order of their comoval. 10, Garry out the check of ne ite ruon- Ing and the exhaust eriasions (ste paragraoh «Check of se cunning and 6x haut emissions (CO}). 04-28 SETTING OF ACCELERATOR BUTTERFLY SWITCH NOTE: Before proceeding tothe adjustnent of ‘he eceeiermine barterny enicarum ae maximum opening sutteh, ake sure ‘thatthe acotlerator butterty setting fe ‘correct (ove Setting of the acoslaratar butterfly ansembiys) 1 Biesannict the power euppty connae- tor from the accelerator balierty swt. 2. Placa the tet prods of @ mutimetee fcroa he terminals 2 and 19 ofthe ac- tnleraor barry sien (1) « 2. ths postion electncal contraty (0.11) should be read on the multimeter with {he acolo uttorty completely coed tnd accalator pal relasod (eat coed 4, Tuning the accelerator buttery stonty and keeping the test prods of the rrulietaron fo tral 2a 18ofthe cece butertyanten(P) an ine fevltance should be cead on ihe ‘mudlimetor bere the buterty has tumad ‘through 1° from the completery closed postion. as2900000000ENGINE FUEL SYSTEM 5. the cored vale i ol ound, cary ute uusimart ofthe secs bie tery awich iby loosening the 28cu0ng serons(@)end wining a weich ur the ‘aus Bie rad on te mutinete a dete at sop 8. @. Rexigetan tn serowe @). oti WW 7. Tum the accelerator buttery 66 fara ‘Ril go (geceterator padal prossed down) ‘and check thatthe power enrichmord con- ‘wo! classe; read a value of OD on the rmultrnster with the test progs of the ‘mulimete onthe terminals Sand 18-0 the apeoterotor butery emiich, 8. Ifthe speci values are not found, ‘oheektne neeelornor sonvtor replace the switch. MDUNMUM OPENING, 2, te running inminl errepponaing 6 secelerator tty coma pastor) 8. Punk pan. running (Coreaponctng 0 te _acederaoybutety open poation) ‘9. Roconneci the pomer sunny connec tor fo the accelerator butterty switch, ‘pae2ge900c0000 SETTING OF THE ACCELERATOR CONTROL 1. Cheek alling of the cable (Check that the accelerstor cate aloo sas in te sheathing. 2. Setting of cable backlash 8. With the scesleraior pedal up check the there isan mal play othe accelerator ‘cable on the contol lever of: 14 2 mt b._ recs pacer tbsont specie nen Sjeang spy (i) a mg te Saoten soe uman eb wen te Species ech tnd hon ‘reinsert the adjusting spring in the new omen ‘3. Check the maximum opening of the batterty waive a. With the accelerator control pedal in ‘tho ond of travol position, etieck mat the “accelerator contol cam can turn by: 142mm . Wowcocearyprocted ihe ase By acing an the ond o aval oosew 2) ue acelrstor pods) 3) 04-29 CHECK OF FUEL DELIVERY PRESSURE AND TIGHTNESS: OF SYSTEM 1. Check fal datvory pressure amy ou tno chek oporating 2s ffs: a Carve tho hc devon he and te samvering damper (3) ce @)y meara of @ Decomber 1887ENGINE FUEL SYSTEM b, Disconect the Oo ‘connects, ‘tho proseuce regulator (6) win to ari take box (7) 60 a8 10 provenl any requlartie It ho ie runing tem casing ‘regula rencingo 48. Vacuum ube (6 Pweeu rgatotor 7. Rr a Do 6 Stor ino angine and wih ihe engine running on ie check thatthe value reed fn the pressure gauge Is equal io the specited value: Fue! preseure 204.9 + 528.8 kPa O68 + a2 ben 29 £39 Kem) 4. Reconnect the tbo (6) to no a taka box (7). the engi cn i the reesure oud tal to spareximaaly 0.5 tbar and then ise agin when the 8¢- cobrater bites vawe is opened This dase ao oct? 208rh for ons loa trom the vacuum tune (5) 2, Checking te tghtneas ot th ayant 2. Kooping the prose. gouge eon- reeted ans wih he engi unig on io, tale he ue edtey downto trom the pressure roguttr (8) a8 rad sn icraie int proteuot me poss guuge up Ho bar 0 ot how the proetiso 1 oxcooo thal vat) .Wihthe presve at 4 be, chock th tno png and a of eft ceery sytem do Wo pezert fas 2 tte presen cot reach he C4 ber andro lakate UNG check Pe fer ana rw fnctorng ofthe Wel pun December 1987 TROUBLE DIAGNOSIS PROCEOURE FOR CHECKING THE TIGHTNESS OF THE FUEL DELIVERY SYSTEM “The procedure shouldbe oartied out atthe Incervals indicated in the *Vehicle malmanance schedules and to the presence af the follwing symeteme: = Smet of pateo! — Visible sigan of oak on tho titings and otras of tha systen “The posite causes may be: — Lepkages of petol rom ine fetngs and ‘he joints ol the system, Cony out the procedure deecsbed in the preceding peragraph for the «hack of the ‘uel prossurer and the ‘8. Disconnect the woe bolweon the ‘vapour lesner and the fuel tank and con- pact itto a source of compressed 2, con necting a pressure paupe between the ‘source and the tube, 1. Prensurie the system wth compos ‘od fir until @ prmssure of: 0.025 bar (2.40 kPa: @.0265 nglem?; 264 mm H,0) |e obtained and close the system. {11142 pet poBste 10 reper tie value, open, ‘he compressed air system and check the fighiress of the system (win an HC ‘analyser of 8 «Scop leak datecton. © Massie ‘ne fal In pressure in the ‘oyeiem (t must not exceed: 0.90125 ber (0.125 KPa; 0.90127 kglem>; 12.7 mim #0) ker 40 minutes, 4. Tahar 10 minutes te fall in prevoure ‘excouds the spected value, locate the take by emearing the tubing and tng. ‘wth soapy water or by using the Seco” (ak dovector. 4 Bubbles appesr in the preeance of blomtys 4. 11the 193k comea tram ine vicar of ‘he flr inketicap,coplace the cap Hist of a W ettor the veplacemant of the can the aazseqoq00000ENGINE FUEL SYSTEM ms Iiggnness of the ystom is restored, ‘igen that the con waa defective, aber ibe rapa the flr net. ‘a. Replace the part that are thought 10 be dalociva andor tighten the loose pipe vp ato, 1h. Rlapnal he steps, and ¢. 1 the check, tho Saomers of the cagnosia. ALTERNATIVE PROGEDURE «8+ Tobe cared out withthe duel tai at east 4 tal, ‘&. Disconnest the tube comnscting ihe ‘vapour leaner and the Wel tank and con edit toa source of compeessod air win ‘2 pressure gauge between the source and. ine tbe, 1, Pressuise the system blowing procen Ime tne vapour breainer Luping ut & pressure of. 0.025 bar (2.49 kPa 0.0256 gfe? 264 men 120) fe obtsi. ‘Cheek for leks of propane from th ‘sytem using an HC senaor (probe) comm ‘ected to an HC ants. ‘Repair the teak (or Vnecassary tihton ‘he pipe cts). 18. Flspeal sieps b. and c. 10 check tha ‘comacinggs of the diagnosis (CHECK OF THE TIGHTNESS OF THE AIR INTAKE SYSTEM DOWNSTREAM FROM THE AIR FLOW GAUGE ( ordor to antity any si eakage trom ‘emia air Intake system. disconnect the exile hove tat connects he constant ihe etoAlor aed he corrugated ir ine duct ‘and blow in compressed sir with a come (reseed oir gun ‘Open the accelerator bulterly vale com: plotty and eptey or smoer soapy water on. allthe joins ofthe system: the appearance ff BUDDIAE oF foam it Indicate the presence of a leak ‘Pa429800000006 CHECKING OF THE IDLE RUNNING R.P.M. (Cary outtie check of theta running with {he engio at normal running tariperature, the gear aver in natral and all he aux Mary soviees exchided. dhe p.m. 00 £80 p.m, ‘The regulation of the idle rpm is ‘automatically piloted in all states of func toning By eigane of ie constant ide ae ‘ator. ‘wan the engine runring on ile We Jun ‘ion ote ectuatr into bringthe ree... {othe nominal! pan. (600 +50 ram) by ating onthe secalortox Dune Dy pase. Aa wel controbing the ie am. he 2c ‘water also functione ag an addiont ait box end regulator fo the operation ofthe ir conditioning ester. ‘When the compressor is ectivaled. the letronic contol unit ats, through the 20- ‘uetor, to malntain automatically the pected p.m. NOTE: ‘With the Motronie system periodic ac [bwonentsof the ier.p.m. are not poe bie, Ht thie check fumianes values ‘outside the specified valves and the ‘vehicle does nol present any mectentest type touts ta probable thet there ia ault in he elneronte etreuts. tn the ‘coun It will be necomsary to resort to the ‘rouble dlagresie procedure using the ‘spectel testa, the check does not fur- alah the specified vatues {n this case iso, & willl be neconanry to replace the detective components. CHECK OF THE EXHASUT EMISSIONS (CO) WITH ENGINE ON IDLE R.P.M. The check te camtad cut with NDIR ype ‘equipmect, analysing the exheust gases ‘akon trom the exhaust bing upstream frors the catalyse. ‘The checks caved ut wih the engine at rormal running temperelure(eRer the fan fhas come on and then yone off and after havng carriod out tha check 01 the ilo p.m. (gee; Check of the idle running p.m). 04-34 ‘The following preliminary checks should 09 be cared out: = Check the level of te engine oA. = Clean the afr titer caridge. — Check the etfeiency of the igriion spten, — Gheok the igntion ting. ‘The CO value should fallwithin the foo tng values: w00 <02 Note: Wm the Motronic MLA.1 systam in this configuration, period adjusimanta af the CO emfesione wh lle p.m. are rot posaibie. H the cheek turiahes values which fal ‘outake the spectied ate and the waht cle dose not present taulta of a macha- clcet type, it 1a probable thet there ia ‘ute ia the electronic circuits, in the ‘case wil be neceueary to tweortto the ‘rouble diagnose procedure using the ‘special eet na check dows not Fur- ‘ah the apeciied values In this case ‘lea, it wil be necessary 10 replace the elective components, December 1987ENGINE FUEL SYSTEM TECHNICAL DATA AND SPECIFICATIONS TECHNICAL DATA FUEL DELIVERY AND INJECTION SYSTEM COMPONENTS Pat runber ALFA ROMEO Main hol pune | ‘reasoncaiqo | osc oseocsama = Rated vohage: 12.¥ = Operating rst: 7 9 18 = Opsratng pressure: <3.0 bar Maximum santa tnt torpor: 00°C Mexinun acrt apereice In tperante Between pup ane tank: <7C. = Oporanag tomperure: 30" + 480°C = ded eoivony emperature 20°C, lwo 12 V,prseune 8.0 ha: 100 Uh (rine) — Curae ineut (ernerature 20°C. terion 12 V. pressure 3.9 bef: 85 A ‘Avatars fuel pure 11541 9200000 | GENERAL MOTORS e441 = Paid ohage: 735 20.08 V = Rave caine: 2110 0h a 180 bar) Bovina 2a0mter (*) Oa me + aereer (*) (0) Prveere measure ot 2ump ol Fu presore raguior teseoazcan00 | 2090H 9280.;¢0219 Ramevwing dameae versooeseooe | BOSCH 0.280.161 050 = Opeming peers: 17 ~ Sober Teanpeatare ange on meuning: 20° = + 100°C lect tue injartors tose 7102000 | BOSCH 0z80.150.702 Componert we ‘ArHow pace Tesssviorac | @0SGu oxen zz 202 Conenart ve repulnion acuator vessetioirar | 60s0Wozensaanre = Raed vaage: 127 = Operating taatens 7 16 = Tempessure range on mounting: —30" + + 120°C = Rao amoage: 037 A — Aiba cgaety wth 8p £0 ber, 2994 = Conve agweney? 100 2 ieetion and Injection slecienis ventral unt efron) wezaitioanea | BORCH ozs 20010 EEngioe ceoant temparsture aensor wsa211ci900 | BOSCH azaasaae28 = Fated rcloance st 20°C° 228 + 272 Rated vlinga: suely fom conta ni = Terrpera range ot muuning: —30" = + 190°C Iesocthe inpuine gonersar (ng ne rm. anreee) ww5aztior00 | BOSCH OZ6r.210.008 ‘Avorn varity ewich vesseinee707 | Bosc 0280120416 Len santo verzarioen | BOSCH O2s8.008.061 ye2261.01600 1) | BOSCH 0258.000.006 () 4) Altomative FUEL TANK Tata caoaciy @ December 1987 04-32 PA«23800000000ENGINE FUEL SYSTEM CHECKS AND ADJUSTMENTS FUEL PRESSURE CHECK 4. Poim at when preset Is manure 2. vaciten tuba fr the pressure opie ‘cheek nwa ores ob ame te ptt F) wine ude 2) domed at ih sce tenega ero ACCELERATOR CONTROL CHECK Acco eer cate Decl (uth wccelerwor Dedel lee) Creeery Pray in acelrat covct cam wih accelraot pedal assed cht daa) Gynt 2mm Paszaeo0000000 04-33 Decerntiey 1987ENGINE FUEL SYSTEM SETTING OF ACCELERATOR BUTTERFLY ASSEMBLY (Flow rate) coeee Youes, ‘iow ty ar wer aezeeraor In the ose postion (Solr Flow reer) Tne racing 21 Ue values on tm Sea Ye miter mst e evi’ out wp he ah to te ‘Beal N peng of te secon aucerty neue 240 + 260 ENGINE IDLE R.P.M. AND EXHAUST CO % Vales Engine Sern tang man er 08 L60eRm. (2 of exes emeaion a le PR, SETTING OF ACCELERATOR BUTTERFLY SWITCH 2. Taxol fr the le cpm. check corazponcitg 6 tho postin Ae aookrtor bry eoged) 18. Terminal for te chock of he peak 1. ecroapeneing ‘me poston Be accor hamerty comet’ Ope) Terie | Towra Creek 2-0 a- ‘Roestaree between te terion wh the eccetaratorpecal released (accatracr user completely saad) oa = Recetorce bewoan the tarminai wth the eccaturar pal prensed faccoleratercoreletly open ect an oo ange 80) Docomber 1987 04-34 adesa0ca00000ENGINE FUEL SYSTEM GENERAL SPECIFICATIONS FLUIDS AND LUBRICANTS: ‘Application Type Mane ay ‘Aeeslerior pec opin (on rubber euppors) ‘QAEASE TSECO Mdykote Longier m2 = ‘Sta No, 967"-68631 ‘Lambe een threes GREASE [BOSCH 5,904.080.105 = GORI Never Seec Engine woaperaiur sonar ‘Sd No, 9677-69850, FUEL Unleaded petrol with Octane Number (R Mj; 285 ALON, Paszie00090000 04-35 December 1987ENGINE FUEL SYSTEM SPECIAL SERVICE TOOLS awonitication umber mae Asonr ‘Spanner forthe suxiary fue! pump securing ting nut e1.0192 Universal trouble dlagnosis instrument 01.0598 Irvortase 2.0055 Buller los measuring accoleraior buttery housing flow rate ©9009 Imtertgoa- universal trouble dbagnosie Inatrument con- necting bead December 1987 04-36 ‘Pade9e00000000ENGINE IGNITION, STARTER, CHARGING BATTERY ELECTRICAL SYSTEM Ignition and injection diagram ‘Starting diagram Charging diagram Technical data and specifications STARTING Technical data and specifications Fault finding and corrective Dismantiing operations Checks and adjustments, -{*) IGNITION Roassembyy . « Dismantiing o Bench testing . 0 Checks and adjustments ° Technical data and specifications nnn (*) Reassambly o Fault finding and corrective Bench testing oO operations Fitting of ignition distributor or vehicle ... (+) () SEE GROUP 00 (@) SEE WORKSHOP MANUAL FOR PETROL ENGINE — GROUP 05 PAAZ3B00000000 05-1 December 1987ENGINE IGNITION, STARTER, CHARGING ATTENTION: ‘©. Do not touch the negathe and postive poles of the battery simultaneously with bare hand, bb, When starting the engine from an ‘auailary battery using Jump lends, the Inport must not exceed 12 V. CHECKS AND ADJUSTMENTS aL Cheek ina were are 0 signs of okays of eld andor cimeks on the oxter- ‘nal casing of the batery . Gheok thatthe top of the Darory ‘elean and that the levine are free “rom oxidation. 6c. Make aure thet the terminals are well fightoned 9 as lo guarantee good contact. CLEANING 4. Clean tne upper part ofthe bemery, the oles and the torminale with a sohtion of ‘water and bicarbonate of sod. i. Balore fiting tho terminals, apply tho specie type cl grease (REINACH E10 Tag) TENSION TEST 4. Check ha tension across the terminals, of the battory periodically, to 600 tat ‘coincides with the exact rating ofthe torr fon regulator. 2. Thevalue ofthe tension ecross the tar- rminale of the batiary should be 13.7 + 44.7 V with the engine running at 3,000 pam. 3. Chak that ner the min mum vai, with the engine wermed up und the au ary devices fat least tho hondiampe! on, ‘oF tha maxiour value withthe engine cold and the ausilary daviogs Of, ¢ aqual tote speciied values. 44. fe values obtained do not fall within the spacitod limits, i wil be naceesary 10 check the components of the eleevical system BATTERY CHARGE CHECK + Bo not use the battery for at last 2 hours as then measure the tansion wth December 1967 BATTERY ‘Wie crown open and he negative terminal disconnected fo prevert the dispersion of current into the electra! system. 2. tthe battery isnot property charped. (lat), the value wil be loss than 12.80 V. 8, The condtion of charge ofthe batery ‘can be estimated approximately from the following table: WARMING: ‘Tha ure of» ight voltmeter be ecvisad 90 i ap hla permits rascinga down 101/900 of a ¥ (en the zeate from 0 to 20 V) and ts chavacteriond by lower ab- sorption. CHARGING 1. Recharging must be effecied with the Ingato a current Gin Ab of approximately 120 of the canaeny of the battery fin Ah) corresponding to approximately 1/400 of the value indioated on the rating plate. 2. Tha recharging is cornplota when the vaslation in he value of ne eamery fension Js ss than 9.06 ¥ for two consecuive readings takan wth an iniarval of 1 hour Laetween them. ‘The curation of the recharging is dcacty ‘ropartonal 1 the condition of charge of sh battery. ‘WARMING: ‘Check that the taraperature of the elec: ‘rolyte during recharging does act ox- ‘cead 50°C and thal the tenaten does 90% exceed 16.5 ¥. 9% Ater wher, check the Deter fn ‘lon agalo ater an terval of 2 hours 05-2 waren: Seated tatters are noted with 109 ing up caps. Some af these ar fited {th ae which should ony be remows ‘dn case of emergency 10 restore the level of the electrolyte by topping up ‘wth distiod watur whan the wroog act- {ing of the teneion eegutor(exrensive ‘on axcosaive GENRAL SAFETY MEASURES 1. Lead batteries generate {especially uring rochargingy an expiosiva mints of hydlogen and oxygen. Ite merotore incieponsicta to take safety measures in ordor fo guard against da- mage to persons and to the vehicle. 2 The rocharging zone must be odo quately ventilated s0 0s 10 facials the persion ofthe gee when is release Ing recharging. (tthe roharging is carredoutinan encoe- ed environment eticial ventilation must ie proved. 3. The lanler ofthe acid must be car. ied ut wie he greatest care vrzang o> teolve clothing (rubber gloves are acid ‘eisian apron) for he protection of othe. ‘and person. Preietive goggtes must also be worn, 4. When mixing acid mtn water or ox: ample forthe dlulon of an exceealely 607 ented sed) the Geld must be poured slomty into the water and not vce versa, 5. Tho use of metalic funnole anc con talnars is not eecommendad, Pertecty claen glass or plastic funni and ‘onlainers ae recommended. 6. Tha use of a naxed Oana (niches oF fgarete Uighlers) is absolutely forbidden, far the checking of banedas, pn423000000000ENGINE IGNITION, STARTER, CHARGING a TECHNICAL DATA AND SPECIFICATIONS ‘TECHNICAL DATA ‘Components oer “ater omen Gon wh coe | aaa " wogine we cheteiwton motule pen Uae meronscence | 195.2808.051.20. 495.4006. 10800 Bosch 2060 ‘see Longe oan 237201 008 pares ; srecccr.c0008 —— sweseosomce x00 BOSCH 0.001 108.011 110.10.06,060.12 soscH esa ete PARE HONE aamamoss assnise | we.asanors01 a oan sopxnas. iets ch Teeeasmem sc Chimon Re8Te anett 1) Ateatve Dla round oh tnd hes 6} Owerasa movie on he og opt Cnt (0 er wecvone erin opacrreonoied Battery iran 1 2 Capechy 10) Gacy cron WW a 1a: aon ee a) paa2se00n00000 05-3ENGINE IGNITION, STARTER, CHARGING GENERAL PRESCRIPTIONS Fluids and lubricants ‘opieaton ype Name ow Spare pug trees on, TSECO weyers A «Wor, aac ave = TIGHTENING TORQUES ‘eit ot moseanemert| een New cs Spar poe wu 25-35 December 1987 05-4 Paazs60e0oc008ENGINE COOLING SYSTEM CONTENTS COOLING SYSTEM .. General description ‘Test tightness of cooling system .. RADIATOR 07.2 ‘THERMOSTAT 073 Removal 07-4 Inspection and adjustment O76 Refitting .. 075 ‘TECHNICAL DATA AND 07-5 SPECIFICATIONS Retiting -. Tightness test .... 075, Checks and adjustments .. ELECTRIC FAN THERMAL CONTACT General specifications _. CONTROL iC Tightening torques Check -. FAULT FINDING AND CORRECTIVE PRESSURISED FILLER OPERATIONS Tightness test WATER PUMP .. Romoval .. Inspection and adjustment Reliting .. (o ) © oO (*) SEE WORKSHOP MANUAL FOR PETROL ENGINES — GR. 07 ‘Pa@z9800000000 O71 December 1987ENGINE COOLING SYSTEM COOLING SYSTEM December 1987 On? FA&29800009000ENGINE COOLING SYSTEM GENERAL DESCRIPTION 1 coating aye ofthe ead po ‘costo tected by moana ctacen- tual pp dren Fo thee shy ears ofa Bok Thorcatnof tho water puma (@)oreles ase proesure In the role cut ‘ich eran te conart, coming hom theirs uh te hades tbe 2) or Yom te heater citor (nen tne To THE RADIATOR Agar tor the nal alr eoling dt (rong, sr 2088 1 teeter enim evtehon eo By ne ne peleonact(2)eronover coda be lowe po he radar el reaches “rere ‘Paaeganoc00000 Ina cenvestan (ls opan (ean of coOlnt n te howieaciatr). ‘Atnarmostat (@)le mounted a the ai of tho hander tube CS). The funtion oF 8 isto enmur that he ange reaches nor ‘nat ening tomperatue in he enriest onable ean subsequent fo matin the engine terspartuewttin tw opti ‘vallies tor engine functioning, “Tho vwrmoctat valve remaine cosa, deviating the coolant directly towards the THERMOSTAT VALVE CLOSED ‘THERMOSTAT VALVE OPEN The crea of cota I be tater maori eraguananyosee ese tons Abe Roan ere tose 07-3 ‘pump (G). until the engine reaches @ lempacauce of 81+ 95°C ‘Atniger temperatures tne apening othe ‘atv permis the passage of the coolant tome reaatoe (1) FROM THE HEADER TUBE, December 1987ENGINE COOLING SYSTEM COOLING SYSTEM Sfp TIGHTNESS TEST ae AN eee cout \ ‘ioe tank 1S Screw ie iarumant (2) oto the ie tet ot the lle tankto tet ho ighneae of the cooknt ston. ©. Pressure he agra anc check th th value indicat on the testing na ment caine at ho spaced velo, the pressure doesnot erin cont tent me specie! vibe, check cexsemtorlake honthe hoses octromthe radiator 1 recassry posed tothe removal anain- spertion an desced inthe paragraph srodston. Pressure tor cooling system test 107.3 kPa (1.08 bar: 1.1 kg?) Ke December 1087 O74 1pne25800000000ENGINE COOLING SYSTEM | Hewe forthe dium of woken fe pump £2 Hea foro cedary of exolara tbe ‘adator 3, Racloebrethar abe REMOVAL 1. connec ne oat. 2 Detach te hove1) wom trator tran ofthe ola acocttn acon wee WARNING: ‘To avold scolds, take care net to drain fff the coolant when the engine Is hot. 3. Delaen tne none (2) anaso mune (3) from the actor. 4. Disoonneet tte lecic fan power ‘supply isads connector (4) and the con- stor (5) nom a ermal contact (6) 5. Uresrew the stew CF) scan Te ‘ator to tha boay, somove he raditcr rom be oagre compartment and x tact suppor pac (8) 6. F necessary ure the soew () ‘and ere tan ‘Paazesoco0000e RADIATOR “4. oct fan pow supply ant 5 Mermal conet aemects. 8, Thar concteet, 8, Eheas pat 10. Scfew tor seaving nf ct tan 1 11. Raise REFITTING 1. Proceed tome rotting ofthe radiator byreversing theorder of removal ad then ‘car our the roiling wit coolant quid by operating 2s follows: Remove the cap of the filer tank and ‘erry out the reliling of the ayatern wh the specited costa. Fefiting of the cooling wystem engeun —“C| | Corcenrated samireeat 1] a2 | 266 Bid No. saan gonee ee 1] 6a | 336 Panay 9 ws soutveeze ste |o Se Mn. gem 40058, WARRING: Progucta are dumaging to paintwork. ‘Avoid contact with painted parts, O75 2 Startthe engine, runt ta nae tuo rng temporature 20 8 alee thecooian tociculate trough the system and switeh the heater on in order ta open the heaton radiator lap. 3. With the engre cold, cary outthe tap ing up of fhe Bystom upto thelevel atthe apimum reierence mark i tefl tank TIGHTNESS TEST 1. lemova the radiator tram the vahils (269:

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