Professional Documents
Culture Documents
33 Workshop Manual
33 Workshop Manual
CONTENTS
May 1983
COMPLETE CAR
GENERAL VIEWS
Wheelbase P m m ( i n ) 2 4 5 5 (96.651
Front Ca 1392 (54.8) -... IT
Track m m (in) .:
Rear CP 1359 (53.5)
May 1 9 8 3
COMPLETE CAR
MODEL VARIATION
(Except Switzerland, Sweden, Australia)
Body
Model 1200
I
5 -door saloon
1350
1500
WADRIFOGLIO
5 - door saloon
1500
-r
Drive Left qight Left Right Left Right Left Right
- on certification
- on identification
905 A - 905 Al 905 A2 905 A2
label
Type approval No.
- on intermediate
905 A00 905 Al 0 906 A20 905A20
bulkhead label
305.02 305.04
Type and serial No. from from
000.000.1 000.000.1
5 ‘/2J x 13 CH 5 ‘/ml x 13 CH
IDENTIFICATION DATA
VEHICLE IDENTIFICATION (2) Serial number: progressively used as vehicle service identification
(AND SERVICE) DATA assigned by Production. number. This number consists of five
(3) “Type approval number”: not figure numbers, divided as follows:
VEHICLE IDENTIFICATION for service identification use; for 4a) Basic type number: it is assigned
CODES service purposes, use the “type to all vehicles having a common
number” which iS stamped on design concept (Ex.: 905: Saloon).
A) Chassis numbering identification label along with the 4b) Type variant number: it identi-
“type approval number”. fies, within the basic type, those
z A I? 9 0 5 A00 0 5 . 0 0 2 . 4 5 8 The following is an example of such vehicles that differ because of some
(I) (3) (2) label. variant that alters their features (Ex.:
905.02 5-door Saloon).
(1) Manufacturer identification let-
ters. (4) Identification number: to be
B) Engine numbering
It consists of two sets of figures,
ALFA ROMEO AUTO SPA
II I II
namely:
305.00 00045 12
(I) (2)
PANTOGRAPH JACK
WARNING:
a. Never get under the vehicle
while it is supported only by the
iack. Always use safety stands to
support frame when you have to
work under the vehicle.
*,-+, - ?’ b. Place wheel chocks at both front
and back of the wheels diagonal-
ly opposite the jack’s position.
TOWING
WARNING:
Closely follow Motor Vehicle Fiegu- d. Set ignition key to “GAR” and
a. When raising vehicle with garage
lations r e g a r d i n g v e h i c l e t o w i n g . do not withdraw it from switch;
jack, be sure to support it with
otherwise antitheft device could
safety stands.
become engaged.
b. When jacking up the rear (front)
e. Release parking brake and set
of the vehicle, place chocks in CAUTION: gearshaft lever to “neutral” be-
front (in back) of the front
Use proper towing equipment to fore starting to tow the vehicle.
(rear) wheels. avoid possible damage to the f. Do not apply lateral forces to
vehicle. towing hook. Keep towing bar
Before towing, make sure that or similar devices always in
front and rear axes as well as line with the vehicle.
CAUTION:
steering system are in good g. Remember that when vehicle is
When raising the vehicle, always
working condition; contrarywise being towed, there is no vacuum
place a wooden block under vehicle’s
use a dolly. in servobrake; consequently,
lifting points.
If vehicle must be towed with its when braking, greater pressure
Position garage jack and safety stands‘
rear wheels raised, front wheels must be applied onto brake
in a safe manner under the points
m u s t b e p l a c e d o n a towing pedal.
shown in the figure.
dolly.
MAINTENANCE SCHEDULE
(Except Switzerland, Sweden, Australia)
i= E E
- - - - -
X X X X X X X X X
- - - - - - -
X X X X X X X X X X
- - - - - - - - -
X X X X X X X X X
- - - - -
X X X X X X X X
- - - - - - - -
X X X X X X
- - - - - -
a= X X X X X
- - - -
0 ::
0 0
P 7
ri
7
5
6 $
00-11 M a y 1983
COMPLETE CAR
X X X X
X X
X X X X
-
X X X X
X X X X
X X X X X
0 0 0
7 ‘r
i IO
8 b-l
MAINTENANCE SCHEDULE
(Swiss version)
Lu LL! tu tu u w w Lu Lu u w ul lu
N
- 5 5 E E
- - - - - - - - - - - -
X X X X X X X X X X X X X x
- - - - - - - - - - - - - -
X X X X X X X X X X X X X X
X X X X X X X X X X X X X X
X X X X X X X X X X X X X X
- - - - - - - - - -
X X X X X X X X X X X X X x
x X X X X X X X X X
- - - -
X X X x X X X
COMPLETE CAR
(Swiss version)
2
0
5
K
w
8
z”
<
T
MAINTENANCE SCHEDULE
lSweden version)
- - -
X X X X X X X x
- - -
X X X X X X X X X X X X
- - - -
X X X X X X X X
- - -
X X X X X X X X
- - - -
X X X X X X X X X X
- - - -
X X X X X X
- -
0 0 R
7 v
P 8 L-4
s a 6
MAINTENANCE SCHEDULE
(Australia version)
X X X X X X X X
- - - - - -
X X
- - - - - -
X X X X X X X X
- - - - - -
X X
- - - - - -
X X X X X X X
- - - - - -
X X
- - - - -
X X X X X X X X
- - - - - -
x X
- - - - - -
x X X X X X X X
- - - - - -
X X
- - - - - -
X X X X
- - - - - -
+G
g
_m
0
:
E
‘G
g
a
._
VI
5
Y
E
6
F
.c1
t 2
E I
2 P
-0
k :
c? z
Pm 5
G
d m
FL F
.-
E
% ‘Z
b 6
z ‘F
e ‘E
.P
2 Ai
0 D
i; 5
- -
N W N
May 1983
COMPLETE CAR
- -
::
c
.P
Y
.-&
.-I
P
!A
-
*
k
z
*
n
*
E
wa
May 1983
COMPLETE CAR
i
GEARBOX-DIFFERENTIAL OIL
- IO”2 (14°F)
2.3 + 2.4 (5.1 + 5.3) -
1.8 (0.40)
CONCENTRATE ANTI FREEZE QUANTITY
DEPENDING ON TEMPERATURE
E - 2 0 ° C (-4’F)
- 35°C (-31°F)
(4’F)
- 2.6 (0.57)
3.65 (0.80)
ENGINE MAINTENANCE
BASIC MECHANICAL
SYSTEM
1 Bolt 3 Screw
2 Bolt
CHECKING, REPLACING
AND ADJUSTING DRIVE
BELTS
6. Fit oil filler cap back and start Refill radiator through relevant filler
the engine letting it idle for about 2 according to following instructions:
minutes.
7. Now check following items for 1. Refill the system till max. level
any oil leaks: filter, pan, seal rings, mark in expansion reservoir is
oil pressure transmitter, gaskets of reached.
cylinder block and cylider head 2. Start the engine and warm it up
covers, and cylinder head gaskets. If to normal running temperature thus
necessary, tighten or replace items allowing the thermostat to open and
that are not oil tight. to expel any air that was left over in
8. Turn the engine off and wait a 1 Coolant drain plugs
the system.
few minutes. 3. When engine is cold, top up
9. Take out dipstick and clean it; 3. Fill cooling system with recom- cooling system till max. level mark in
fit dipstick back, take it out again mended anti-incrustator following expansion reservoir is reached.
and check oil level making sure it relevant instructions for use. 4. Fit filler cap back and.tighten it.
reaches the MAX reference mark.
Recommended anti-incrustator:
NALCO 1006
INTERPROIND Jal Auto Checking the system’
Stand. No. 3681-69955 1. Check coolant level in radiator
making sure it is within MAX and
4. Remove again drain plugs from MIN level marks.
cylinder block bottom and let 2. Check hoses and unions for leaks
anti-incrutiator drain completely. making sure they are not in any way
5. Thoroughly flush the system damaged.
with running water. 3. Check filler cap making sure
6. Fit drain plugs back to cylinder relevant spring, gasket and valves are
block and fill the radiator. in good working condition.
4. Test the electric fan as follows:
(1) Disconnect thermostat wires and
System refill short-circuit them.
(2) Turn ignition key and check if
After having drained the cooling electric fan-starts up.
system, refill it with the kind and 5. Check radiator as per instruc-
CAUTION: quantity of coolant as shown in tions contained in Group 07 - Radia-
When checking oil level, park the car the following chart. tor.
on a level surFace. 6. If top-up requires an abnormally
large amount of coolant, check entire
cooling system for leaks and elimi-
Sunimertime
nate them.
Drinkable water I 7.3
COOLING SYSTEM (Imp Gal ) (1.61)
If picked up values are not within then fit them in relevant seat tighten-
ing them according to specified
specified ones, look for the trouble’s
torque.
cause in poor tightness of the valves
CHECKING IGNITION
WIRING
Fixed advance
8% 1”
Max. advance
36”+ 1”
3. Start the workshop’s gas ex- Sweden, Australia) idling speed is medium rpm, the vapors going up the
hauster. reached. oil filler go through the flame trap
4. Srart the engine and warm it up (5) Act on mixture metering located in the hose @ connecting
to normal running temperature. screw @ till the smoothest possible oil filler to air cleaner; from here
5. Now check if engine rpm is engine running is obtained, while then they go through the min. rpm
within specified value. keeping CO% within the prescribed blow-by hose @ and, downstream
valves. from throttle valve, are distributed
Idle-rpm onto intake manifold @ _
900 + 1000 r.p.m. CO% Since when the accelerator ‘is fully
850 + 950 r.p.m. ( l ) < 3.5% total depressed the vacuum generated by
0 . 7 + 2 . 4 % (*) the engine is not sufficient to com-
pletely suck exhaust gases solely
(“1 (for Switzerland, Sweden,
(“) for Switzerland, Sweden, Aus- through the min. rpm hose, gases are
Australia)
also conveyed inside air cleaner,
tralia
upstream from carburetor, by means
6. If not within specified value,
(6) Fit back into place mixture of the max. rpm blow-by hose 0.
adjust idle-r-pm just by turning
relevant idle-adjusting screw @ metering and throttle valve screw
seals, CHECKING HOSES AND
which makes it possible to change
(7) ff further optimizing of idle-rpm UNIONS
rpm without changing CO percentage
(Carbon monoxide). is desired, just act on.relevant idling 1. Inspect hoses and unions to
.. 7. Verify that CO percentage adjusting screw 0. make sure they are not in any way
picked up by tester corresponds to damaged and that are no leaks.
specified value and that engine 2. Disconnect all hoses and clean
runs smoothly. them blowing a jet of compressed air
through them.
Ajlowed CO % Replace any damaged hose.
< 3.5 % total 3. Remove flame trap located in
main blow-by hose near the oil filler;
If not within specified value or in wash it with suitable cleaner, blow it
case of engine tune up after engine with compressed air and, then fit
overhauling or after having cleaned it into place.
or replaced the carburetor, an
adjustment involving also mixture
metering screw @) and throttle
valve screw @) is required. In this
instance, proceed as follows:
(1) Remove seals from mixture
metering screw 0 and from throt-
tle valve screw 0.
(2) Tighten idling screw @ all the 1 Idling mixture metering screw
2 Idling adjusting screw
way.
3 Throttle valve adjusting screw
( 3 ) N o w act on throttle valve
screw 0 3 and on mixture metering
screw @ till following conditions are
present:
EMISSION CONTROL
Rpm
850
SYSTEM
Air cleaner
8 0 0 (*) Recycling of exhaust gas and oil Max. rpm blow-by hose
C O % vapors, generating in the cylinder Main blow-by hose
block and then burned in the cylin- Oil filter
0.5 + 1% total
Min. rpm blow-by hose
ders, is achieved through a series of
Carburetor
blow-by hoses. Intake manifold
(“) for Switzerland, Sweden, At any rpm, the vacuum created in Cvlinder block
Australia the carburetor is sufficient to convey
gas and vapors into intake duct and
(4) Loosen idling adjusting from here into cylinders for final
screw @ till a 900 + 1000 rpm combustion.
(850 + 950 rpm for Switzerland, When engine is idling or running at
00-3 1 May 1 9 8 3
COMPLETE CAR /
CANNOT CRANK ENGINE l Dead battery Recharge and check recharge system
OR SLOW CRANKING
l Faulty battery Replace
In most cases the trouble lies either in the ignition system or in the fuel system.
(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 part
and let the starter run.
CAUTION
Above test must be performed with uttermost care.
Spark is good:
Ignition system is out of order l Low or no current in primary Check primary circuit for loose or
circuit disconnected terminals
l Compression leaks from valve Remove cylinder head and lap valves
seats
Other Petrol used has low octane rating Replace with petrol having specified
octane rating
m Knocking due to improper petrol Use petrol having specified octane rating
. Preignition (due to wrong type Replace with specified type spark plugs
spark plugs)
Mechanical knocking
Crankshaft bearings knocking l Worn crankshaft bearings Replace bearings and either grind or
replace crankshaft. Check lubrication
This strong dull noise increases as system
engine is accelerated
Connecting rod bearings l Worn connecting rod bearings Same as for above crankshaft bearings
knocking
This is a slightly higher-pitched
noise than the one caused by knock-
ing of crankshaft bearings and it
also increases as engine is acceler-
ated
ABNORMAL COMBUSTION
(backfire, self-ignition,
detonations)
l Worn or damaged cylinder block Replace gaskets and oil seal rings
and cylinder head gaskets and oil
seal rings
Excessive oil consumption l Worn cylinders and pistons Grind cylinders and replace pistons
l Worn valve guides and grommets Replace valve guides and grommets
OTHER PROBLEMS
Reduced oil pressure l Improper oil grade Replace with specified oil type
ASSEMBLY
DRIVE SHAFT
CHECKING DRIVE SHAFT
ASSEMBLY
Visually check drive shaft assembly
for wear or deformation of its
various components, making sure
protecting boots are not in any way
damaged or show grease leakage.
If necessary, replace damaged or
worn parts.
1 Clutch pump
2 Clutchcontrol cylinder FRONT AXLE AND
FRONT SUSPENSION
GEARBOX- CHECKING FRONT AXLE
DIFFERENTIAL AND SUSPENSION
CHECKING 2. Let oil drain completely (wait at 1. Block rear wheels with chocks
and raise front of vehicle fitting jack
GEARBOX-D1 FFERENTIAL least 15 minutes); clean drain
plug @ and tighten it. to proper lifting points (Refer to:
OIL LEVEL
3 . R e f i l l o i l p a n t h r o u g h SUPPIY “Lifting Points and Towing”).
Check oil level making sure it reaches 2. Check front suspension parts for
hole 0 with specified oil type and
filler lower edge; clean relevant cap wear or damage.
quantity. Refer to “LUBRICANTS”
and tighten it. Also check all bolts for proper
chart for recommended oil type.
tightening; refer to: Group 21 -
REPLACING Tightening Torques - for relevant
GEARBOX-DIFFERENTIAL Gearbox-Differential casing Oil tightening torques.
OIL wpacity Replace worn parts according to
1. While engine is warm, remove oil 2.3 + 2.4 kg (5.07 + 5.29 lb) relevant procedures described in
pan drain @ and supply 0 plugs. G r o u p 2 1 Front Suspension.
ADJUSTING WHEEL
BEARING PRELOAD
After replacement or disassembly of
bearings, carry out adjustment oper-
ating as follows.
1 Probe
2 Height check tool
3 Rule
1 Magnetic adapter
2 Tool for suspension height check
3 Rule ’
2. Camber angle
0 = 2015’+ 30’
a= O”1 2 5 ’
CHANGING BRAKE FLUID
1. Connect a hose to wheel
/+ I- _ bleeders and let brake fluid drain
a 1 a into a suitable container (refer
to: Group 22).
-4&
’I I CAUTION:
Be extremely careful not to drop any
of the brake fluid on painted s’urfaces
since it is highly corrosive.
Cylinder compression
00-45 May 1 9 8 3
COMPLETE CAR
Vehicle static loading arrangement (1) N kg, lb) A+6 =490 -1-245 =735 (50+25 =75)
(110 +55 =165)
Fronr wheel semi toc-out (21 (3) mm (in) L = (1/2 M +2 * 0.5) (l/Z M +0.08 *O.OZ)
(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) 9 (0.354)
Pad min. thickness m m (in) 7 (0.276)
Drum brake
Lining min. thickness m m (in) 0.5 (0.019)
Max drum inner diameter m m (in) 229.6 (9.04)
Parking brake
Lever stroke, when applying a pulling force of
= 98 N Il0 k g ) (22 lb) 2 notches
REMOVAL
Drive u n i t s u p p o r t s
DETAIL A
040 c4s
(4.1 + 5
29.6 f 36.2)
DETAIL 6
DETAIL C
(kg.m
ftlb)
E n g i n e c o m p a r t m e n t - Plplng r e l e a s e
1 Fuel pipe
2 Clutch oil supply pipe
3 Expansion tank plug
4 Air bleeder into crankcase
5 Sleeve for water return from radiator
6 Sleeve for water delivery to radiator
7 Servobrake vacuum pipe
6 Hot water to heater supply pipe
9 Heater warer return pipe
During engine removal from car, it is 6. With reference to the figure on after draining.
necessary to remove engine and page 01-3 disconnect the following 9. Depending on what is to be
gearbox - differential as single electric cables, preferably as indi- done, drain the oil from the oil sump
unit. cated : - by removing the plug @ and, if
Put the vehicle on the auto lift and . earth cable @I, from the necessary, drain the oil from the
engage first gear. engine rear cover gearbox by removing the drain
. high voltage cable @, from the plug 0. Screw the plugs again after
coil draining.
Great care is required when dealing . low voltage and tachometer
~~tY~~~~~ngine~ j cables @ from coil
. alternator and warning light
1. Operating from passenger com- supply cable @, from the
partment inside withdraw knob of alternator
gearbox lever, then remove the l water temperature thermal con-
two lever bellows. tact cable @, from the thermal
2. Remove the hood (refer to: contact on the right hand head
Group 56 - Hoods). . electric fan supply cable 0 ,
3. Working from inside the engine from the fan
compartment, disconnect the battery . windshield and rear window
earth cab le. washers pump cables @ from
4. Disassemble the air filter as the pump
follo\lvs: l starter motor supply I@ and
(1) Disconnect the corrugated air energization @ cables from
intake pipes from the air filter by the starter motor
taking off the fixing clamps. . oil pressure switch cable @ , 1 Gearbox oil drain plug
(2) Disconnect the blow-by pipes. from manual contact on the rear 2 Engine oil drain plug
1
2
3
Bracket
screw
Screw
4
5
6
Spring
Retaining ring
Adjuster
remove the right hand drain plug 3
INSTALLATION
CAUTION: 3. Remove the lifter and unloose illustration put the side rod @ in
Drive unit assembly must be per- the lower bolt @ securing the the support @ on the right side
formed in such a way that the gearbox to the rear support. rail @ then tighten, first,
gearbox rear support and the engine 4. Put the rod @ in the rear screw @, second, screw 0.
front support are not respectively support 0, positioning it on its
upwards a n d l o n g i t u d i n a l l y pre- body clamping points and screw up
loaded. 0.
the screws 5
5. Screw up the drive shafts to
Referring to preceding illustration, differential shafts joint screws in oil
follow as indicated. with the prescribed torque.
1. Raise the drive unit with the
column lifter used for disassembly
0: Tightening torque
until the centre support axis @ is at
Drive shafts to differential
about the halfway point of the
shafts connection screws
body slot and tighten the relevant
33 f 36 N-m
bolt-@, -+’
(3.4 + 3.7 k g - m
Connect the left strut to the engine
24.58 + 26.75 ft-lb)
support cross member and fasten the
cross member in position to the body
with the screws @.
6. Assemble the exhaust pipe 0.
1 Right cylinder 4 Side rod
2. Fasten the front support @ in 7. Clamp the lower bolt @ secur- head 5 Screw
position to the cross member tighten- ing the rear support to the gearbox. 2 Right side rail 6 Screw
ing the correct screws. 8. With reference to the following 3 Support
SEPARATION ASSEMBLY
With the drive unit on the rotatory 2. Remove the lower cover @ 1. Lubricate the direct drive shaft
stand fitted with suitable supporting protecting the engine flywheel after working seat with the prescribed
equipment, separate the engine unit disassembling the screws and wash- grease (Grease Molykote paste G).
from the gearbox unit for the pur-
pose of replacement or overhaul of
0
ers 2 securing the lower cover to 2. Perform assembly operations in
the engine rear cover and to the the reverse order to the separation,
the two units and of the clutch, as gearbox. tightening connecting nuts and bolts
follows: 3. Unscrew and remove the remain- to the prescribed torque.
1. Unscrew and take off the nuts ing nuts and washers @ and com-
and washers @ from the starter plete the separation of the two units. 0: Tightening torque
motor 0 securing screws 0 Nuts and bolts connecting the
and remove the starter motor from Withdraw the thrust beating from its two units
the engine unit. support on the gearbox so as not to 39 + 48 N-m
(4 + 4.9 kg-m
28.92 + 35.43 ft.lb)
1 Nut and washer 3 Starter motor 1 Lower cover 3 Nut and washer
2 Screw 2 Screw and washer
0 1 - Q M a y 1983
ENGINE MAIN MECHANICAL UNIT
ENGINE DISASSEMBLY
@xl
May 1983
ENGINE MAIN MECHANICAL UNIT
(6.7 + 7.4
48.4 + 53.5)
@ N.m
5.8 f 7.2)
(kwm
fr-lb)
ENGINE UNIT
1 Vacuum advance pipe
2 Distributor securing nut
1. Sequentially remove following
1 Pipe union 2 Screws
parts:
- Oil filter @ u s i n g p r o p e r 4. Remove alternator. Remove carburettor
7.
spanner (1) Loosen securing bolts @ fixing (1) Unscrew the four nuts with
- Dipstick 0. alternator @ and remove driving securing washers carburettor to in-
- P r e s s u r e s w i t c h @ for mini- belt. take manifold.
mum oil pressure check (2) Complete bolts 0 removal and (2) Remove the accelerator cable
-- Thermal contact @ for water take out alternator @ _ return spring securing bracket, carbu-
temperature check from right (3) Unscrews screws @ and re- rettor, relevant gaskets and spacer.
cylinder head. move bracket @.
1 Bolts 3 Screws
2 Alternator 4 Bracket
5. Remove pipings.
8. Remove thermostat
(1) Loosen screws of clamps and (1) Unscrew screws 0, r e m o v e
1 Oil filter 3 Dipstick remove fuel supply pipe 0.
cover @ and thermostat.
2 Pressure switch 4 Thermal contact ( 2 ) L o o s e n s c r e w s @ of water
(2) Unscrew nuts 2 and remove
system coupling @ clamp @ and
thermostat housing8 1 from intake
remove coupling.
manifold @.
2. Remove sparking plugs using
proper box spanner.
1 Thermostat 3 Screws
1 Fuel pipe 3 Coupling housing 4 Intake manifold
2 Clamp 2 Nuts 5 Cover
14.
14. Remove camshaft driving belts
rear covers.
15. Remove water pump assembly.
(1) Unscrew screws 1 with wash- . .
(I)
ers
ers securing
securing pulley
pulley
8 22 to
to water
water
pump hub and* remove pump driving
pulley.
1 Jockey pulley 2 Belt stretcher
1 Intake manifold 3 Nuts
2 Bracket
1 Screws 2 Pulley
17. Lock flywheel by tool A.2.0378. (2) Suck oil from camshaft supports (2) Withdraw upward pump from
18. Unscrew screws 0 and @, tanks with a suitable syringe. block.
remove guard @and engine front ( 3 ) U n s c r e w s c r e w s @ and @
0.
support 4 securing cylinder heads to block;
remove heads with relevant gaskets.
24. Remove block front cover.
( I ) Unscrew screws @ and nuts
with washers @ securing cover @
and remove cover with relevant
gasket.
(2) Remove front oil retaining
ring @ from cover by lever with a
screwdriver.
Replace ring at assembly.
I N u t 5 Toothed pulley
2 Washer 6 Spacer
3 Spacer 7 Toothed pulley 23. Remove oil sump assembly.
4 Pulley 8 Washer (1) Unscrew screws with wash-
ers 0
1 securing oil pump @ to
20. Remove flywheel locking tool, block rear cover.
previously fitted.
21. Remove cylinder heads.
(1) Unscrew screws @ fixing COV-
0
ers 2 to camshaft supports; remove
covers with relevant gaskets.
1 Camshaft 2 cups
A.2.0:7$$7=
1 Support 3 Cover
2 Screws 4 Screws
i.
under
camshaft cups and journals for scores
1
load
23.25 (0.9153) and for any evidence of pitting or Diameter of camshaft bearings
mm (in)
abnormal wear. Front = 35.015 + 35.040 mm
0. = outer spring
(1) Reset reamer to testing di- (1.3785 + 1.3795 in)
i. = inner spring
mension. Centre = 46.500 + 46.525 mm
(I.8307 + 1.6317 in)
Rear = 47.000 + 47.025 mm
(1.8504 + 1.8514 in)
CAMSHAFT
1. Carefully examine working sur-
faces of cams and of camshaft
journals making sure that there
are no scores, no evidence of seizure,
S overheating or abnormal wear.
2. With a micrometer measure the
CUPS diameter of camshaft journals.
Check that the outer surface of the
cups as well as the upper surface on (2) Measure the diameter of cam-
which cams work, show no scores, no
shaft bearings.
evidence of pitting or Abnormal wear.
Further verify that- calking of- the
AND CONNECTING
and tolerances see: Service Data and
ROD BEARINGS
Specifications - “Piston” chart.
Cylinder wall to piston play them with oil. Select bearings accord-
Standard 0.03 + 0.05 mm ing to the diameter of crankshaft
(0.0012+ 0.0020 in) journals.
Oversize 0.03 + 0.06 mm
(0.0012 + 0.0024 in) -
Connecting rod
1 Bush 2 Pump drive gear
Piston pin
Spring ring
Left head piston (No. 2 and 4)
Right head piston (No. 1 and 3)
successive steps, according to speci- block having the gauge’s indicating 4. Fit seal ring in the main oil
fied torque and sequence (from A finger touch the crankshaft parallel- gallery of the cylinder block rear
to F). wise to the shaft’s axis. cover.
(2) Using a screwdriver, move the
0: Tightening torque crankshaft along its axis and check
Caps to cylinder supports se- the gauge’s reading to ensure that
curing screws: “g” end play is within specified
6 6 + 73 N - m values.
(6.7 + 7.4 k g - m
46.4 + 53.5 ft-lb) Crankshaft end play
0.35 mm (0.0137 in)
Head to cylinder block re- 3 Washer if it is, modify the profile of the
taining screws: support till it meets the specified
‘81 + 87 Narn value.
(8.3 + 8.9 kg-m
60 + 64.4 ftdlb) “S” min. clearance between camshaft
belt and engine from mounting
9 mm (0,3543 in)
Y-
01-29 M a y 1983
ENGINE MAIN MECHANICAL UNIT
20. Fit distributor on rear cover. 23. Fit support covers @ with
(I) Turn the distributor’s shaft so relevant gaskets 0.
1 Distributor coupling
that the rotor arm @ is positioned
on the reference mark stamped on
(3) Fit the oil sump pump on rear the distributor’s body.
cover and tighten screws 0 accord- The rotor arm 0 should point
ing to specified torque. toward the No. 1 cylinder. This
position corresponds to ignition in
a: Tightening torque No. 1 cylinder and to correct cou-
Oil sump to rear cover re- pling of the oil pump and distributor
taining screws shafts.
IQ+24 Nhrn (2) If necessary, correct misalign-
(1.9 + 2.4 kg-m ment of the rotor arm with the
13.7 + 17.4 ft+lb) reference mark stamped on the
distributor’s body by rotating the
(4) Tighten retaining screws @ latter and then tightening the lock
b e t w e e n p u m p body and support nut @ securing the distributor to
according to specified torque. the cylinder block rear cover. 1 Cover 2 Gaskets
34. Assemble carburetor with spacer (3) Key alternator and water pump
@I: Tightening torque
and the interposed gaskets on intake drive belt on relevant pulleys.
Spark plugs:
manifold studs. (4) Adjust belt tension according to
2 5 G34 N-m
specifiedvalue and then lock
(2.5 + 3.5 kg-m
0: Tightening torque bolts 0. For adjusting procedure
18.1 + 25.3 ft.lb)
Carburetor nuts refer to Group 00 - Engine Main-
19+24 N.m tenance.
38. Secure cap to distributor body
(1.9 + 2.4 kg-m
with relevant springs, then connect
13.7 + 17.4 ft.lb) L o a d : 7 8 . 4 0 N (8 k g ) (
ignition cables between spark plugs
Arrow: 15 mm (0.5905 in)
and distributor cap, securing them to
35. Perform following connections.
relevant clamps.
- Fuel supply pipe @ from fuel
Cables connection must take place
pump to carburettor.
according to the ignition sequence of
- Vacuum advance pipe @ from
cylinders.
carburettor and advance con-
troller located on distributor.
1 Bolts 3 screws
2 Alternator 4 Bracket
-
The engine is pressure lubricated by
means of a gear pump. The pump is
mounted on the rear cover of the
? I. -4I M
engine and is actuated by a shaft
which is driven by a gear fitted to the
i F --, .I& ,
Oil pump -1 Oil filter cartridge
crankshaft.
The maximum oil pressure is ad-
justed by means of a proper valve
I I Oil strainer I I Block oil galleries I
fitted on the pump.
Oil is completely filtered in the
suction head by a strainer then by a
filter with cartridge placed on the oil
passage and provided with a bypass
safety valve, should the cartridge
become clogged.
The oil filter, on the engine rear
cover, has unions for the recircula-
tion of the oil vapours at minimum
and high running.
The insufficient oil pressure is
indicated on the combination meter
by means of a warning light con-
II I Connecting rod
half-bearings
nected to a manual contact inserted
on the main oil gallery of the block.
OIL PUMP
OIL PRESSURE CHECK
NOTE 1. Start engine and heat oil to 90°C
(194°F).
Oil passagi
2. Remove oil pressure checking
manual contact.
3. Fit gauge to manual. contact
- Return
hole.
)- BYpass passage
4. Start engine and record oil
pressure as shown on gauge.
M a y 1 9 8 3 01-34
-ENGINE MAIN MECHANICAL UNIT
CAMSHAFT SYSTEM
U n i t : m m (in)
Unit: mm (in)
Engine
1200 1350 1500
305.00 305.02 305.04
CYLINDER BLOCK
Unit: mm (in)
Engine
inspection data
1200 1358 1500
Front
63.663 G 63.673 (2.5064 + 2.5068)
Main bearing diameter “b” Rear
01-37 IWay 7 9 8 3
ENGINE MAIN MECHANICAL UNIT
Pistons
u
-a
Ia
Unit: mm (in)
Engir
Inspection data
1200 1350 1500
Class A (Blua) 79.96 +79.97 (3.1480 + 3.1484) 83.96 f 83.97 (3.3055 + 3.3059)
Class B (Pink) 79.97 f79.98 (3.1484+3.1488) 83.97 f 83.98 (3.3059 + 3.3063)
Standard Class C (Green) 79.98+79.99 (3.1488-3.1492) 83.98 -83.99 (3.3063 + 3.3067)
Class 0 (Yellow) 79.99 + 80.00 (3.1492 e-3.14961 83.99 + 84.00 (3.3067 + 3.3071)
Piston diameter
Class E (White) 80.00 G-80.01 (3.1496 +3.1500) 84.00-84.01 (3.3071 f3.3075)
“ a ” (I)
1st 80.15+80.17-(3.1X5+3.1563) 84.15F84.17 (3.3130 t3.3138)
Oversize 2nd 80.35-80.37 (3.1634+3.1642) 84.35f84.37 (3.3209f3.3217)
3rd 80.55-80.57 (3.1713-3.1720) 84.55G64.57 (3.3287 -3.3296)
1.525 + 1.550
0.0600+0.0610)
1.525+1.545 (2)
First compression ring groove height “c” 1.525 + 1.545 (0.0600 + 0.0608)
0.0600+0.0608)
1.525e1.545
0.0600+0.0608)
(3)
1.775+1.800
0.0699 + 0.0709)
4.015+4.w0
(0.1581 -0.1590)
(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
Unit: m m (in)
Engine
lnspecrion data
1200 1350 1500
I I
Small end bush bore diameter “a” 21.007 + 21.015 (0.8270 f 0.8274)
Engine
Inspection data
12ctcl I 1350 I SO0
--e
Blue 1.831 + 1.835
(0.0721 +0.0722) T (0.0720 + 0.0722)
a Standard
Red 1.827 + 1.831 Red 1.8?6 + 1.832
(0.0719+0.0721) (0.0719 + 0.0721)
M a y 1983 0 i-40
ENGINE MAIN MECHANICAL UNIT
FLYWHEEL
Unit: mm (in)
Engine
Inspection data
1200 1350 1500
(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.
Unit: mm (in)
Engine
Inspection data
1200 1350 1500
I I
Thrust rings
Unit: mm (in)
~ ~
Engine
Inspection data
1200 * 1350 I 1500
Main -bearings
Unit: mm (in)
Engine
Inspection data 1200 1350 I 1500
Camshaft support
Unit: mm (in)
Engine
Inspection data
1200 1350 1500
1
Camshaft
Unit: mm (in)
I Enaine
Inspection data
t 1200 I 1350 I 1500
Intake
Cam height 8 . 5 (0.3346)
Exhaust
Tappet bucket
Unit: mm (in)
Engine
Inspection data
1200 1350 1500
May 1 9 8 3 01-44
ENGINE MAIN MECHANICAL UNIT
Cylinder head
Unit: mm (in)
Engine
Inspection data
1200 I 1350 I 1500
Min. cylinder head thickness after resurfacing “c” 77.25 (3.04131 (1)
(1) Resurfacing of cylinder head with hemispherical combustion chamber must be done on both banks of the same engine
Valves
Unit: mm (in)
Engine
1200 1350 1500
1
S p r i n g s
Engine
1200 I 1350 I
15w
recutting
Unit: mm (in)
Engine
1350 1500
Intake
Reference diametere “6 R ”
Exhaust
Intake 500
Valve seat inner face limit
angle “y’ Exhaust 300
Unit: mm (in)
Engine
Inspection data
1200 I 1 3 5 0 I 1500
1
Second 0.035 + 0.067 (;;~4;;~;2,,l 0.036 + 0.067
Ring/groove end float compression ring (0.0074 + 0.0026) (0.0014 + 0.0026)
(f;;4y(;;26)@’
* *
Maximum for
0.1 (0.0039)
each ring
Red/Blue Red/Blue
0.034+ 0.662 0.032 + 0.064
Standard
Connecting rod bsaring- (0.0013 + 0.0024) (0.0013 + 0.0025)
to-crankpin play Maximum (with
0.090 (0.0035)
bearing in seat)
0.1 (0.0039)
Engine
Inspection data
1200 1350 1500
I
Max 0 . 0 9 (0.0035)
Valve guide-to-seat
interference fit
I Standard
Spare
0 . 0 3 2 + 0.068 (0.0013 + 0.0027)
TEMPERATURES
Part Temperature
Oil pump/distributor drive gear for shrinking onto the crankshaft 150°C (302°F)
GENERAL SPECIFICATIONS
FLUIDS AND LUBRICANTS
Q-KY
Application TYPE
kg (lb)
Engine oil when full OIL AGIP SIN-T 2000 lOW50 3.15 (6.94)
Std.rd 3631-69352
SEALING COMPOUNDS
Joint face, cylinder block-to41 sump CEMENT DOW CORNING: Silastick 732 RTV -
(I 1 Before applying LOCTITE, remove all traces of old Loctite and degrease threads using trichlorethylene or chlorothene
(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 N+m 57 f 62
kg.m 5.8 + 6.3
Ib.ft 41.9 + 45.6
I. Noisy engine
Knocking of crankshaft and Excessive crankshaft end play Replace thrust bearing
bearing
Water pump knocking Improper shaft end play Replace water pump assembly
I I I. Lubrication
oil leakage l Loosen engine oil drain plug Tighten
AIR CLEANER
IDLE COMPENSATOR
DEsCRlPTlON CHECKS AND 3. When thermometer shows speci-
FUEL PUMP
CHECKS AND
INSPECTIONS FUEL PUMP PRESSURE
reading is within specified values at
relevant engine rpm.
FISPA P u m p
, 17.7 G29.4 KPa
CAUTION: (0.177 + 0.294 bar, at 5000 rpm
When disconnecting fuel system 0.18 f 0.30 kg/cm2,
hoses, use a container with safety lid 2.56 + 4.27 psi)
to collect the petrol that is left over
in the hoses. SAVARA Pump
17.7 + 29.4 KPa
(0.177 + 0.294 bar, at 6000 r-pm
FUEL PUMP DELIVERY 0.18 + 0.30 kg/cm2 ,
PRESSURE 2.56 + 4.27 psi)
1. Disconnect fuel delivery hose
from pump and from carburetor. 5. If delivery pressure is not within
2. Replace same with a T-shaped specified values, replace the pump.
hose equipped with cutoff cocks. 6. Disconnect T-shaped hose and
3. Connect a pressure gauge to the restore normal operating conditions.
hose’s free end.
4. Start engine up and with zero
delivery (cock on carburetor side is
closed), while keeping gauge at same
height as pump, verify that gauge
CARBURETORS
W E B E R TWIN CARBURETOR
1 Carburetor cover including: 35 Safety washer 72 Bush for sealed idling cap
2 -Stud 36 Spring for loosen lever 73 Adjustment screw cap
3 Starting throttle 37 Secondary shaft securing nut 74 Idling mixture adjustment screw
4 Starting securing screw 38 Spring washer 75 Sealed idling cap
5 Starting shaft 39 Shim adjustment washer 76 Pump cover
6 Lever for starting shaft 40 Secondary throttle control lever 77 Pump cover securing screw
7 Corrugated washer 41 Sheath securing screw 78 Pump diaphragm
8 Starting shaft lever securing nut 42 Cap for secondar/ idling hole 79 Primary shaft return spring
9 Starting control tie rod 43 Throttle control lever 80 Pump filling spring
10 Tie rod split pin 44 Shim 81 Throttles securing screw
11 Tie rod washer 45 Loosen lever 82 Primary main shaft
12 Dust cover cap 46 Bush for loosen lever 82 Oversize primary main shaft
13 Dust cover plate 47 Secondary throttle adjustment screw 83 * Idling cut-off together with:
14 Carburetor cover gasket 48 Stop lever together with: 84 - Gasket
15 Primary auxiliary Venturi 49 - Bush for sealed idling cap 85 Conic seal needle
15 Secondary auxiliary Venturi 50 - Spring 86 Bush
16 Pump delivery valve 51 Adjustment screw 87 - Primary idling jet
17 Pump jet 52 Sealed cap for lever adjustment screw 88 Secondary main shaft
18 Pump jet gasket 53 Primary shaft return spring 88 Oversize secondary main shaft
19 Primary corrector jet 54 Shim adjustment washer 89 Throttle valve
19 Secondary corrector jet 55 Spring for adjustment screw of corrector idling 90 Secondary shaft return spring
20 Primary emulsioning tube 56 Adjustment screw for idling mixture corrector 91 Closing screw for pump discharge space
20 Secondary emulsioning tube 57 Gasket for de-flood device 92 Primary main jet
21 Carburetor body 58 Securing screw for de-flood device 92 Secondary main jet
22 Secondary idling jet 59 Economiser body including: 93 Float
23 Secondary idling jet carrier 60 Cap for adjustment screw 94 Float fulcrum pin
24 Shim adjustment washer 61 Spring washer 95 Needle valve
25 Lever return spring 62 - Diaphragm adjustment screw 96 Needle valve gasket
26 Fast idling regulation lever together.with: 63 - Device box 97 Filter inspection cap
27 - Nut 64 r Spring for diaphragm 98 Filter
28 - Adjustment screw 65 - Diaphragm 99 Tie rod spring
29 Bush for fast idling regulation lever 66 - Device cover 100 *Cut-off cbmp
30 Lever securing screw 67 - Cover securing screw 101 Economiser body control tie rod
31 Starting control lever together with: 68 Retaining ring 102 Eonomiser control lever
32 Cable securing screw 69 Retaining ring 103 Washer for cover securing screw
33 Bush for starting control lever 70 Washer for economiser body control lever 104 Carburetor cover securing screw
34 Shaft securing nut 71 Economiser control lever
1 Throttle valve
1 Ckoke air valve
2 Srarting confrol lever
2 Ckoke control lever
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.
KEY
“GS,” Dimension
4.5 + 4.75 mm (0.177 + 0.187 in) 1 Economiser body
CAUTION:
Clevis slot to pin clearance To easy adjustment buck action of
G, = 1 mm (0.039 in) return spring by manually partially
opening the throttle valve. 1 Adjusting screw 3 Pin
2 Lock nut 4 Clevis
PIPES
Check and make sure pipes are not
clogged, oxidized or dented.
CHECK VALVE
1. Blow in an air into the valve
1 Float securing screw located of fuel pipe side.
2 Electric connections
In doing so, one should notice some
3 Fuel delivery pipe
resistance and some air should come
I Ground cable 3 Clamp out of the outer union.
2 Clamp FUEL LINE 2. Now blow in an air jet into the
valve from outer side union.
The air jet should go right through
4. support tank by means of CAUTION: and come out of the fuel pipe side
column lift and loosen screws secur- Disconnect feedings pipes only if union, without encountering any
ing the clamps supporting tank absolutely necessary. resistance.
to body.
3. If check valve does not comply
5. Slowly lower column lift so as to
with above, replace it.
gain access to tank upper side. 1. Remove filler cap and take out
6. Remove from float the electric all petrol from tank with the help of
connections of warning lamp and a suitable pump.
INSTALLATION
indicator of fuel level, then, operat- 2. Remove clamps from hose
ing from tank rear side, remove unions; plug all hoses and pipes to Carefully fit all fuel line parts back
breather pipe together with retaining prevent dust or dirt from going together following removal opera-
valve. in during disassembly operations. tions in reverse sequence and paying
7. Remove tank and, if required 3. Free pipes from relevant holding special attention to below instruc-
disassemble it. clamps on underbody. tions.
EXHAUST SYSTEM
CHECKS AND 3. Check buffer on exhaust pipe allow separate removal of the
exhaust system’s single compo-
INSPECTIONS end.
4. Check surface of hot air intake nents.
1. C h e c k m u f f l e r s a n d e x h a u s t making sure there are no warps or b. Consequently, removal proce-
pipes making sure they are not in any dents that could impair normal air dure may be changed depending
way damaged or cracked and show flow. on the operation’s purpose.
no evidence of corrosion; contrary- c. When removing the entire ex-
-haust system, it is advisable to
wise, replace them. REMOVAL
2. Thoroughly check supports ring get someone to help you with
and do not hesitate to replace them a. Instructions hereafter described it.
if they are cracked, porous or worn. have been compiled so as t o
1 Sleeve 4 Clamp
4. Remove front manifolds as fol- 2 Hot air intake 5 Bolt
lows: 3 Screw 6 Nut
TECHNICAL DATA
FUEL PUMP
-. FUEL TANK
-- I
Type
ALFA ROMEO
part No.
Brand
1200
305.00
Model
1350
305.02
1500
305.04
Overall capacity
Reserve
I
Imp. Gall 11
I
Imp. Gall
50
6.5
1.43
GENERAL SPECIFICATIONS
$ .6-
s ‘5
T-r+
1
1
M a y 1983
FUEL SYSTEM
6
LL
- P
5:
MN B
1.
- - - -
z 2
L
- -
R 8
L
- - -
* *
3 a 3
- -
:
E J
?
j
ar 6000 rpm
ACCELARATOR CONTROL
Gl mm (in) 1 (0.039)
p
R
In
TIGHTENING TORQUES
Unit
N-m kg.m ft-lb
Item
Fuel leakage l Needle valve is dirty or its seat is Thoroughly clean petrol filter and
loose on thread needle valve; tighten seat firmly: if
necessary, replace it with a new one
(original parts)
l Float sticks (hard on pin or sides) or Free the float and adjust its move-
is heavy ment: if necessary replace it (original
parts)
l Gaskets are hard, worn or improperly Replace gaskets and tighten them
tightened properly
l Acceleration pump diaphragm is Replace diaphragm
l Fuel pump or pipes are overheated Let bubbles out and try to eliminate
overheating causes
l Fuel pump is mechanically defective Overhaul pump replacing defective
components or replace the whole
pump
l Pipes, fuel filter or carburetor ducts Thoroughly clean pipes, filter and
are clogged by foreign matter carburetor
l Fuel tank breather hose is clogged or Unclog breather hose and eliminate
there is a water deposit on tank water also from pipes and from car-
bottom buretor float chamber
Cold starting is difficult or l Having verified that fuel level in float Restore proper fuel level in float
impossible chamber is absolutely correct, pro- chamber
teed to check following possible
carburetor troubles.
l Starting control cable does not slide Repair or replace cable
freely, is broken, unhooked, etc.
l Choke sticks so that it tends to stay Free choke movement
either fully open or fully closed
l Starting jet, if any, is dirty or has Clean or replace jet
been tampered with
I I
Cold starting is difficult or Starting control valve, if any, is Free valve movement so that it can
impossible (continue) sticky properly follow control cable
Ignition and starting systems are out Overhaul ignition and starting
of order systems
Air cleaner intake stopped in the warm Replace thermostat located into
position cleaner air intake
CAUTION:
Special attention should be paid
when checking fuel consumption
since speed load, road type as well as
driving habits play an important part
in establishing actual running fuel
consumption
Slow pickup especially when Carburation, ignition or compression Checking operations to be performed
in direct drive are defective, as also mentioned in same as previously mentioned
case of insufficient max speed (pres-
ence of exhaust smoke is possible)
A c c e l e r a t i o n p u m p n o t .properly Overhaul pump and relevant circuits
adjusted or defective or pump circuit
of jet and valves is defective
Diffuser well is clogged or otherwise Carefully overhaul air jet, diffuser
defective and relevant well making sure that
all components are properly rated
Engine easily knocks, over- Carburation or ignition are defective, Checking operations to be performed
heats or self-ignites as also mentioned in case of insuffi- same as previously mentioned
cient max speed
Octane rating of petrol used is too Replace petrol in tank with a kind
low having a higher octane rating
Improper engine idling or l Inadequate fuel level in float cham- Perform same checks and repairs as
progression phases ber or defective starter, ignition or previously described
overall engine operation as previously
mentioned in connection with diffi-
cult cold starting
l Adjustment of idling adjusting screws Carefully repeat all relevant adjust-
is incorrect ments as per maintenance instruc-
tions
D Idling jet is dirty, loose or has been Check or replace idling jet
tampered with
1 Progression holes or channels of Check and thoroughly clean holes
idling circuit are clogged or have and channels
been tampered with
b Air leaks from fitting flanges or other Tighten as required and, if necessary,
connections replace relevant worn gaskets
b Throttle valve shaft has air leaks Replace shaft and, if necessary, fit an
from intakes oversize shaft after having suitably
reamed relevant holes in the body
b Throttle valve or relevant controlling Free throttle valve
parts are sticky
b Twin carburetor’s second throttle Overhaul and clean
valve does not work properly
Power shortage (insufficient I Inadequate fuel level in float cham- Perform same checks and repairs as
max speed) ber or defective starting, ignition or previously described
compression as previously mentioned
m Main jet, power jet, air adjusting Check, thoroughly clean or replace
screw or diffuser are clogged, loose defective parts
or have been tampered with
b Fuel filter in tank or in carburetor Clean the filter
is clogged
b Air cleaner clogged Clean air cleaner and replace car-
tridge
0 Throttle valve does not fully open Check throttle valve and relevant
controlling parts
Refer to
Tool name
Tool number page
with C.4.0101)
CONTENTS
BATTERY . . . . . . . . . . . . . . . . . . . . . . . .05-2 Test stand inspection . . . . . . . . . . . . . 05-24
STARTER . . . . . , . . . . . . . . . . . . . . . . . .05-4 Service data and specifications. . . . . . 05-24
Wiring diagram. . . . . . . . . . . . . . . . . .05-4 Trouble diagnosis and corrections . . . 05-25
Disassembly . . . . . . . . . . . . . . . . . . . . 05-7 TRANSISTORIZED IGNITION
Checks and inspections . . . . . . . . . . . 05-l 0 WITHOUT CONTACTS. . . . . . . . . . . . . .05-26
Reassembly . . . . . . . . . . . . . . . . . . . .05-l 2 Wiring diagram. . . . . . . . . . . . . . . . . . 05-26
Test stand inspection . . . . . . . . . . . . . 05-I 2 Description . . . . . . . . . . . . . . . . . . . . 05-27
Service data and specifications. . . . . . 05-l 2 Checks and adjustments. . . . . . . . . . .05-28
Trouble diagnosis and corrections . . . 05-13 Disassembly . . . . . . . . . . . . . . . . . . . . 05-31
CHARGING . . . . . . . . . . . . . . . . . . . . . . .05-15 Checks and inspections . . . . . . . . . . . 05-32
Wiring diagram. . . . . . . . . . . . . . . . . . 05-15 Reassembly . . . . . . . . . . . . . . . . . . . .05-33
Disassembly . . . . . . . . . . . . . . . . . . . . 05-l 8 Test stand inspections . . . . . . . . . . . . 05-33
Checks and inspections . . . . . . . . . . .05-21 Service data and inspections. . . . . . . . 05-33
Reassembly . . . . . . . . . . . . . . . . . . . . . 05-24 Trouble diagnosis and corrections . . . 05-36
May 1983
IGNITION, STARTING, CHARGING SYSTEM
BATTERY
CHECKS WARNING:
1. The container has no cracks in a. Remove the negative connection
it. before starting to charge the
2. Verify that electrolyte level battery.
covers electrodes of about 4 + 5 mm b. Do not let the electrolyte heat
(0.16 4 0.2 in). up above 45°C (113°F) during
3. The top of the battery is clean charging.
3. Take the temperature “t” of the
and the terminals are not oxidized or electrolyte with a thermometer.
dirty. CAUTION:
4. Calculate the specific gravity at
4. The lead terminals are well a. Do not use naked flames near
25°C (77°F) f r o m t h e f o r m u l a
fastened on to the battery terminals the battery while charging.
and make good contact. sg,, = sgt + 0.0007 (t - 25) (kg/dm3) b. First connect the battery to the
where: charger and then switch on the
= Specific gravity of electrolyte charger.
$gt
CLEANING at PC
1. Clean the top of the battery, its t = Electrolyte temperature CELLS TEST
terminals and the lead terminals with
a solution of sodium bicarbonate in Examples This test should be performed with
water. 1. SElectrolyte s.g. at 15°C ( 5 9 ° F ) : the correct electrolyte s.g.
2. Before reassembling terminals, it 1.290 kg/dm3 Measure the discharge voltage at the
is necessary to grease them with the s.g. at 25°C (77°F) will be: terminals of each cell.
prescribed grease: Grease REINACH
sg*s = 1.290 + 0.0007 (15 -- 25) 1. Remove the plugs from the filler
E 10 Tat.
= 1.283 kg/dm3 holes.
WARNING: (35.51 Ib/cu in) 2. Put the test probes in two
Do not let the cleaning fluid get into adjacent holes (positive and negative)
the battery: it will react with the 2 . E l e c t r o l y t e s.g. at 35°C (95°F): as shown. The needle should flip over
1.275 kg/dm3 to the green zone (charged).
electrolyte.
The electrolyte is acid and therefore s.g. ar 25°C ( 7 7 ° F ) w i l l b e : 3. Repeat for the other two pairs
dangerous to eyes, hands and clothes. of holes.
sg,, = 1.275 + 0.0007 (35 -- 25)
= 1.282 kg/dm3
(35.48 Ib/cu in)
SPECIFIC GRAVITY
5. Compare then the clensitycalcu-
1. Verify that electrolyte is at lated at 25% (77°F) with the value
correct level. prescribed for an efficient battery.
2. By means of a bulb hydrometer,
extract electrolyte from each cell and
An efficient battery electrolyte spe-
check the specific gravity.
cific gravity is
d = 1.28 * 0.01 kg/dm3 4. If the needle stops in the red
zone (low charge) at the same point
6. If necessary charge the battery. for each cell, charge the battery.
5. If the needle stops in the red 3. If b a t t e r y v o l t a g e s h o w s l e s s Also check alternator belt tension
zone (low charge) but at quite than 12.4V, charge the battery and (see: Group 00 Engine Mainte-
different points for the different repeat the test. If the voltage again nance).
cells, put in another battery. shows less than 12.4V. a celle may
be shortcircuited. Change the battery Starting test
USING THE ELECTRONIC for another one. 1. Set instrument selector switch to
BATTERY TESTER VOLT.
(MOTOROLA) Battery state 2. Take the ignition HT lead off
Connect the positive instrument clip 1. Set the instrument selector the coil.
to battery positive (+) and negative switch to “Cond. Batt.“. 3. Start the engine and check the
to negative (-). Set battery voltage 2. The needle should flip over to needle does not drop below 9 V on
s w i t c h @ to 12V. t e m p e r a t u r e t h e G R E E N z o n e o n t h e RED- the Volt scale.
compensator @ to the estimated GREEN scale. 4. If it does, examine the starting
battery temperature, and current 3. If it does not, put in another system (see: Starting).
calibrator @ to the battery amps battery.
according to type.
Power test
Voltage test 1. Set instrument selector switch to
1. Switch selector 0 t o V O L T . “kW”.
2. The reading on the VOLT scale 2. The needle should read be-
must be greater than 12.4 V. tween 2 and 4 kW on the kW scale.
3. If it does not, put in another
battery.
Charge test
1. Set instrument selector switch to
VOLT.
2. Start the engine and let it idle
until the needle settles to its reading.
3. The reading should be be-
tween 13.6 and 15V.
4. If the reading is outside (above
or below) these limits, check the
1 Selector switch
alternator for defects, especially the
2 Temperature compensation
3 Battery voltage switch
voltage regulator (see Charging -
4 Current calibration Checks and Inspections).
Technical Data
Car
1200 1350 - 1500 1500 Quadrifoglio
Battery
Voltage V 12
43 55
Capacity Ah 45 60
181 255
Discharge current A 185 275
General Specifications
STARTER
WIRING DIAGRAM
0
All
Al. Battery
Al I. Starter
Gl. Fuseholder box
ci85. Front service junction
El. Ignition switch
I
I
I
1 Washer 11 Trunnion
2 Bush 12 Fork
3 Commutator casing 13 Screw
4 Brush holder 14 Rotor
5 Brush spring 15 Starting clutch
6 Brush 16 Snap ring
7 Yoke 17 Pinion stop ring
8 Electromagnet 18 Drive housing
9 Plate 19 Bush
10 Locator
8
11. Withdraw the rotor 2 together
with the starting clutch 3 and the
forked lever 0.
1 Fork 3 Clutch
2 Rotor
1 Electromagnet 3 Nut
2 Excitation 4 Yoke 1 Starting clutch
winding lug
15. Unscrew the inductor wind- 4. Punch on the trunnion 6 for 0 8. Strip the rotor as for the Bosch
(see: Bosch Starter Motor, steps 12
ing 1 securing screw on the the fork on the pinion housing 0.
y o k e82 and extract the winding. and 13).
1 Lug 4 Rotor
2 Commutator 5 Pinion housing
casing 6 Trunnion
3 Brush holder
1 Inductor winding 2 Y o k e
1 Nut 2 Fork
1 Electromagnet 2 Nuts
0
rotor 4 . take the starter engaging fork pivot.
1 Commutator
Commutator wear
1. Put the rotor on a lathe.
2. Place a magnetic-based centesi-
mal dial gauge on the lathe carriage 3. The blade will stick to the pack
with the gauge feeler in contact with in correspondence with the faulty
the commutator 0. lead cables if there is a short circuit.
3. Bosch and Marelli Starter Motors
If there is no electrical continuity,
Eccentricity should not be more than Excitation winding insulation
put in a new rotor.
the stated maximum. test
May 1 9 8 3 OS-IO
IGNITION, STARTING, CHARGING SYSTEM
3. The tester should give no sign of 2. Put one prod on the brush 3. Eye check the pinion teeth.
Starter Motor, step 15). shown in the figure. It should rotate 0.02+ 0.05 mm
freely. (0.00079 + 0.00197 in)
Positive brush holder insulation 2. Rotate the pinion counter-
test c l o c k w i s e , i.e. in the direction of 2. If wear is excessive, put in new
1. Set the tester to the ax 1 scale. meshing. It should lock. bushes (see: Disassembly Bosch
Starter Motor, step 16). stand to correspond with the crown adjust the absorber current to the
wheel and connect up to the electri- value in the under-load test.
CAUTION: cal system. The torque should be that shown in
Make sure the bushes are assembled the technical particulars.
properly and the rotor shaft turns CAUTION: 2. Across-line test
easily and without play. The battery used in the test should (1) Apply the rated voltage to the
have a high enough capacity to avoid starter motor.
REASSEMBLY voltage variations. (2) Lock the crown wheel brake.
Follow the disassembly steps in the (3) Start up the starter motor and
opposite order and lubricate t h e take a quick reading. Current, voltage
following parts with the prescribed and torque should be those given in
grease. the technical particulars.
Surfaces in motion relative to the
starter motor 3 . T e s t w i t h e-m. s w i t c h o n t h e
. Commutator casing bush starter motor
. Drive housing bush (1) Remove the starter motor away
. Pinion gear from the crown wheel so that the
. Starting system sliding spiral pinion will not engage it.
coupling 1. Under-load test (2) Apply the rated voltage to the
. Electromagnet push rod (I) Apply the rated voltage to the starter motor. Switch on the starter
starter motor. Switch on the starter motor. The absorbed current should
TEST STAND so that the pinion turns the crown be that given in the technical data.
INSPECTION wheel and check for good working. (3) PICK-UP/CUT-IN voltage should
Put the starter motor on the test (2) Brake the crown wheel and be that given in the technical data.
MARELLI
E95 0.9 kW
12 v
Voltage V
- Voltage V 10 10 9.8
- Voltage V 8 8 8
- Absorbed currant A G400 G380 400
- Torque N.m >lO.S 211 12
(kg.m) (21) PI.11 (1.2)
(ft.1 b) (2 7.231 I> 7.95) (8.68)
May 1 9 8 3 05-12
IGNITION, STARTING, CHARGING SYSTEM
Starter Motor
533.051 533.052 536.611
BOSCH MARELLI
DUCELLIER
EF 12V 0.8 kW E95 - 0.9 kW
6246/C
0001211215 12v
Starter motor does not turn I Break in electric circuit between Locate and repair it Check battery
and no current flows battery and starter motor terminals and starter cable terminals.
Tighten up the securing screws
m Break in electric circuit between Locate and repair it. Check switch
starter motor and starter switch contacts and replace if necessary
m Battery terminals dirty or loose Clean the terminals and tighten up
c.onnections the connections
b Starter motor electromagnet or wind- Clean the moving and fixed contacts
ing or is earthed of the switch when possible and
replace it if necessary
1 Excessively worn brushes not making Replace the brushes with other origi-
contact on the commutator nal ones after checking state of com-
muTator
Current flows but starter motor 1 Rotor is rubbing against the pole Replace the bearings if the bushes
does not turn, or turns slowly, pieces or is being held between the are too worn. Check bearing align-
or starting does not take place poles ment. Examine rotor shaft. See that
the poles are well located and se-
curely clamped into the yoke
1 Rotor shaft seized UP Replace the rotor and the piece with
the seized-up bush
) Field winding short circuited or Take out rhe field coils and put in
earthed new ones
l Broken or earthed rotor Replace the rotor
l Rotor short circuited Clean the carbon and copper dust
off-the commutator and brush hold-
ers and if necessary replace the
rotor
Starter motor turns but starting D Crown wheel teeth worn: pinion Replace starting ring gear
does not take place does not engage
Starter motor turns but starting l Wrong assembly: pinion engages only Check concentricity and pinion-ring
does not take place partially gear distance
(continued) l Impurities in the coupling: Clutch Clean and lubricate. If necessary
does not slide on rotor shaft clean the coupling completely
l Pinion engages ring gear properly Pinion free wheel defective and must
but the engine does not start be replaced. Faulty clutch to over-
haul or replace. Electra-magnet not
working properly: repair or replace
Starter motor turns normally l Defective mechanical parts Check bearings. Examine bushes and
but makes excessive or un- if necessary replace bearings
usual noise
. Foreign bodies have got into it Clean them out
Starter motor does not develop l Brush contact on commutator not Replace brushes or snug them by
max power good running the motor on no-load for
some time. Check brush spring
loading and replace them if they have
lost their elasticity
l Brushes do not slide freely in the Clean the brush-holder guides or
guides replace the brush holders if neces-
sary
Excessive brush wear l Ovalized commutator Turn within in prescribed limits, re-
move mica and clean commutator
l Mica projecting out of commutator Remove mica and clean commutator
copper sections
l Brushes press excessively on com- Check brush spring loadings for
mutator prescribed values
l Wrong brushes Replace with others of prescribed
we
l Mica projecting from copper Remove mica and clean the com-
mutator
. .
BOSCH ALTERNATOR
MARELLI A L T E R N A T O R
'-1
.J
BOSCH ALTERNATOR
1. Hold the alternator pulleys 2
in a vice with caps, Release fan 81
and pulley to rotor shaft @ secur-
ing nut 0. Take off the nut,
the lock washer, the two semipulleys
with distance pieces and the fan with 1 Fan 3 Nut 1 Voltage regulator
washers and feather key. 2 Pulley 4 Shaft 2 Regulator mounting
CAUTION:
At reassemble use a new bearing if
the old one is worn or damaged and
put it on the press with the help of a
pipe which must rest only on the
inner ring of the bearing.
1 Bearing 2 Shaft
DUCELLIER A L T E R N A T O R +
1. Hold the alternator in a vice
with caps. Unscrew the screws 0
tor 38
a n d 2 securing the voltage regula-
to its mounting and extract
the voltage regulator.
CAUTION :
At reassembly, use a new bearing if
the old one is worn or damaged.
MARELLI ALTERNATOR
1. On a vice fitted with protective
jaws, secure pulley @ of alternator.
1 Pin 3 Nuts Loosen nut @ securing pulley and
2 Cover fan @ to rotor shaft @; remove
nut, washer, pulley and fan together
6. Unscrew the alternator charge with spacers and feather.
indicator pin 0 screw,
6. Unscrew the three alternator 9. Hold the rotor in a vice with
pack assembly stud bolts nuts 0. caps. Unscrew the nut securing the
pulley @ and the fan @ -to the
rotor shaft. In order take off the nut,
the washer, the distance piece, the
pulley, the second distance piece and
the fan with washers and feather key.
1 Pulley 3 Fan
2 Nut 4 Shaft
1 Pulley 2 Fan
1 Pin 2 Nuts
2. Disconnect voltage regulator 5. Withdraw rotor @ h a m m e r i n g suitable press with plates and punch,
c o n n e c t o r s @ and @ of rectifier by means of a plastic hammer on withdraw bearing on voltage regula-
bridge. Unscrew screw securing brush shaft @ of rotor itself, as shown in tor support side from rotor shaft.
holder 4
8 to voltage regulator
support 3 and withdraw it.
figure.
CAUTION:
On reassembly, use a new bearing (in
case bearing is damaged or worn) by
mounting it on press with the aid of
a tube which must face bearing
retaining ring.
1 Guard 2 Pin
CAUTION:
Before starting electrical checks
blow-clean all the components
thoroughly with compressed air.
1. Slip rings
8. Withdraw rectifier bridge and (1) Inspect for wear,
stator from voltage regulator sup- (2) If the rings are scored, but not
port; then unscrew positive terminal badly, put the rotor. on a lathe and
with relevant washer. rectify the rings with rotor cloth. If
9. By means of an extractor (see: the rings are badly scored, put in a
Regulator Alternator Bosch) or a new rotor.
(4) If the insulation is broken, put unsolders the brush cable as shown in
in a new rotor. the illustration and put in new
2. Rotor winding continuity test
4. Stator windings insulation test brushes.
(1) Ser the tester to the AL x 1 scale.
(I) Set the tester to the a x 1 scale.
(2) Put the prods on the slip rings.
(2) Put one prod on the stator pack
(3) Winding resistance should be:
and the other prod on the termi-
Bosch alternator 4 f 0.1 a nals 0 of the first phase, then of
Marelli alternator 3.1 * 0.2 CL the second phase, and finally of the
DUCELLIER
7. Brush spring inspection Reverse the two prods The tester Diode resistance in direct conduction
The brush springs should be stiff should show the prescribed re- R = 0 -lOa
enough to assure good brush contact sistance.
on the slip rings. If they are not, put Power diodes - bridge inverted test
in a new voltage regulator unit. Direct current resistance (I) Zero tester in the a x 100 range
8. Brush holder unit electrical R = O+lOa scale.
continuity inspection (2) Carry out inverted-test of bridge
(1) Set the tester to the 52 x 100 (2b)The rester shows current flow operating as per direct test, by
scale. and therefore the prescribed resis- inverting (in sequence) probes be-
(2) Put one prod on one and then tance. tween positive heat sink and the
on the other brush 0. Reverse the prods and the tester three phases of bridge when testing
(3) Put the other prod on the shows no current flow (infinite positive bridge.
terminal 0. resistance). Inverts (in sequence) probes between
(4) The tester should show current negative heat sink and the three
flow. CAUTION: phases when testing negative bridge.
( 5 ) I f t h e r e i s n o eletrical conri- All excitation diodes must be tested (3) Verify on tester that current is
nuity, check the brush holder and if in this way. not present.
necessary put in new brushes and/or
brush holder. Diode resistance for inverted
conduction
R =mcL
STAND INSPECTION
3,000 rpm for an hour with rheostat
load to give a voltage of 13 + 14V.
1. Put the alternator on the test 4. Slow down the motor until the
stand and connect it to the stand’s current output is from 1 + 2 A and
electric motor. then disconnect load rheostats to get
2. Make the following electrical a voltage again of 13 + 14V. Take the
connections: current reading and the correspond-
(I) Terminal B+ to test stand ing rpm.
positive.
5. Keeping the voltage constant,
(2) Terminal B+- to the pilot light
vary the speed and the load rheostats
and to terminal D+.
and take current readings together
CAUTION : (3) Connection for test stand feet.
If the required resistance values are with the corresponding rpm at
not measured, replace rectifier different point up to max current
bridge. output.
6. The output current readings at
the various speeds should all be equal
REASSEMBLY to or greater than those reported in
Reassemble the alternator following the Technical Data.
the disassembly steps in the opposite
order, and taking care that:
CAUTION:
W h e n s o l d e r i n g t h e t h r e e stator
cables on to the diode holder plate
and, for the Bosch Alternator,
changing the brushes, the soldering
must be done as quickly as possible
so the diodes are not overheated. 1 Terminal B + 2 Terminal D +
Alternator
0.120.489.798 125 - 14V - 45A
(I) Minimum readings when hot after 1 hour’s working at 5000 rpm with loading of 25 A
T R O U B LE D I A G N O S I S ,AND CORRECTIONS
Before starting alternator troubleshooting, the battery should be fully charged (see: Battery)
arm and cap, The pulses are gener- i n g heat maximum elimination and
DESCRIPTION ated by a magnetic pulse generator stable performances.
The electronic ignition is an induc- located into a variable air gap circuit. Besides conducting or interdicting
tive discharge transistorized system During rotation of distributor shaft, the output transistor, the electronic
without contacts, constituted by the each time a tooth of the timer passes module has also the purpose of
following components. in front of the fixed pole piece processing the signal provided by the
a. ignition distributor with mag expansion, a signal is generated (by magnetic pulse generator of distribu-
netic pulse generator A5 with
mechanic centrifugal spark
0 induction) at the winding ends of
coil (pulse generator), with conse-
tor, conducting one linked with the
engine rotation revolution numbers.
advance and vacuum advance quent control of the electronic It is thus obtained a control of the
calibrator. module. coil charge current and of time
b.
module.
0
Ignition coil A8 with electronic The electronic module, constituted
by a set of integrated circuits
duration of conduction with genera-
tion of constant energy spark,
C. Electronic module Nl
0
The ignition distributor with mag-
mounted onto a ceramic support
enclosed into a proof container is, in
independently of engine speed and
battery voltage.
netic pulse generator differs from the its turn, mounted together with coil, A coupling capacitor, secured to
traditional type as, in the place of onto an aluminium finned support m o d u l e r a d i a t o r and electrically
contacts and of capacitor, it has a which also operates as heat dissi- connected with coil terminal and
m a g n e t i c p u l s e g e n e r a t o r (stator) pator. Between the electronic mod- to ground, allows optimization of
and, in the place of the cam, a ule and the support, it is interposed a primary voltage wave form on coil
toothed timer (rotor). grease coat with thermal high con- and, consequently, higher perfor-
High voltage distribution to spark dutivity, with the purpose of ensur- mances.
plugs is obtained by means of a rotor
BOSCH DISTRIBUTOR
/’
MARELLI DISTRIBUTOR
DISASSEMBLY
BOSCH DISTRIBUTOR
Clamp distributor on a vice fitted
with protective jaws.
1. Remove cap 0 and withdraw
f i r s t t h e r o t o r a r m @ with rev
limiter and then the lubrication
felt.
0
ing stator to distributor
0
s c r e w s 2 T h e n u n s c r e w 1 secur-
body and
remove the advance regulator
1 Inductive winding
2 Advance ragulator
1 Cap 3 Dust cover 1 Stator securing screw
2 Rotor arm 2 Spring securing screw
3 Regulator securing screw
4 Spring
1 Counterweights 4 Screws
2 Springs 5 Insulating
3 Pulse generator support
CHECKS
AND INSPECtIONS
MARELLI DISTRIBUTOR
1 Counterweights 3 Retaining ring
2 Securing screws By m e a n s of a feeler gauge, v e r i f y
2 Springs 1 Rotor arm
that air gap between pulse genera-
tor @ and timer 0 corresponds
to the “S” prescribed value.
MARELLI DISTRIBUTOR 3 . W i t h d r a w s p r i n g s @ and re-
Clamp distributor on a vice fitted move counterweights 0. Air gap
with protective jaws. 4. Unscrew securing screws 4 , S = 0.4 + 0.5 mm (0.016 + 0.02 id
0
1. Unscrew screws 2 securing cap then remove pulse generator8 3
to distributor body; then withdraw (stator) a n d m a g n e t i c i n s u l a t i n g
cap (iJ. support 5 0.
May 1983 05-32
IGNITION, STARTING, CHARGING SYSTEM
2. Counterweights advance
CAUTION:
(I) Carry out steps 1 and 2
Marelli Distributor
relevant to vacuum advance verifica-
Every time it is carried out a disas-
tion.
sembly or replacement operation of
(2) On vacuum spark advance con-
magnetic pulse generator, it is
trol disconnected from test bed
anyway required to reassemble the
vacuometer, r e a d , o n increasing
magnetic spacer of pulse generator
r.p.m., the automatic advance curve
support.
(see: Service Data and Specifi-
cations).
(3) If the particulars are not within
the prescribed values, carefully exam-
TEST ine the distributor and, particularly
STAND INSPECTIONS the counterweights and relevant
1. Vacuum advance return springs, timer, and pulse
(1) Mount the ignition distributor generator. Replace faulty the parts.
1 Timer 2 Pulse generator
on a test bed and carry out electric
connections.
(2) C a r r y o u t s p a r k r e s e t t i n g o n
goniometer disc of test bed by
REASSEMBLY rotating distributor manually or
For reassembly reverse the order of with the test bed motor without
disassembly and comply with the exceeding 50 r.p.m. speed.
following: (3) Carry out connection of vacuum
1. L u b r i c a t e the following com- pipe to vacuometer of test bed.
ponents by means of distributor (4) On increasing vacuum, read the
special grease. advance curve (see Service Data and
. Counterweights springs Specifications).
. Counterweights (5) If the read curve -is not within
2 . L u b r i c a t e f e l t of. d i s t r i b u t o r the prescribed deviations, replace the
shaft with few oil drops. vacuum advance device.
Ignition Distributor
Type I
MARELLI
SM 802 AX
I
BOSCH
0.237.005.004
ELECTRONIC MODULE
05-33 M a y 1983
IGNITION, STARTING, CHARGING SYSTEM
IGNITION COIL
MARELLI BOSCH
Type
BAE 207B 0.221.6C10.002
SPARK PLUGS
Type LODGE 25 HL
TIGHTENING TORQUES
Unit
N.m kg.m ft.1 b
Item
Spark plugs in IS-EC0 oil: Molykote A 25+34 2.5 + 3.5 18.08 + 25.31
,CONTENTS
May 1983
ENGINE COOLING SYSTEM
COOLING SYSTEM
GENERAL DESCRIPTION
1 Electric fan
2 Thermostat
3 Radiator
4 Electric fan thermal contact
5 Cooling drain plugs
6 Centrifugal pump
7 Header tank
8 Cooling temperature transmitter
9 Heater
IO Cooling temperature warning light thermal contact
11 Cooling temperature indicator
12 Cooling temperature warning light
13 Cooling water level sensor for check control
(I 500 Quadrifoglio model)
14 Cooling water minimum level warning light
(1500 Quadrifoglio model)
THERMOSTAT
REMOVAL CHECKS AND
1. Drain coolant up to the lower
INSPECTlOONS
level of thermostat housing.
2. Detach coupling @ connecting
thermostat cover to radiator. Thermostat should be checked in
3. Screw out screws @ and accordance with the following pro-
remove cover
gasket @ _
0 3 with relevant cedure:
1. Fit thermostat @ to suitable
4. Withdraw thermostat @ from test equipment.
Imousing @ . 2. Fill container with water and
switch on equipment to heat water.
3. Check that, when thermostat
opens, temperature value read on
thermometer @ dial indicator is
84 + 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).
If above values are not met, thermo- 1 Thermometer 2 Thermostat
stat must be replaced.
1 Coupling 5 Washer
2 Clamp 6 Thermostat
3 Cover 7 Gasket
4 Screw 8 Housing
LEAK TEST compressed air through radiator 6. Test again radiator for leakages
breather pipe until a pressure of as described above and then refinish
98.1 + 107.9 kPa; (0.9 + 1.0 bar; radiator with black synthetic enamel.
I. Remove radiator from car (Refer
to: Radiator Removal and Installa- 1 + 1 .I kg/cm2 ; 14.22 + 15.64 psi) is In case of leakages from radiator
reached. fitted with side tanks (with gaskets),
tion).
2. Close radiator outlet and inlet 4. If leakages are found, clean area replace the radiator.
unions. to be soldered by a wire brush and 7. Refit radiator to car (Refer to:
3. lmmerge radiator in a tank deoxidate by “baked” hydrochloric Radiator - Removal and Installation).
previously filled with water and acid (zinc chloride). Fill with coolant and check for
check for possible leakages inflating 5. Solder the leaking area., leakages.
LEAK TEST
THERMOSTAT COOLANT
TEMPERATURE Summer
- Start of opening 84 + 88°C
(183.2 + 190.4”F) Water I 7.3
Imp. Gall 1.61
- End of opening 986
(2084°F) Winter
- Bulb travel >7
Min. tempera-
(> 0.28 :;
tu re T -10 -20 -35
OF (14) i-4) 1-31 I
RADIATOR
Antifreeze cat.
Radiator leak control
3661-69956 I 1.8 2.6 3.65
pressure 1 0 7 . 9 kPa
(Imp. gall) (0.391 (0.57: 10.80)
(1.0 bar;
1 .I kg/cm2; Water I 5.5 4.7 3.65
15.64 psi) (Imp. gall) (I .2) (I .03 IO.801
Antifreeze ready
PRESSURIZED PLUG for use cat.
Pressurized @lug setting 3681-69958 I - 7.3
pressure 68.6 kPa (Imp. gall) - (1.61
(0.69 bar;
0 . 7 kg/cm’;
9.95 Psi)
Sealing compound for cooling &tern Sealing powder AREXONS Cat. 3522-00101 7.3 g
0.20 (az)
TIGHTENING TORQUES
ft*lb
0 Damaged cylinder head gasket Replace. Check engine oil for contami-
nation
l Dirty and scaled radiator Clean pipes flushing with the specified
descaling compound. Follow instructions
for use shown on packaging.
DESCRIPTION
This is a hydraulic controlled, dry, al @, operated through a master moves thrust bearing (self centering)
singledisc clutch provided with a c y l i n d e r0
7 which transmits fluid and wins diaphragm spring action.
thrust bearing @ which is always pressure increase to operating cylin- By means of gaskets performing on
in contact with pressure plate der @ piston. cylinder, piston takes up possible
spring @ . Diaphragm spring @ The latter operates on the with- slacks and therefore driven plate
pressure engaged driven plate. Dis- drawal lever @ by a push rod @, wear recovery is automatic.
engagement is obtained by a ped-
(1.5 + 1.9
10.8 4 13.7)
(!$I15 + 23
(1.5 + 2.4
10.8 + 17.41
1 Clutch disc
2 Bleeder screw
3 Operating cylinder
4 Control push rod
5 Flexible hose
6 Brake and clutch hydraulic system reservoir
J Clutch master cylinder
8 Pedal
9 Clutch withdrawal lever
10 Diaphragm spring
11 Direct drive shaft
12 Thrust bearing support
13 Self centering thrust bearing
14 Clutch cover
15 Pressure plate
16 Flywheel
17 Bush
CLUTCH MASTER
CYLINDER
REMOVAL
1. Remove filler plug 0 o n
reservoir 0, relevant gasket and 1 Master cylinder 7 Fork
filter then, with a syringe, drain 2 Stopper ring 8 Washer
1 Fork 3 Pedal 3 Gasket 9 Spring
enough fluid to make level fall below
2 Pin 4 Stopper ring 4 Piston 10 Gasket
connection to master cylinder @. 5 Gasket 11 Connection
2. Disconnect SUPPlY flexible 6 Boot
2. Operating from the engine room, hose @ from master cylinder.
remove pedal pin stopper spring @ 3. Loosen connection and discon-
and relev’ant nect rigid pipe @ from master CHECKS AND INSPECTIONS
washer. Unscrew
screw @ securing the bracket @ cylinder.
for sheath stopper of accelerator 4. Operating from inside the car,
control cable, in order to be able to remove stopper ring, remove pin and
CAUTION:
withdraw pedal pin enough to disconnect cylinder control fork
To clean or wash all parts of master
recuperate the clutch pedal from the from pedal (see: Clutch P e d a l -
cylinder, recommended clean brake
interior compartment. Removal).
fluid must be used. Never use mineral
5. Unscrew screws 0 fixing
oils or gasoline and kerosene to avoid
master cylinder to pedal assy and
damaging rubber parts.
then remove master cylinder.
ASSEMBLY DISASSEMBLY
1. Lubricate sliding part surfaces. 1. Remove filler plug on supply
2. Install piston assembly to cylin- reservoir, together with gasket and
der body. filter, and by means of a syringe
3. Make sure that master cylinder drain enough fluid to make level fall
operates normally. below connection to master cylinder.
4. Make sure that piston can move 2. Remove flexible hose connecting
maximum stroke smoothly. reservoir and clutch master cylinder
and remove pipe.
INSTALLATION 3. Loosen the rigid and flexible
pipes connections, connecting master
1. Install clutch master cylinder in
cylinder and clutch operating cylin-
reserve order of disassembly. Push rod 6 Cylinder body
Boot 7 Bleeder screw der and remove pipes.
2. Top up oil to correct level in
reservoir. Gasket 8 Gasket
Spring 9 Piston INSTALLATION
3. Bleed air out of hydraulic Ring
system (Refer to: Hydraulic System 1. Install clutch line in the reverse
Bleeding). order of disassembly.
CHECKS AND INSPECTIONS 2. Top up oil in reservoir to correct
@ : Tightening torque level.
Visually inspect all disassembled
Clutch hydraulic piping con- 3. Bleed air out of hydraulic
parts and replace parts which are
nections system. (Refer to: Hydraulic System
worn or damaged.
15+18 Narn Bleeding).
(1.5 + 1.9 kg-m CAUTION:
10.8 + 13.7 ft-lb) To clean or wash all parts of operat- HYDRAULIC SYSTEM
BLEEDING
ing cylinder, recommended clean
CLUTCH OPERATING brake fluid must be used. Never
1 Lock ring
2 Clutch operating cylinder HYDRAULIC SYSTEM
3 Back cover
P IPIN G 1. Remove clutch and brake hy-
draulic system reservoir plug and top
DISASSEMBLY
CHECKS AND INSPECTIONS up with recommended brake fluid
1. Remove push rod @ with (ATE “S” or AGIP Fl B r a k e
b o o t 0, p i s t o n @) a n d p i s t o n Visually inspect clutch lines for
Fluid Super HD corresponding to
spring @ from operating cylin- evidence of its integrity. Replace
Alfa Romeo Part No. 3681.69905).
der 0. damaged parts. If leakage occurs at
2. Remove bleeder screw pro-
2. Remove push rod from boot. joints due to loosening, retighten
tection b o o t @ o n O p e r a t i n g
3 . R e m o v e b l e e d e r s c r e w 0. and if necessary replace damaged
cylinder 0; install a hose on same
parts.
’ & 1 LA.2.0378
A.4.0144 A
- IP Autogrease FD
Std. N . 367 I-69833134
CLUTCH DISC
TIGHTENING TORQUES
Clutch caver to angine flywheel unit securing 15 + 23 1.5 + 2.4 10.8 + 17.4
screws
Hvdraulic system pipe fitting securing nuts 15 + 18 1.5 + 1.9 10.8 + 13.7
Clutch slip Some trouble symptoms may also be attributable to engine problems. First
determine whether engine or clutch is causing the problem.
Symptoms:
Clutch does not disengage well T O test for dragging clutch proceed as follows:
Refer to
Tool number Tool name
page
CONTENTS
May 1983
GEARBOX
13.74 + 17.36)
b
21
(4 + 4.9
28.92 + 35.43)
-.,Y . ,.C
‘~19 + 24
(1.9 + 2.4
13.74 + 17.36)
@ N.m
(kg-m
ft4b)
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 + 25
162.70 + 180.771
QI 69 + 8 5
(7 + a.7
50.61 + 62.91)
67 + 74
(6.8 f 7.5
/
49.17 + 54.23)
@ N+m
(kg-m
ft4b)
1 Direct drive shaft 14 R.G. driven gear 27 3rd speed driven gear
2 Spring 15 Bushing 28 4th speed driven gear
3 Bushing 16 1 st speed driven gear 29 Shim
4 P i n 17 Retainer 30 Bearing
5 Bearing 18 Guide sector 31 5th speed driven gear
6 Reverse gear shaft 19 Locking sector 32 Nut
7 Reverse gear 20 Synchronizing ring 33 Bearing
8 Primary shaft 21 Lock ring 34 Shim
9 longue 22 Sleeve 35 Pinion
10 Bearing 23 HUb 36 Bearing
11 Lock ring 24 Fietainer 37 Differential casing
12 5th speed driving gear 25 2nd speed drive gear 38 Bearing
13 Oil deflector 26 Shouldered ring 39 Crown gear
@ 25 + 2 6
(2.5 - 2.7 T N*m
0
18.07 + 19.52) (kg-m
ftdb)
May 1 9 8 3 13-4
GEARBOX
TRANSMISSION RATIOS
Overall ratio
A.3.Q42g7
r-i-l 10. Remove main selector rod 4
and recover selector 0, spring 8 3
and lever 0.
1 R e a r caver 3 Seal r i n g
2 Main selector rod
1 Screw
5. Remove guide pin @ for main 2 1st and 2nd speed rod
s e l e c t o r r o d @ return spring 1 3 Screw
7. U n s c r e w a n d r e m o v e screws8 4 4 3rd and 4th speed control fork
5 1st and 2nd speed lever
with relevant fixing washers from oil
6 Screw
sump; remove oil sump @ together 7 1st and 2nd speed control fork 1 Selector 3 Spring
with relevanr gasket. 2 Lever 4 Main selector rod
12. Remove 5th speed and reverse 14. Remove the following compo- ASSEMBLY
gear rod @ together with 5th speed nents from the seats on the rear 1. Set the corresponding 1st.2nd
c o n t r o l f o r k @ and sleeve 0. support of gearbox casing: and 3rd-4th speed control forks on
- The three detent halls @ from relevant synchronirer sleeve.
the three rods 2 . Insert d u m m y r o d . A . 3 . 0 3 0 3
- The two interlock plungers 3
after unscrewing screw 4
which give access to a channel
8 into assembly seat of 3rd and 4th
speed rod. Assemble through hole on
dummy rod a new spring with
w h i c h cari b e inspected b y a relevant detent hall, after greasing,
screwdriver able to move the t h e n b y means of the driver tool
interlock plungers considered. A.3.0309 insert: and compress t h e m
SO as to be able to move backward
rool rod to keep them into position.
3. Insert relevant rod into gearbox
casing seat pushing at the same time
tool rod. Complete assembly of rod
1 5rh speed and 3 5th speed control
reverse gear rod fork b y i n t r o d u c i n g i t i n t o t h e small
2 Sleeve hub of the fork and by aligning the
hole on the latter with the slot on
the rod.
13. Use a driftpin @ to remove 3rd
and 4th speed rod 2 and recover
its relevant fork 8 1 from syn-
chronizer sleeve. Proceed as above
for removal of 1st and 2nd speed
r o d @ t o g e t h e r w i t h f o r k @.
During removal o f s p e e d r o d s ,
depending upon the operation to be
carried out, i t may b e useful t o
keep in their seats detent halls and
interlock plungers: u s e f o r t h i s 4. Grease and assemble the two
purpose tool A.3.0303. interlock plungers in the horizontal
1 3rd and 4th speed control fork seats on the gearbox casing using
2 3rd and 4th speed rod guide tool A.3.0304 and driver tool
3 Driftpin CHECKS AND INSPECTIONS A-3.0309.
4 1st and 2nd speed control fork
Wash parts carefully before operating
5 1st and 2nd speed rod
on them. Superficial faults, wear and
efficiency of certain organs cari be
better detected. A.3.0304 - ,A.3.0309
The withdrawal 3rd and 4th speed
rods and 1st and 2nd speed rods 1. Inspect whether speed control
proceeds, as the millings appear, forks are not excessively worn or
respectively circular and rectangular warped.
shaped, in correspondence with the 2. Inspect w h e t h e r rods a r e n o t
rear support of the gearbox, it is warped.
n e c e s s a r y t o rotate t h e r o d s t o 3. Inspect w h e t h e r s l o t s o n r o d s
prevent the halls from getting in- bear any nickings.
serted into the millings themselves, 4. I nspect whether detent halls and
preventing thus the withdrawal from interlock plungers bear any nickings
being completed. or seizing marks.
5. Grease and assemble spring and together with relevant spring, then
1st~2nd speed rod detent hall, using lock securing plug and unscrew it by
tools A.3.0304 and A.3.0309. Grease one quarter of a rotation.
a n d insert relevant bal1 into radial M o u n t lock ring of 5th speed and
hole on rod. Insert then rod itself reverse gear rod on the end of the
into its seat on the gearbox casing, rod itself, on the differential side.
paying attention to the reciprocal
position of milling and of detent hall, 9. Assemble partially main selector
and make it pass through the small rod, by introducing it from the rear
hub of relevant fork. side of the gearbox casing, insert it
6. Use relevant securing plug to then into the selector lever, into the
close interlock plunger hole. spring and into the lever. Complete
7. Grease and use tools A.3.0303 then introduction of rod.
and A-3.0309 to assemble spring and Align axes of lever holes with the
c o r r e s p o n d i n g ones on rod and Screw
5th speed and reverse gear rod Ist-2nd speed rod
detent hall. mount spring pins using tool
6th speed and R.G. rod
Insert then rod 0, together with A.3.0322. R.G fork
5 t h s p e e d c o n t r o l f o r k 0, i n t o 3rdAth speed rod
Selector
small hubs of 5th speed and reverse
Main selector rod
gear lever @ and into reverse gear The speed selector lever pin @ 1 st-2nd speed lever
control fork @ together with must be shim fitted while the other
relevant sliding sleeve. lever% p i n @ must be fitted as a
striker on the edges of the pin
itself, with the excess portion of the “S” clearance between 1st”2nd speed
pin protruding on the selector’s side. lever and 3rd-4th speed rod
1.4 + 1.9 mm (0.055 + 0.075 in)
0: Tightening torque
Screw securing 1st2nd speed
selector lever to rod:
25326 N-m
(2.5 + 2.7 kgm
18.07+ 19.52 ftalb)
0: Tightening torque
R.G. switch to gearbox casing
40+49 N-m
(4 + 4.9 kg-m
2 8 . 9 2 + 3 5 . 4 3 ft-lb)
TESTING
Check working condition of spring-
plunger-rod assembly making sure
that speed selection is smooth and
that speeds do not jump out of their
position and become disengaged.
1 5th speed gear 3 Nur
2 Hub
Check working condition of spring-
plunger-rod assembly making sure /
that speed selection is smooth and
that speeds do not jump out of their
position and become disengaged.
SHAFTS AND GEARS
May 1 9 8 3 13-10
GEARBOX
CAUTION:
If friction between the pinion and
the inner race of the rear taper roller
bearing hinders withdrawal of the
pinion 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 h
relevant taper roller bearing @ and Synchronizing units
adjusting washer 0, from the R e m o v e t h e lock r i n g @ a n d
gearbox-differential casing. then remove in sequence: the syn-
9. Using tools A.3.0296 and chronizer ring 0, the guide sec-
A.3.0297, remove the pinion front ror 0, the locking sectoi-@, and
bearing outer race from the gearbox- the retainers @.
differential casing.
d--- - cl
1 R.G. shaft retaining screw
-3 lo2
1 Lock ring
2 Thrust bearing support 1 Pin retaining 3 Joint
spring ring 4 Spring ring
2 Direct drive shaft 5 Pin
2. Remove the direct drive shaft oil
seal ring located on the front of the
gearbox casing. 4. Having removed the direct drive
shaft, if necessaryL remove the direct
drive shaft bush with the help of tool
A.3.0291. This tool removes also
T O remove oil seal ring, with the oil seal ring.
mounted unit, operate as per figure
making use of tool A.3.0452.
Primary shaft
1 . F i t lock t o o l A . 2 . 0 3 0 0 a t t h e
end of the primary shaft @ in order
to prevent it from turning.
3; R e m o v e t h e s p r i n g ring 0
retaining the pin @ connecting the
direct drive shaft @ to the
joint 0.
Remove the pin in question and pull
out t h e d i r e c t d r i v e s h a f t . N o w Reverse gear shaft
remove the spring ring @ retaininq
1. Loosen a n d r e m o v e t h e R-G.
the pin that connects the primary
shaft to the joint; remove this latter
shaft @ r e t a i n i n q screw 1 and 0
then remove the shaft, with relevant
pin and pull out the joint from the
“q q e a r @ ‘and R . G . fork @
primary shaft. on gearbox-
its l o c a t i o n
differential casing. 1 Primary shaft
May 1 9 8 3 13-12
GEARBOX
7 . F i t pinion 0 back i n t o t h e
gearbox-differential casing.
8. Fit rear bearing on pinion
shaft 0, together with the first
section (fork shaped) o f tool
A-3.0490, at the location of the 4th
1 5th speed driving gear
speed driving gear. Now fit the
s e c o n d s e c t i o n o f tool A.3.0490
locking it on the pinion, by means of
4. Pull out the tongue securing the the relevant nut, a’t: the location of
5th speed driving gear to the primary the 5th speed driven gear.
shaft.
remove the A.3.0490
5. Loosen and Now remove the front floating
7 P’
screw 5
8 securing
shaft 3 front: floating bearing @.
the primary bearing from the primary shaft.
11. Remove the 4th speed driving
gear and relevant tongue.
1 Pinion
Bushings
Check pinion bushings for excessive
wear making sure that working
surfaces in contact with gears do not
s h o w any scratches or evidence of
pitting. Replace all parts that are not
flawless.
Carefully t i g h t e n screws o f t o o l
Bearings A.3.0296 on the gearbox casing to
avoid damaging the casing’s threads.
1. Carefully inspect all bearings by
slowly rotating them: no vibrations,
noise or sticking should be noticed if
bearings are in good working con- A.3.0491-
dition.
2. Check surface of all rings and
rotating parts making sure there are
no scores, marks or roughness due to
friction of foreign matter. Replace all
parts that are not flawless.
6. With the help of suitable plyers outer races and then fit them on the 3 . I f p r e v i o u s l y disassembled f o r
fit the lock ring in its seat on tha gearbox casing, using the same tools overhaul purposes, reassemble syn-
primary shaft’s rear bearing support. u s e d during d i s a s s e m b l y ( T o o l chronizing units (refer to: Synchro-
A.3.0296 for the rear bearing race, nizing units).
Make sure the lock ring is properly and tool A.3.0296 - together with 4. Apply the prescribed engine oil
lodged in its seat. tool A.3.0297 - for the front bearing to outer surface of bushings and then
race). fit them on gears according to their
7. Keeping the primary shaft relevant position at time of disas-
locked by means o f t o o l A . 2 . 0 3 0 0 , CAUTION: sembly thus restoring the original
fit tool A.3.0300 on same s h a f t ’ s T a k e special tare during a s s e m b l y working surface pattern.
rear end; center the shaft in the rear making sure that bearing races are 5. Partially insert bevel pinion into
bal1 bearing. exactly flat against casing surface. the gearbox casing and then fit all
Fit primat-y shaft on rear bearing. parts making up the train, while
8. Fit roller bearing on the primary 2. Fit the proper shim, selected in slowly p u s h i n g t h e pinion in till
shaft’s front end being careful to advance, on the pinion shaft (refer is reaches its final position. During
align the hole of the bearing’s outer to: Adjustments - How to determine this operation be sure to follow the
race with the corresponding hale pinion height). sequence and positioning show in the
in the gearbox-differential casing. Fit Using a press and tool A.3.0307, fit relevant figure, paying special atten-
securing screw into the hole in the the taper roller bearing inner race on t i o n to the R.G. driven gear @
gearbox-differential casing. the pinion shaft. and to the 4th speed shoulder
Fit securing screw into the hole and washer 0.
fully tighten it. Fit standard shim A.4.0141 @
(9.60 mm (0.378 in) thick) and the
Having completed primary shaft inner race of the rear taper roller
assembly, check and make sure it bearing @, making sure that it fits
turns freely on the bearings, without flat against the shoulder washer.
sticking.
0: Tightening torque
R.C. shaft to gearbox casing
retaining screw
19-24 N-m
(1.9+ 2.4 kg-m
13.74 + 17.36 ft-lb)
0: Tightening torque
Pinion gear train to pinion
shaft lock nut
2 2 0 . 5 + 245 N - m
(22.5 + 25 k g - m ” ’ k.4.0142 ’
162.70+ 1 8 0 . 7 7 ft-lb)
3. Fit rear taper roller bearing inner
0
race 2 and relevant lock nut onto
dummy pinion 0.
May 1 9 8 3 13-16
GEARBOX
0: Tightening torque
A.2.0274 Screws securing tool C.6.0162
A.4.0142 to gearbox-differential casing:
C.5.0124 40+49 N-m
1 (4 + 4.9 kgmm
28.92 + 35.43 f-t-lb)
~ A.4.0136 C.6.0162
7 Example:
Ll = 0 . 8 6
L2 = 0 . 8 8
c = 0.13
L, + L2 0.86W.88
s z!z- - (IC) = - (0.13)
2 2
0.86
(1) + 0.88
1.74
1.74:2=
(2) 0.67
0.67
(3) - 0.13
Computed shim
s = 0.74
thickness
Selected shim
thicknesr S = 0.75 m m
How to determine pre-load of roller bearings pre-loading: various parts do not rotate.
pinion &aft taper roller 6. Fit the shim selected as per
bearings S = 9.60 - G - 0.10 above computation; now fit the
bearing inner race, all the parts
CAUTION: whereas 0.10 is a play-correcting making up the 5th speed driven gear
Use only metric system in order to factor for taper roller bearing pre- set and lastly the nut.
avoid confusion in computations. loading. 7. Tighten the nut to specified
torque.
After having fitted all various parts as
described in paragraph “Reassembly - 0: Tightening torque
Pinion Shaft: Gears, item no. 5”, Pinion shaft gear train locking
measure pinion end play by carefully nut
following the procedure described 220 + 245 N-m
hereafter: ( 2 2 . 5 + 25 k g - m
162.70,+ 1 8 0 . 7 7 ft.lb)
1. Fit bracket A.2.0242 to gearbox
casing with the interposed spacers 8. Coat all gears of primary and
A-2.0234 and then a centesimal dial pinion shafts with specified gearbox-
gauge to the bracket. differential type oil (AGIP FI Rotra
- - F - J - -
MP SAE 8OW90 or IP Pontiax HD
1 Pinion 3 Rear bearing 8OW90).
2 Front bearing
Turn pinion shaft a few times in both
rotating directions to allow bearings
Select the shim with thickness to settle.
nearest to the value determined as 9. Fit coupling tool A.2.0274, the
per above instructions keeping in 1 dm rad. sheave C.!%O124, and The
mind, however, that max. allowed C.2.0037 weight to the pinion shaft
tolerance is * 0.02 mm and that nut.
thicknesses available as spare parts
have a 0.05 mm variation step.
A.2.0274 -
Example:
Standard shim
thickness = 9.60
G = 0.37
Play -correcting factor = 0.m
S =9.60-G-0.10
Properly tighten the screws securing = 9.60 - 0.37 - 0.10
9.23
2. Turn pinion @ a few times in (2)
0 . 1 0
-
both directions to allow bearings @
9.13
and @ to settle. Push pinion by
Computed shim
hand in one direction and reset the C-2.0037
thickness S = 9.13
dial gauge.
3. Move pinion in the opposite Tolerance = 0.02
direction and take reading of “G” Dimensional variation
play on dial gauge. steps of available spare 6
shims = 0.05
In case of subsequent end-play Selected shim
readings, it is necessan/ to rotate thickness S = 9.15 mm
again the pinion in both directions to 10. Check that weight descends
allow bearings to settle. 5. Loosen and remove the nut as normally without stopping and with-
well as the hub, rhe bushing, the out pulling the disc too fast.
4. Determine as follows the rear bearing inner race, and the standard Check that in such condition rolling
shim “S” thickness for pinion taper shim making sure that the train’s torque is as specified.
4
In case of rolling torque values sequent pin fitting are aligned; fit
A.3.0453 1
greater or lower than specified ones, the pin and a new retaining spring
correct them by fitting a rear shim ring.
either 0.05 mm thinner or thicker 3. Insert direct drive shaft into its
than the one previously fitted. seat and connect it to the bushing by
In this instance, rechecking of rolling fitting the pin and a new retaining
CAUTION:
torque is required. spring ring.
Cover direct drive shaft splines with
tape.
11. Caulk the nut with punch and Make sure that retaining spring rings
hammer. are properly lodged in their respec-
5. Fit the clutch drive thrust
12. First prevent shafts from rotat- tive seats so as to prevent pins from
bearing support and secure it to its
ing by engaging two speeds and then dropping out.
seat on the differential casing by
tighten the screw securing the oil
means of the relevant lock ring.
deflector to the primary shaft 4. After having applied grease
according to specified torque. ( I S E C O : M o l y k o t e BR2) t o i t s
Make sure that lock ring is correctly
sealing lip and to its work seat on
lodged; check that its tongues are
0: Tightening torque the shaft, fit a new oil seal ring on
facing the sleeve seat and thus
Oil deflector retaining screw the direct drive shaft with the help of
pressing it on the casing.
69; 8 5 N-m tool A.3.0323. During this operation
(7 + 8.7 kg-m be careful not to damage the sealing
TESTING
50.61 + 62.91 ft.lb) lip of coupling splines.
Check that hubs and synchronizing
Use tool A.3.0453 to assemble oil rings are in perfect working condi-
seal ring on direct .drive shaft, on tion and that engagement of gears is
assembled unit. noiseless and easy.
DIFFERENTIAL CARRIERS
13-19
GEARBOX
1. Loosen and remove oil sump Taper roller bearing outer race
retaining screws with relevant Phonic wheel
washers, now remove the sump and Ring nut
Spring ring
the seal gasket.
Bearing
2. Loosen and remove the
Oil seal ring
8
screws 1 securing the differential. Seal ring 7. Remove the bearing lock ring
carrier 2 to the gearbox casing Differential carrier from its seat in the differential
Partially pull back the carrier and Differential shaft carrier.
remove the two shims 0, being
4. Lock differential carrier in a vice
careful to mark the relevant position
and remove the ring nut securing the
to be later followed during reas-
differential carrier on the bearing and
sembly. Now completely disassemble
phonic wheel using tool A.3.0298.
differential carrier.
1 screw 3 Shim
2 Differential carrier
-.I -.
Following the same procedure, disas- ential carrier, proceed as follows:
semble the left hand differential 1. Apply gearbox oil to the oil seal
carrier. ring outer surface and fit it into its
seat on the differential carrier using Ff
9. In case of malfunction of speed
indicator device, remove sensor @
from gearbox after removing retain-
tool A.3.0430.
CAUTION:
L-.-J 1X.3.0292
ing spring @ and replace it.
Make sure the crowfoot on the oil
seal ring points in the direction of
the differential shaft rotation.
T T
i.- .-i
A.3.0430
Following fhe same procedure, reas- scribed in paragraph “Differential 3. With tool A.3.0287 remove
semble the left hand differential Casing - Assembly”, fit crown gear inner races of taper roller bearings
carrier. to differential casing. from the differential casing.
IO. Fit oil sump with relevant 2. Fit differential casing back to
sealing gasket. gearbox casing.
Pinion
Position the pinion into its seat in
the gearboxdifferential casing and fit
bearings and gears (refer to: Shafts
CROWN GEAR
and Gears).
AND PINION
DISASSEMBLY TESTING
A.3.0287 1 1
Verify back-lash between crown gear
Crown gear and pinion in four diametrically
1. Remove differential carriers opposite positions. Irregular back-
from the gearbox-differential casing lash, with excessive differences be-
(refer to: Differential’ Carriers tween the measured points, is an
- Disassembly). indication of crown gear deformation
2. Remove differential casing from with consequent flatness error
the gearboxdifferential casing (refer between gearbox casing/crown gear
to: Differential casing - Disassembly). place and differential casing plane.
3. Loosen and remove the screws Make sure the differential works
securing the crown gear to the properly and is completely noiseless.
differential casing and then remove Incorrect assembly of’crown gear and
the crown gear. pinion or worn taper roller bearings
could be the cause of the trouble.
Pinion
1. Remove gears from pinion shaft
4. Loosen and remove the screws
and then withdraw the shaft from its
seat in the gearbox-differential cas-
DIFFERENTIAL and washers securing the crown gear
ing, with relevant bearings (refer to: CASING to the differential casing.
Shafts and Gears). Now remove the crown gear.
DISASSEMBLY
CHECKS AND INSPECTIONS 1. Remove left and right hand
differential carriers (refer to: Dif-
Having thoroughly washed all parts,
ferential Carriers - Disassembly). CHECKS AND INSPECTIONS
proceed as follows:
2. Remove differential casing from Having thoroughly washed all parts,
1. Slowly rotate bearings checking
gearbox-casing, perform the followingchecking
them for vibrations, noise or sticking.
2. Check surface of all rotating operations:
parts and of roiling tracks for scores 1. Slowly rotate bearings checking
or any evidence of abnormal wear, them for vibrations, noise or sticking.
pitting or overheating; in the affir- 2. Check the surface of all rotating
mative, replace the parts involved. parts and of all rolling tracks for
3. Make sure that contact pattern scores and any evidence of abnormal
of bevel pinion teeth extends to their wear, pitting or overheating; in the
entire working surface. If any of the affirmative, replace the parts in-
teeth are nicked, replace the pinion volved.
and make sure the crown gear has 3. Visually check gears, both plane-
not been damaged as a consequence. tary and side gears, making sure that
Check both toothings for scores there are no scores or evidence of
and any evidence of pitting or excess pitting, that contact pattern extends
wear. to their entire working surface and
further that mating is noiseless and
ASSEMBLY smooth.
If necessary, replace the whole
1 Differential 3 Crown gear
Crown gear differential casing; in this case also
casing 4 Taper roller
2 Retaining screw bearing replace taper roller bearings.
1. Following the procedure de-
CHECKS AND INSPECTIONS Shafts and Gears Assembly). then fit thrust bearing on direct drive
2. Fit differential casing (Refer to: shaft (Refer to: Group 12).
1. Thoroughly clean casing with
Differential Casing -Assembly). 7. Fit rear support (Refer to: Rear
solvent and check it for scores, nicks
3. Fit differential carriers (Refer Support - Assembly).
or evidence of pitting.
to: Differential Carriers - Assembly).
2. Check the casing’s mating sur-
4. Fit rods and forks. Thoroughly
faces making sure there are no nicks,
clean rear cover and oil sump mating
no evidence of roughness nor or old
surfaces; fit new gaskets with speci-
sealants.
fied sealants and then fit cover
3. Check that the clutch for
and sump (Refer to: Rods and Forks
retaining pin is not in any way
damaged. - Assembly).
ASSEMB.LY
1. Fit rear support (Refer to:
5-Speed M a n u a l G e a r b o x - R e a r
Support).
2. Apply grease (AGIP Fl G r e a s e
15 or SHELL Retinax G) to the
1 Support 5 Spacer
1 Gearbox lever 5 Rear support spacer 0 on the speed selector
2 Nut 6 kasher
2 Spacer 6 Main selector rod 3 Washer 7 Screw lever to main selector rod connec-
3 Bushing
4 Nut with washer
7 Retaining screw
4 Flexible bush tion 40 and to the spacer 0
securing the fork to the flexible bush
2. Loosen and remove the gearbox 4. Remove rear support (Refer to: on the gearbox cover.
lever guide @ retaining screws with 5-Speed M a n u a l G e a r b o x - R e a r Apply 5 g (0.176 oz) of same grease
washers 0; now remove the guide, Support). to the speed selector lever guide 0.
the boot aand the bushing 0 6. Lastly remove the flexible bush 3. Go on to fit all gearbox outer
located at lever’s end. with the help of following tools: a linkage following disassembly pro-
press, a plate, a base and punch tool. cedure in reverse sequence.
1 Boot 3 Bushing
4 Guide 1 Spacer 3 Spacer
2 Screws with
2 Guide 4 Main selector rod
washers
TECHNICAL DATA
Differential ratio
GENERAL SPECIFICATIONS
APP.
“0.
Application Type Name Q.W
Lower screws securing differential carriers CEMENT DOW CORNING: Silastic RTV732
to gearbox casing Std. No. 3522-00040
N.B. For surface cleaning use: SURFACE Omnifit - Std. No. 3514-90003 -
FIXING
AGENT
“fl’ positioning of gearbox rear flexible support 1. ‘5” clearance between 3rd-4th speed rod 0 and
lst-2nd speed selector lever @
S mm 1.4 + 1.9
P degree 90 4 2
(in) (5.5. 10.*+7.4 IO-*)
ROLLING TORQUES
I tern N*dm
Dummy pinion
Thickness ‘3” of shims B for pre-loading of differential 1. Thickness ‘3” of shims for setting of pinion height
casing taper roller bearings
s = H (avg.) - 0 . 2 0
0.20 = corrective value for bearing preloading Ll, L2 = crown gear shaft deviation values
2. Thickness “S” of shims for pre-loading of pinion 3. Pinion to crown gear backlash
taper roller bearings
S = 9.60 - G - 0.10
TIGHTENING TORQUES
Unit
N*m kg-m ft-lb
Item
Noisy both during acceleration l Differential gears are worn or Replace gears
and deceleration (drive shaft damaged
assy already checked) l Excess play of hypoid gears Check and replace, if necessary
l Crown gear securing screws are Tighten
loose
l Bevel pinion shim is worn or Replace shim
damaged
l Pinion shaft retaining nut is loose Check gearbox components and
then tighten the nut
l Excess play in gear train Adjust gear train
Transmission is noisy when in l Teeth of planetary and side gears Replace differential casing
curve, both with speed engaged are worn, damaged or show evi-
or when in neutral (drive shaft dence of pitting
assy already checked)
Transmission is noisy when in l Reverse gears are worn or damaged Replace defective parts
reverse gear
Engagement/disengagement of First of all it should be established if the trouble is caused by the gearbox or by
speed is not easy the 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 gearbox
or from the control system.
Speeds become disengaged l Sleeves and gears are worn or Replace worn parts
defective
l Excess end-play of the gear that Verify adjustment of gear train
becomes disengaged (Noisy both
during acceleration and deceler-
ation)
Synchronizing unit is faulty l Sleeve and gear front toothing are 3eplace defective parts
or grinds worn or damaged
l Distance between gear and sleeve 3eplace defective parts
front toothing is incorrect
l Synchronizing ring is worn Replace
l Sleeve splines are worn or damaged Replace
Reverse gear light do not light l Switch of R.G. light is faulty Replace the switch
up when R.G. is engaged
Seizure, pitting or breakage l Oil level is below normal or oil is Replace faulty parts and use
not of the specified type specified oil
l Incorrect clearances (not enough) Adjust clearances and replace
faulty parts
l Bearing and gear ‘adjustments are
incorrect
l Excessive torque or improper use Replace faulty parts
of clutch
l Retaining screws are loose Replace faulty parts and tighten
screws to specified torque
CL-
-.
Refer to
Tool number Tool name
paw
Refer to
Tool number Tool name
page
-
($-$D
Refer to
Tool number Tool name
paw
CONTENTS
May 1983
DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY
DIFFERENTIAL
CROWN GEAR DIFFERENTIAL
AND PINION CASING
For crown gear and pinion over- Fey differential casing overhauling
hauling procedure refer to: Group 13 procedure refer to: Group 13
- 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.
1 Shaft
2 Wheel nut
3 Washer
4 Drive shaft
5 Washers
6 Stopper ring
7 inner race
8 Cage
9 Ball
10 Clamp
11 Boot
12 Clamp
13 Clamp
14 Boot
15 Clamp
16 Inner cover
17 Seal ring
18 Outer ring
19 Inner race
20 Cage
21 Ball @ N*m
2 2 Stopper ring A Outer joint
Ikgmm
23 Outer cover B Inner joint
ftdb)
24 Plate
ASSEMBLY
Reassemble joints being careful to fit
parts back into their original posi-
tion, as marked at time of disas-
sembly, and following the procedure
hereafter described.
6. Fit washers on shaft, wheel side, way along the splines; to this effect 7. Fit lock ring following disas-
according to numbering marked at splines should be covered with tape. sembly procedure in reverse se-
time of disassembly. Now fit the 2. Following disassembly proce- quence.
constant-speed joint with the help of dure in reverse sequence, now fit the 8. Fit the boot; fit new clamps and
a press, of two half-plates and of tool inner race and the cage. tighten them using suitable pliers
A.3.0605. 3. Fit steel balls as shown in the being careful not to damage the boot
figure and verify that the joint works in doing so.
properly. 9. Fit the three plates to the inner
cover, insert relevant screws and
washers, and lastly fit the outer cover
onto the six screws.
INSTALLATION
@ : Tightening torque
33 -F 36 N-m
(3.4 + 3.7 kg-m
7. Finish up lubricating by packing
24.56 f 26.75 ft-lb)
joint with 40 g (1.41 02) more of the
CAUTION:
above mentioned grease and make
Do not exchange this joint’s steel
sure that balls are completely sur-
balls with those of the outer joint as
rounded by grease.
their diameter is different.
8. Fit boot on joint; fit new clamps
and tighten them using suitable pliers
being careful not to damage the boot
in doing so. 4. Fit inner cover to the joint and
then fit the latter on the shaft with
the help of a press, of two half-
plates, of a base and a punch. 3. By means of a new nut, secure
wheel hub to shaft. Tighten nut to
specified torque, then caulk it.
0: Tightening torque
226 + 275 Ndrn
(23+ 28 kg-m
166.30 + 202.46 ft.lb)
TIGHTENING TORQUES
N.m
Screws securing (in oil), with outer spacer, drive 33 + 36 3.4 + 3.7 24.58 + 26.75
shaft assembly to differential shaft
Nuts securing drive shaft assembly to wheel hub 226 + 275 23 f 28 166.30 + 202.46
Necking during sudden torque l Too much play between seats and Replace the joint
reversal steel balls
l No r enough lubricating grease and Smear with grease and replace boots
leakage from the boots
Refer to
Tool number Tool name
we
CONTENTS
May 1983
FRONT SUSPENSION
DESCRIPTION
- A.3.0330
@ : Tightening torque
Bearing ring nut
226 + 225 N-m
(23 + 27 kg-m
116.3 + 195.2 ft-lb)
CHECKS
AND INSPECTIONS
l . Carefully clean hub and hub
support and visually check surfaces
for damage. Replace damaged parts,
if required.
2. Replace, at any rate, bearing
assembly, ring nut and seal ring.
ASSEMBLY
6. Clamp hub support in vice
1. Fit new bearing @ to hub 4. Insert support 0 into relevant
provided with jaws and fit dust cover
support @ by means of press, tool hub @ using press, tool A.3.0330
and brake disc.
A-3.0330 and stand A.3.0415. and plate.
FRONT SUSPENSION
COIL SPRING AND SHOCK ABSORBER
39.05 + 62.91k
I
‘
.lj
@ N-m
(kg-m
ftlb)
39.05 + 62.91)
1 Washer 10 Lower washer 19 Strut bracket
2 Upper washer 11 Rubber bound bumper 20 Flexible bush
3 Rubber support 12 Lower cap 21 Semi-trailing link
4 Complementary retainer 13 Lower retainer 22 Ball joint
5 Retainer 14 Thrust bearing 23 Flexible bush
6 Rubber seat 15 Bearing washer 24 Transverse link
7 Upper cap 16 Seal ring 25 Flexible bush
8 Boot 17 Strut
9 Spring 18 Steering lever
WARNING:
Compress spring as minimum as
possible so as to allow upper cap
rotation with relevant gasket and
retainer.
When compressing spring, ensure that
tool is always hooked firmly to
spring and lower cap.
CHECKS AND INSPECTIONS Refit remaining parts of strut .as- 2. Remove wheel from the opera-
sembly complying with sequence tive side.
Clean all the components.
shown on figure. 3. Loosen and remove shaft secur-
.;-’ Self-lubricating bush
j’.. ing nut (wheel side).
Check self-lubricating bushes embod- 4. Detach constant-speed joint
;..;,,,ied in strut lower cap retainers for from differential drive shaft by
’ : signs of excessive wear which are loosening the six securing screws
showed by metallic dust appearing and remove shaft.
,,- on’bush working surface. 5. Remove nut securing semi-trail-
ing link ball joint pin @ to hub
Shock absorber support and withdraw pin using tool
A.3.0157.
If required verified setting data re- 6. Loosen bolt @ securing trans-
levant to shock absorber built-in
verse link @ to engine cross mem-
strut. (Refer to Service Data and
ber @ and bolt @ securing to
Specifications-Checks and Inspec- semi-trailing link @ , then with-
tions). draw the removing transverse link.
Replace shock absorber in case they 7. Loosen bolt @ securing semi-
are removed because of inefficiency trailing link to body and remove the
or oil leakages are detected. link.
Spring lower and upper caps should
Springs be those corresponding with the-side
Visually check springs for anomalous .(righthand .or l&hand) to which
,
signs. strut is installed.
Rubber parts
INSTALLATION
Replace rubber parts if deformed,
damaged or aged. 1, Install strut in the reverse order
of removal and tighten following
parts to the specified torque:
ASSEMBLY
@ : Tightening torque
1. Lubricate seal ring and thrust
Screw securing hub support to 1 Cross member 5 Bolt
bearing of spring lower cap 0
strut bracket 2 Bolt 6 Semi-trailing link
retainer with grease (AGIP Fl Grease 3 Transverse link 7 Bolt
39t48 N - m
33 FD, IP Atitogrease FD). 4 Fin
(4 + 4.9 kg-m
Refit all parts of retainer to strut
28.9: 35.43 ft-lb)
complying with direction and order
marked during disassembly. 8. If required, after checking flex-
Nut securing strut to body
2. If previously removed, refit tool ible joints: remove flexible joints
12+ 15 N-m from semi-trailing links and trans-
A.2.0251 to spring @ and lower
(I,2 + I,5 kg-m verse jinks by means of proper tool.
cap @ with tool clamped in vice;
8,84 + 11 ft.lb)
compress spring so that subsequent
assembly procedure can be carried
Nut, steering tie rod ball joint
out.
on bracket lever
39 + 48 N-m
A.2.0251 (4 + 4.9 kg-m
1 2 8 . 9 + 3 5 . 4 3 ft.lb)
ro
TRANSVERSE AND
SEMI-TRAILING LINK
REMOVAL
1. Place car on lift. Support front
of vehicle on stands sited in adjacent
-position to jacking points and block
1 Lower cap 2 Spring rear wheels by hand brake.
TECHNICAL DATA
GENERAL SPECIFICATIONS
Seal ring and spring lower cap retainer GREASE AGIP Fl Grease 33 FD -
thrust bearing IP Autogrease FD
Norm. 3671-69833134
Hub support seal ring outer surface FLUID AGIP Fl ROTRA HP SAE 8OW90
IP Pontiax HD 8OW90
Norm. 3631-69408
Outer surface of the semitrailing link FLUID MILL01 L: Slider for rubber sections -
and front link silent block UNION CARBIDE CHEMICALS COMPANY
Ucon Lubricant 50 HB-5100
Norm. 1500-l 7502
Steering wheel shocks, l Excessive play in steering linkage Check and replace if required
vibrations or shimmying Tighten
l Loose screws securing steering
(cont.)
box
l Unserviceable shock absorber or Tighten or replace
loose securing points
Vehicle drifts or wanders Drifting becomes evident when vehicle is running on a flat surface with hands
off steering wheel. Reference should also be made to: Group 25 - Trouble
Diagnosis and Corrections
Abnormal tires wear l Refer to: Group 28-Wheels and Wheels and tires
(or uneven) Tires
Refer to
Tool number Tool name
I page
Refer to
Tool number Tool name
Page
IO
21-5
A.3.0415 Base of withdrawal fitment (to be used
with driver A.3.0330)
cl
21-5
A.5.0239 Wrench for bearing front hub nuts
CONTENTS
Mav 1 9 8 3
FRONT AND REAR BRAKES
SERVICE BRAKE
PEDAL ASSEMBLY
@ N-m
(kg-m
ft-lb)
0: Tightening torques
Unions of brake master cylin-
REASSEMBLY der pipes
For pedal assembly, reassembly, 8+10 N - m
reverse the order of disassembly and (0.8+ 1 kgam
apply a coat of the prescribed 5.78 + 7.23 ft.lb)
grease (AGIP Fl Grease 15) to the
1 Electric 5 Clutch master parts subject to sliding and to return Union of clutch master cylin-
connection cylinder fork springs. der pipe
2 Cable 6 Brake master 15 + 1 9 N - m
3 Nut cylinder fork (1.5+ 1.9 kg-m
4 Bolt
10.85 + 13.74 ft-lb)
INSTALLATION
1. Reinstall pedal assembly to body 6. Fill the brake and clutch oil tank
by reversing order of removal and up to maximum level.
complying with the following. 7. Carry out bleeding of brake
DISASSEMBLY
(1) Replace, if required, the gasket hydraulic system (see: Brake System
Disassemble pedal assembly operat- between pedal assembly and body. Bleeding) and of clutch (see: Group
ing as follows: (2) Tighten, to the prescribed 12 Hydraulic Control Sub-assembly
1. Remove retainer @ of pedals torque, t h e n u t s secuging p e d a l Hydraulic System Bleeding).
pin @ and washer @ . assembly to body.
2. Withdraw Pin and recover ped-
a l s @ a n d 0, a n d s p a c e r ‘@. 0: Tightening torque of pedal
3. Remove plastic bushes @ from assembly nuts
pedals. 9+15 N-m
( 0 . 9 5 1.5 k g - m
6.51 + 10.85 ft.lb)
N-m
(h-m
*lb)
b. Tighten to the prescribed torque syringe in order to suck the 3. Loosen and remove bolt @
two new nuts securing brake liquid of brake clutch tank. connecting the Panhard rod @ to
master cylinder to servobrake. b. A S piping is removed, remember body and loosen the equalizer
to plug up the ends in order to securing bolt @.
(T): Tightening torque avoid foreign matter from en-
Brake master cylinder nuts to tering.
servobrake . To remove pipes, loosen unions
BENDITALIA on both ends.
12+ 1 5 N-m . To remove hoses, unscrew
(1.2+ 1 . 5 kgmm unions collecting pipes-to hoses
8.68 + 10.85 ft4b) and remove them. Then, discon-
nect hose on the other side.
ATE c. At the end of installation on car,
21 + 28 N-m both front and rear flexible
(2.1 + 2.9 kg.m cables must not result to be
15.2 + 21 ft4b) kink. For their check, take as
reference the writing with the
c. Pipes must be connected to relevant manufacturer mark
master cylinder and tightened to located on end of pipes, or the
the indicative prescribed torque. light coloured band (for front
cables) located along pipe itself.
@ : Tightening torque d. Having completed installation of
1 Unions 5 Bolt
Unions securing pipes to brake piping, fill up brake fluid reser- 6 Bolt
2 Fork
master cylinder voir to proper level and bleed 3 Spring 7 screws
8-10 N - m the brakes (Refer to: Brake 4 Panhard rod
(0.8 + 1 kgmm System Bleeding).
5.78 + 7.23 ft.lb)
4 . L o w e r Panhard bar in order to
Tightening torques
d: Fill reservoir up to proper level easy spring @ withdrawing from
Hose unions of brake hydraulic
using only specified fluid (ATE pin 0, and from rubber ring @
system
“ S ” o r AGIP Fl B r a k e F l u i d located on rod itself. Remove spring
IO+ 1 5 N - m
Super ED, or IP Auto Fluid FR). by withdrawing i t f r o m equaliz-
(1 + 1.5 kgmm
7.23 + 10.85 ft-lb)
er 0 4
2. Bleed brake system (Refer to: 5. If necessary, remove bolt @
Brake System Bleeding) and, if and equaliter.
Pipe unions of brake hydraulic
required, also clutch system (Refer
system
to: Group 12 Subgroup Hydraulic 8+10 N - m
Control - Hydraulic System (O-S+ 1 kg-m
Bleeding). 5.78 + 7.23 ft.lb)
INSTALLATION 2. Remove non-return valve (iJ so that the crawfoot in the above
after having removti relevant figure points towards the intake
1. On bank, reconnect master cyl-
clips 0, manifold _
inder to servobrake tightening secur-
ing nuts to the prescribed torque
(see: Brake Master Cylinder - Instal-
lation).
2. For reinstallation on car of the
whole unit, reverse order of removal
and comply with the following.
(1) Tighten unions of pipes to the A Intake manifold side (black)
prescribed torque: IO + 14 N.m B Servobrake side (white)
(1 + 1,4 kg-m) (7.23 + 10.84 ft.lb).
(2) Lubricate connecting pin with
prescribed grease (AGIP Fl GREASE
15); then reconnect fork to brake
pedal.
(3) Restore level of brake fluid; then
carry out bleeding (see: Brake Valve 2 Clips
System Bleeding).
3. Check valve thoroughly making
sure it works properly, meaning that
VACUUM SYSTEM it allows air flow only in the direc-
1. Visually check hoses making tion shown by crawfoot.
sure they are in no way damaged or
clogged; also make sure clips are all 4. When fitting non-return valve
properly tightened. back to hose, be careful to position it
FRONT
DISC BRAKE
DBA CALIPER
@ 59 + 73
(6 + 7.5
43.38 + 54.23)
(0.2 f 0.35
1.45 + 2.53) b
Pad replacement 5. Remove both pads, each with 11. Restore proper brake fluid level
relevant dowel pin 0, and then in reservoir (ATE “S” or AGIP Fl
I. Lift car’s front end positioning it
remove pins from pads, Brake Fluid Super ED or IP Auto
on safety stands (Refer to: Group 00
-1 Fluid FR).
- Lifting Points and Towing).
2. Using suitable pliers remove
CAUTION:
retainers @ from setting plates 0
To restore correct braking, push
as shown in the figure below.
brake pedal all the way down a few
times.
Caliper unit
REMOVAL
CAUTION:
Do not lubricate in any way either
the pad’s resting seats on calipers nor
pad dowel pins.
CAUTION: ment).
Do not use metal tools and deter- 4. Connect oil pipe back to floating
caliper and tighten relevant union to
gents containing mineral oil.
specified torque; fill reservoir up
Floating caliper body with specified brake fluid (ATE “S”
or AGIP Fl Brake Fluid Super ED or
1. Check cylinder surface for
IP Auto Fluid FR).
cracks, evidence of excessive wear
and presence of rust or foreign
0: Tightening torque
matter. Brake pipe to caliper union
2. T o r e m o v e rust or foreign
IO+14 N-m
matter, clean the surface with a very
(1 + 1.5 kg-m
fine emery cloth. 7.23 f 10.84 ft.lb)
3. In case of more severe damage
replace floating caliper body.
5. Bleed brakes (Refer to: Brake
4. Check bleeder and make sure it
2. Connect brake fluid hose (Refer System Bleeding).
is in good working condition.
to: Hydraulic System Piping).
CAUTION:
3. Fill brake fluid reservoir up to
Piston At the end of installation on car,
max. level (ATE “S” or AGIP F 1
Check piston outer surface for make sure that hose are not kink.
Brake Fluid Super ED or IP Auto
cracks, evidence of excessive wear,
Fluid FR).
4. Bleed brake system (Refer to:
deterioration and presence of rust Brake disc
Brake System Bleeding). or foreign matter. In case just one of
above flaws is present, replace the REMOVAL AND INSTALLATION
Floating caliper piston or the whole floating caliper. 1. Remove from hub support, the
whole brake caliper without discon-
DISASSEMBLY CAUTION: necting it from hose (see: Group 21 -
Do not clean piston surface with Front Wheel Hub).
If required, carry out disassembly of
emery cloth but go on and replace it. 2. Remove brake disc from hub
brake caliper operating as follows:
1. Empty brake fluid reservoir with support after having removed the
Seal ring and boot dowel pin.
a syringe.
2. Disconnect brake fluid hose. Replace seal ring and booteach time 3. Install disc and caliper following
3. Remove floating caliper (Refer they are disassembled. removal procedure in reverse se-
to: Pad Replacement) and close it in quence.
a vice equipped with protecting jaws. Caliper support
4. Remove dust cover @ and then Check element good condition and
use a jet of compressed air to remove replace it if necessary.
brake piston @ from cylinder. CHECKS AND INSPECTIONS
5. Remove seal ring @ from its 1. Thoroughly clean brake discs
Clips
seat on cylinder. and check that working surfaces are
Make sure they are not damaged or
not deeply scored or porous. Replace
abnormally worn; replace them if
or machine them if necessary.
necessary.
2. Should machining of disc work-
ing surfaces be required, keep in
INSTALLATION
mind the following:
If previously disassembled, carry out
reassembly of floating caliper operat- (1) Always machine both surfaces of
ing as follows: each disc, removing the same amount
1. G r e a s e c y l i n d e r , p i s t o n a n d of material from each surface.
sealing ring applying a coat of rhe (2) Machining must be performed
prescribed brake grease (Grease ATE according to tolerances indicated in
Bremsrylinder Paste or DBA Grease); the Service Data and Specifications
1 Floating caliper 3 Piston fit seal ring on cylinder and then Section - “Checks and Adjustments”.
2 Dust cover 4 Seal ring insert control piston.
1 Pins
CAUTION:
Do not lubricate in any way the
3. Remove, in sequence: the lower
pads’ retaining seats on calipers.
pin, the cross spring plate 0, and
the upper pin.
7. Push piston back into floating
caliper.
CAUTION:
1 Floating caliper 2 Caliper support
To avoid overflow of brake fluid
when the piston is pushed back, it is
5. Fit caliper on a vice equipped
advisable to withdraw some of the
with protecting jaws and remove the
fluid from the reservoir with a
dust cover’s @ lock ring 0 as well
syringe.
as the boot.
6. Use a jet of compressed air to
8. Fit pads into their relevant seat
remove brake piston @ from
and then complete assembly by
cylinder on floating caliper body
fitting, in sequence: the first dowel
a
pin, the cross spring plate, and the
7. Remove seal ring @ from its
second dowel pin.
1 Cross spring plate seat on cylinder.
9. Restore proper brake fluid in
reservoir (ATE “ S ” o r -AGIP Fl
4. With suitable pliers, remove the Brake Fluid Super ED or IP Auto
pad on cylinder’s side. Fluid FR).
5. With a plastic hammer, strike
floating caliper on cylinder’s side CAUTION:
thus removing the other pad. To restore correct braking, push
brake pedal all the way down a few
times.
Caliper unit
1 Lock ring 4 Seal ring
REMOVAL AND INSTALLATION 2 Oust cowr 5 Floating caliper
Removal and installation procedures 3 Piston
May 1983 2 2 - 1 4
FRONT AND REAR BRAKES
0: Tightening torque
Brake pipe to caliper union
IO+ 14 N-m
(1 + 1.5 kg-m
7.23 + 10.84 ftelb)
@ N-m
(kg-m
ft.lb)
1 Bleeder cap
2 Bleeder
3 Dust cover
4 Piston 14 Vibration -damping spring
5 Seal ring Vibration - damping spring stop
6 Spring
7 Cylinder body
8 Knuckle pin securing plate
9 Jaw driving plate 19 Adjustment lever
10 Jaw return spring 20 Jaw
11 Spring 21 Shoe holder disc
JAW REPLACEMENT 6. Disassemble, (if required) the c. On installed drum, adjust dis-
adjustement device, operating as tance between jaw-drum b y
1 Handle 9 Bush
2 Lever 10 Sector gear
3 Pushbutton 11 Light switch
4 Spring 12 Bolt
5 Stopper 13 support
6 Rod 14 Pin
7 Paw1 15 Adiustment fork
8 Pin
- on operation (clearance
determined by pad auto- 0.05 + 0.2 mm
matic feed) ( 1 . 9 7 low3 + 7.87. 1O-.3 in) Min. S (wear limit or min.
serviceability thickness) 7 mm (0.276 in)
TIGHTENING TORQUES
Unit
Item
N*m I kg*m ft.lb
Screw securing front brake disc to wheel hub 6 A 8 0.6 + 0.8 4.34 + 5.78
Nut securing pedal assembly unit to body 9 f15 0.9 + 1.5 6.51 + IO.84
Securing bolt of brake pressure regulator valve 15 f 24 1.5 f 2.4 10.84 t 17.3
Screws securing wheel cylinder to back plate 6 -5 .9 0.6 + 0.9 4.34 + 6.51
Bolt fixing parking brake lever to support 9 f 15 0.9 + 1.5 6.51 + 10.84
- Tyre wear
- Tyre pressure
- Brake fluid or any way, verification of compliance with programmed maintenance specifications.
Excessive pedal travel l Leakage in brake master cylinder Overhaul brake master cylinder
l Use of a brake fluid with too low Replace with specified brake fluid
boiling point and bleed system
Poor braking effect l Fluid leakage in brake lines Check master cylinder, piping and
wheel cylinder for leaks, and repair
l Grease oil mud or water on lin- Clean brake mechanism and check for
ings or pads cause of problem. Replace lrnrngs or
pads
22-22
FRONT AND REAR BRAKES
l On disc brakes, lateral runout of Check with dial indicator, turning disc
brake rotor is excessive my hand. If runout exceeds specifica-
ions, repair or replace disc
Rear lock (Under light brake Faulty brake pressure regulator ?eplace
pedal force)
Rear lock (Under heavy l Poor front braking effect Disassemble and adjust front brakes
brake pedal force)
l Grease oil mud or water on linings Jean or replace
or pads
Servobrake out of order l Air leakage at check valve nspect check valve
l A i r l e a k a g e a t p i s t o n s e a l riny
Not adjustable engine idle Engine sucks air through servobrake Replace check valve or servobrake as-
speed (no leakage at con- semblv
nectors)
When parking brake control l Shoes are jammed on drums Unlock or replace faulty parts
lever is released, the car re-
l Return travel of cables is ob- Remove obstacle and replace cables
mains braked
structed
-
When parking brake control l Control lever release pushbutton Disassemble lever, and release or re-
lever is released, the car re- does nor spring back place if
mains braked
(continued)
regulator
CONTENTS
May 1983
STEERING SYSTEM
STEERING SYSTE.M
39 4 48
28.92 + 35.43)
1 Track rods
2 Steering rack @ N.m
3 Universal joints
kg-m
4 Lower column (4 + 4.9 ft.lb)
5 Upper column 28.32 + 35.43)
GENERAL DESCRIPTION
Steering i s b y r a c k a n d p i n i o n . they reduce the variation of wheel is positioned so as to collapse under
The track rods are connected to the movement resulting from suspension axial loads. The upper part is pivoted
centre of the rack by means of movements. The steering column is to allow adjustment of the steering
flexible joints. Owing to their length, in two sections The lower part column height.
@ N.m @39 f 4 8
(kg-m (4 + 4.9
fMl) 1 Spacer 7 Nut 28.92 + 35.43)
2 Plate 8 Elastic joint
3 Rod 9 Nut
4 Nut 10 Washer
5 Ball joint 11 Plate
6 Washer
INSPECTIONS
that on the static load position,
ball joint @ and remove it from
upper plane of ball pin is parallel to
rod 0.
gasket face.
1. Check against damage or wear in
the steering rods ball joints, .and
verify that pivot free from crawling
or with notable sla.ck in their seats. If
necessary, replace them.
2. Check elastic joints against
damage, wear or excessive slack. If
necessary, replace them.
3. Check steering rods against
1 Rod 3 Ball joint
damage or deformations. If neces-
2 Nut
sary, replace them.
3. Lock the elastic joint fixing nuts
ASSEMBLY to the rack studs, with the front
INSTALLATION
(4 f 4.9 kg-m
28.92 + 35.43 ft.lb)
STEERING BOX
DISASSEMBLY 6. Remove the cover @ from rack 9. Remove pinion from rack box
b o x 0, s c r e w U P a n d e x t r a c t together with the bearings, by means
1. Remove clamp @ fixing right adjustment screw 0, spring @ of a plastic hammer and a supporting
b o o t @ t o s l i d i n g s l e e v e 0. and plunger @ for backlash. Then base.
2 . E x t r a c t e n d c a p 0, r e m o v e lever with a screwdriver and remove
plastic support @ and extract right lower protection cap @ of rack
boot 0. control pinion.
CAUTI0.N:
Plastic bellows be replaced whenever
disassembled from steering tube for
any reason.
1 Covei- 4 Plunger
-2 Adjustment 5 Rack box
screw 6 Lower cap
1 End cap 4 Clamp 3 Spring
2 Support 5 Sleeve
3 Right boot
7. Extract rack @ from guide 10. Remove lock ring 1 fixing
3. By means of nut and lock tube 0. bearing @ on pinion 83 , after
unscrew and extract studs 0, then placing it in a vice provided with
remove plate @ and spacer @ for protective jaws.
rod support.
4 . R e m o v e c l a m p @ fixing left
boat
84 and extract it from
sleeve 1 , then extract sleeve from
rack tube.
1 Rack 2 Guide tube
1 Sleeve 5 Plate
2 Spacer 6 Nut and lock nut
3 Clamp 7 Studs
4 Left boot
1 Lock ring
1 Tube 2 Sliding member
INSTALLATION
1. Mount steering box assembly on
vehicle by tightening securing screws
I CJ
4 at the prescribed torque 39 + 48 N.m
(4 t 4.9 kg.m, 28.92 + 35.43 ft.lb).
1 Steering box Refit end cap on the rack box.
2 Adjusting screw
2. With the wheels in the straight
2 Aligned space and notch
4 Screw rotation ahead position, mount steering rods
(2) Check with space in the screw is and Tighten them at the prescribed
most centered with respect to a 10. Verify that steering pinion ro- t o r q u e 3 9 + 48 N-m (4 + 4.9 kg.m,
notch in the box; loosen screw until tates up to the rack rod end-of-stroke 28.92 + 35.43 ft.lb) with vehicle at
the diametrically opposite space to in both directions smoothly. nominal height.
the one centered with the first 11. Tighten boots fixing clamps, for 3. Check toe-out (Refer to:
notch on the box is aligned. both ends of each boot not to be Group 00 - Chassis and Body Main-
tenance).
GENERAL SPECIFICATIONS
2. u cutout positioning angle on rack pinion (rack 4. Thickness of rack guide pad. The available thickness,
centered as per point 1) in increasing order are provided in the below list (they
can be distinguished by the paint mark on pads):
white yellow red green blackish blue
TIGHTENING TORQUES
Unit
N.m kg*m frlb
Item
Nut securing track rod ball joint to lever 39 + 4 8 4 + 4.9 28.92 + 35.43
on strut
Nut securing steering wheel to steering column 17 + 21 1.7 + 2.1 12.29 + 15.18
Bolts securing upper steering column to lower 27 + 31 2.7 f 3.1 19.52 + 22.41
steering column and to steering box pmron
Bolt securing steering column lower support 14 f 18 1.4 + 1.8 10.29 + 13.01
to body
Nut securing steering column upper support 16 + 20 1.6 + 2.0 11.56 + 14.46
to body (“1
Excessive steering wheel backlash l Loose steering box screws Tighten screws
23-13 M a v 1983
CONTENTS
May 1983
REAR SUSPENSION
DESCRIPTION
The rear suspension is a rigid axle The transversal connection is carried Between axle and body near the
one. The axle longitudinal anchorage out by means of a tension rod wheel hubs are interposed the
is carried out by means of two (Panhard b a r ) anchored on one suspension springs with coaxial shock
tension rods, on each side, connected side to the axle and on the other to absorberry. The wheel rebounds are
to the body and placed according to the body, in order to prevent body limited by rubber pads assembled on
a Watt parallelogram, so as to limit side movements with respect to the the shock absorbery.
car raising when braking. wheels.
REAR HUB
REMOVAL
WHEEL BEARING
If the surfaces of tracks and conical
rollers present pittings, roughnesses
and ovalizations, replace bearing
unit.
CAUTION:
Should a bearing be no more utili-
zable, replace both the inner and the 3. Lubricate outer rings of bearings
outer one at the same time. with bearing specified grease (AGIP
Fl Grease 33 FD, or IP Autogrease
FD), and insert 40 + 55 g. into
the hub inner chamber.
KNUCKLE PIN
Make sure knuckle pin is not dam- 5. Assemble hub on stem pin and
aged and thread is sound; replace pin then insert outer bearing lubricated
if necessary (for replacement see: with specific greade, washer and new
Rigid Axle). check nut.
9. Carry out wheel bearings pre-
loading adjustment (see: Group 00
Maintenance of Mechanical Com-
CAUTION:
The grease must not get in touch
A.3.0328
with drum braking surface.
/
REAR SUSPENSION
@ 33.35 + 36.26
(3.4 + 3.9
24.58 + 28.2)
@ N-m
(7 + 8.7 (kg-m
50.63 + 62.93) h-lb)
24.58 + 28.2)
13 Front tie rod
Upper cup 7 Coil spring
14 Brake adjuster
Rubber bumpers 6 Shook absorber anchor fork
15 Panhard bar
Lower cup 9 Rear tie rod
16 Pin
Upper gasket 10 Stud plate
17 Rear axle
Upper cap 11 Stem pin
Shock absorber 12 Gaskets
SHOCKS
ABSORBERS
REMOVAL
3. Release bolts 0 and bolt @
After duly blocking front wheels,
securing rear tie rods and Panhard
lifting car front and placing it on
bar to body respectively.
supports stands (see: Group 00 -
Lifting Points and Towing) remove
shock absorbers as follows:
1. Remove wheels.
2. Release bolts 2
0securing front
tie rods @ to body.
May 1983
25-5
REAR SUSPENSION
INSTALLATION
Assemble shock absorbers on car in d. Restore rear brake oil delivery
the inversed order with respect to tube connection and perform
removal and remember the following brake system air bleeding (see:
indications: Group 22 - Front and Rear
a. Assemble shock absorber com- Brakes - Brake Air Bleeding).
ponents and secure their upper
part to the b o d y .
M
nents and Body).
L A.2.0070
body coupling.
REMOVAL
If necessary, disassemble axle as
IMPORTANT
. With static load car (see: Group
INSTALLATION
00 - Maintenance of Mechanical
Assemble coil springs onto car again Components and Body) set the
in the inversed order of removal and bolts securing tie rods and
bear in mind all indications and notes Panhard bar to the prescribed
reported in paragraph Shock Ab- torque.
sorbers Installation. 3. Extract dust cover from brake
@) : Tightening Torque drum and caulk wheel hub nut.
Tie rod and Panhard bar Remove nut and drum complete with
hub and bearings.
REAR RIGID AXLE securing bolts
4 . S c r e w o u t c o n n e c t i o n02 o f
3 3 . 3 5 + 3 8 . 2 6 N-m
(3.4 + 3.9 kg-m brake hydraulic system rigid tube on
24.58 f 28.2 ft-lb) jaw control cylinders and remove
REMOVAL AND rear tubes @.
INSTALLATION 5. Screw out and remove nuts @
Lubricate with prescribed grease
Place car on hoist bridge, support its fastening stem pin and brake shoe
(AGIP Fl Grease 15) the hole in 7
rear part by placing some stands in plate @J to rear axle.
the brake adjustment spring
the jack seats and remove the whole
support stud on the Panhard bar
rear suspension as follows.
and the fork.
1. Remove wheels.
Carry out brake adjustment
2. Working from passenger com-
spring calibration (see: Group 22
partment, remove rear console for
- Brake Adjustment).
parking brake equalizer to be ac-
Set the brake hydraulic system
cessible. Then act on adjustment fork
connections to the prescribed
nut and lock nut and loosen parking
torque and perform air bleeding
brake control cables as much as to
(see: Group 22 - Brake System
allow their releasing from equalizer;
Air Bleeding).
extract them from sheath locking
bracket.
@ : Tightening Torque
3. After providing the column hoist
Rigid tube connections
with support A.2.0070, remove coil 7.85 + 9.8 N-m
springs with caps and gaskets (see:
(0.8 + 1 kg-m 1 Block shoe plate 3 Nuts
Coil Springs - Removal).
5.78 - 7.23 ft-lb) 2 Connection 4 Rear tubes
GENERAL SPECIFICATIONS
Wheel hub inner cavity and dust cover GREASE AGIP Fl Grease 33 FD 40+55 g
IP Autogrease FD 1.41+1.94 oz.
Std. No. 367 l-69833/34
Seal ring rim
Tie rod end (front and rear) silentblock FLUID UNION CARBIDE CHEMICALS CO.
outer surface and Panhard bar (at Ucon Lubricant 50 HB-5100
assembly)
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
STEERING GEOMETRY
(See: Group 00 - Rear Axle and Suspension)
TIGHTENING TORQUES
Bolts securing Panhard bar to body 68.67 + 86.35 7 + 8.7 50.63 + 62.93
Bolts securing front and rear tie rods to body 33.35 + 38.26 3.4 + 3.9 24.58 + 28.2
Bolts securing stem pin to axle 39.24 + 48.1 4 + 4.9 29.92 + 35.43
Brake hydraulic system rigid tube connections 7.85 + 9.8 0.8 + 1 5.78 + 7.23
Brake hydraulic system flexible hose connections _. 9.8 + 14.7 1 + 1.5 7.23 + 10.85
Refer to
Tool number Tool name
page
CONTENTS
May 1983
WHEELS AND TIRES
CHECKING TIRE
If tires are provided with “tread wear Trouble Probable cause Corrective action
indicator”, when marks appear, re-
place tires.
1 Underinflation Check and adjust
2. Remove pebbles, glass or any (both sides wear) pressure
other foreign material embedded in
1 Hard cornering Reduce speed
the threads.
3. Check tread and side walls for 1 Lack of rotation Rotate tires
cracks, holes, separation or damage.
4. Check tire valves for air leakage.
Shoulder wear
Feathered edge
Tire pressure should be measured
when tire is cold.
Uneven wear
TIRE ROTATION
Operation to be carried out every
5,000 km (3,107 miles).
TIRE REPLACEMENT
CAUTION:
Two types of wheel screws are used:
one is designed for use with steel
wheels and the other for use with
light alloy wheels. Do not mix
different type wheel screws.
1 Screw for light alloy type wheels
2 Screw for steel type wheels
Inspect wheels thoroughly paying it taking the following points into 4. Lock rear wheels by means of
special attention to the following consideration: two wedges, one for each wheel.
points, in order to ensure satisfactory 1. Correct unbalance as soon a s 5. Set up balancing machine and
steering condition as well as maxi- relevant symptoms appear such as auxiliary equipment; make sure indi-
mum tire life. If any defect is pres- wheel tramp and shimmy. cating finger is placed under suspen-
ent, repair or replace as required. 2. Balance wheel with tire both sion’s cross arm and in line with the
statically and dynamically. arm-wheel support joint.
1. Check wheel rim, especially rim 6. Start up the engine, engage 4th
flange and bead set, for rust, dis- speed and then rev engine up to max.
tortion, cracks or other faults which WHEEL BALANCING speed as per speedometer reading.
might cause air leaks. Proper func- PROCEDURE 7. Perform wheel balancing accord-
tioning of tubeless tires depends on ing to usual “Equitron” type balanc-
effective sealing between tire bead ing machine procedure.
and wheel rim. CAUTION:
2. Thoroughly remove rust, dust, Considering the special construction
oxidixed rubber or sand from wheel features of the differential assembly, Rear wheels
rim. it is imperative that balancing of 1. Lock front wheels by means of
Rim’s bead seats should be suitably wheels - especially of front ones - two wedges, one for each wheel.
cleaned (for ex. using neutral type be performed according to the 2. Lift car rear, inserting jack under
detergent, cloth, etc...) being careful procedure hereafter described in axle. Position two stands in corre-
not to damage the wheel surface’s order to avoid serious damage. spondance with stand rear seats and
protecting film. then lower the car.
3. Replace wheel when any of the 3. Set up balancing machine and
following occurs: auxiliary equipment; make sure
. Bent, dented or heavily rusted Front wheels probe is placed under the suspension
wheel 1. Lift car front with a dolly-type spring. Let the wheel rotate by
. Bolt holes are out-of-round hydraulic jack placing same under means of a wheel accelerator device,
. Excessive side or radial runout relevant lifting point (Refer to: then carry out balancing operations
. Air leaks through welds Lifting Points for jacking up). with the modalities for balancing
2. Place two stands in line with machine of the .“Equitron” type.
front jacking points located under
WHEEL BALANCE car body.
3. Lower car till it rests on stands
Inspect wheel and tire for proper but locking the jack as well (thus
wheel balance; if unbalanced, correct achieving a three-point support).
BALANCE WEIGHTS
POSITIONING a. Be sure to place correct balance
weights on inner edge of rim.
b. Do not pure more than two
weights on each side.
c. Two types of balance weights
are used: one is designed for use
with steel wheels and the other
Q Li for use with light allowy wheels.
Do not mix different type
balance weights.
d. Properly rebalance wheel and
tire whenever puncture is re-
1. Balance weights paired.
GENERAL SPECIFICATIONS
DYNAMIC BALANCE
Max. 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)
TECHNICAL DATA
..
CONTENTS
May 1983
ELECTRICAL SYSTEM
pI----- @
HG Grey - yellow
iiP%?
- 1’ HN Grey - black
HP? Grey - red
HV Grey - green
The chain line, on wiring diagram, G Yellow
delimits those areas containing the GB Yellow-white
specific variations for the models GN Yellow - black
indicated by “U .,.I’. GR Yellow - red
The detail shows a reference to knot GV Yellow - green
relevant to electronic device N ._. N Black
NZ Black - violet
M Brown
MB Brown -white
l+++(m) MG
R
RN
Brown - yellow
Red
Red - black
FT(‘) S
SB
Pink
Pink -white
The connection identifies two wiring Pink - black
SN
variations, present in alternative and V Green
connected in the same way. The The figure shows the type of diagram Green -white
VB
wiring variations are referred to the used to identify the two connectors Green -black
VN
models indicated by “U . . . “, relevant to each joint: for the male z Violet
connector it is applicable diagram ZN Violet - black
(m); for the female one it is applica-
In case of mixed color, the base color
ble diagram (f).
is indicated first, followed by the
present stripe col.or.
i.e. BN = White with Black stripes
Cable colors
Cable section
A Light blue
AB Light blue - white Cable section not indicated is
AN Light blue - black 0 . 5 mm2 (0.39 . 10m3 in2).
AR Light blue _ red
In the horizontal line, table shows 6 White
position of control or of switch to be RN W h i t e - b l a c k
operated. In the vertical line it shows BR White red
the terminals between which conti- BLN Blue - black
nuity generates. BLR Blue - red
This type of diagram is helpful in that supply of both instrumentation Failure must then be due either to
identification of specific troubles and windscreen wiper are realized via fusebox (see.: Fuses- Services protect-
relevant to the part of electric ignition switch and fusebox. T h e ed by fuses) or to the following parts
diagrams concerning supply i.e.: the result is then that ignition switch of the electric system, that is in
windscreen wiper is not functioning. operates correctly and no failure is the wiring windscreen wiper or in the
A first check’ shows efficiency of present along wiring between battery ground connection.
instrumentation supply. From dis- and switch itself. For fault identification, refer then to
tribution diagram it can be noted the windscreen wiper wiring diagram.
r- - - -1
4
fO(I\
E -
I
\I
I
-,
-
I
/
\c
-
-
I
\I
-
\
-
I
m+
r“!N
”
0: ;
LL z
Y
P
0
Y
n
II
- - - -
-
-
- - -
- - -
- - - - -
I
I -
May 1983
ELECTRICAL SYSiEM
FUSES CHECK
LOCATION CAUTION:
?he fusebox is integral part of the a. In case a fuse blows, before
support board and is lo&d on left replacing it, make sure that the
side of the intermediate bulkhead, in cause of failure has been re-
the engine compartment. moved.
b. Use fuse having the prescribed
amperage, only. Do never use
fuses having amperage greater
than the prescribed one.
C. Correctly insert fuse into fuse-
box, aligning it carefully with
respect to its seat.
cl. Should car remain stationary
1 Fuse for a long time, remove fuse
protecting supply circuit of
clock.
SERVICES PROTECTED BY FUSES
In the following table, for each model, it is specified which are the services protected by each fuse.
Model
---I-
Protected Service 1350 1500 Q.* 1500
905.02 905.04 905.06
905.03 905.05 905.07
I
Power windows X X
Clock X
16
Horns-cigar lighter X
Trip Computer
- .--
Windscreen wiper-Windscreen Wiper electronic intermittence genera-
%
--l---
tor. Windscreen wiper controlWindscreen washer pump control- 8 X
Cluster
Heater switch
Clock
Modal
81 1200 1360 1500 a.* 1500
: Protected Service Ampere
905.00 905.02 905.04 905.06
305.03 905.05 905.07
Cut-off solenoid valve - Reverse switch 8 X X X
8
Trip Computer - Check Control X
Side lights left front and right rear-R. H.number plate light X
Clock X
9
Check Control
Cigar lighter X
Side lights right front and left rear-i. H.number plate light X
a* = Quadrifoglio
IGNITION SWITCH
REMOVAL AND
INSTALLATION
For removal and installation of the
ignition switch - antitheft steering
lock group, refer to: Groupe 23 -
Steering Wheel and Column.
LOCATION
The electronic device for headlights The device which controls intermit- CHECK
and flashing changeover, and the tences of both side lights and hazard The electronic devices and intermit-
windscreen wiper electronic intermit- lights, is located in the dashboard tences must be of the type indicated
tence generator, are mounted on a inside. in the specific table on page 40-g.
support board, located in the inter- For identification of the various
mediate bulkhead, in proximity to devices, see: “Electric Component
the fuse holder box. .Location”.
Passenger compartment
roof lamp timer NlO
4%+L
1
Horns relay 13 2
++
40-9 M a y 1983
ELECTRICAL SYSTEM
LIGHTING SYSTEM
LAMPS
CAUTION:
Before starting operations on lighting
system, make sure that the ignition Lamp characteristic data, type and
switch is to the “ST” position and e l e c t r i c p o w e r a r e l i s t e d i n the
the battery ground cable is discon- following table.
netted.
Electric power
Lamps TYPe
IWI
- reversing light 21
Roof lamp IO
TYPES OF LAMPS
The lamps used for the car are of 2. Bayonet lamp - type B
four types. For removal the follow- To remove it from lampholder, press
ing procedure is recommended. the bulb, rotate it counterclockwise,
then withdraw it.
1. Halogen lamp - type A
4. Whole glass - type D
To remove it from lampholder,
It is pressed into lamp holder and to
disconnect connector, then rotate
remove it, it is necessary to withdraw
retaining spring being careful not to
lamp out of lampholder.
touch it with naked hands.
VIEW FROM M
d
5
0 - zero position
2 - low beams
A - zero position
Left lever
Movement parallel
B - full beam flashing (paired to rotation in
the 0 and 1 positions)
to steering wheel axis
D
I .
- Headlight change over (paired to rota-
tion in position 2 )
- zero position
REMOVAL AND
INSTALLATION
1. Removing steering wheel.
2. Unscrew the five securing
screws and remove upper and lower
shell covers of steering column
(see Group 23 - Steering Wheel and
Column).
3. Disconnect connectors @ of
the combination switch unit.
4. Remove combination switch
unit by unscrewing the two
screws 0 1 securing it to steering 1 Screw
column. 2 Connectors
If necessary, disassemble combina-
tion switch unit separating the ‘CWO
levers.
5. For installation reverse order of
CHECKS AND INSPECTIONS means of a tester, check electric
removal.
continuity.
Check harness integrity and, by
OUTSIDE LIGHTING
May 1983
ELECTRICAL SYSTEM
d1
-
-
i
,
I’
Check
DIRECTION LIGHT SWITCH
Connect a tester to terminals of
Operation of direction indicators is
reverse switch and verify the follow-
executed via left lever of combina-
ing resistance values.
tion switch (see: Combination
Switch Assembly).
W h e n in the O F F position = -a
HAZARD LIGHTS SWITCH When in the ON position = 0 a
Check
Verify switch functioning by check-
ing whether continuity between Location
terminals occurs in accordance with The switch is mounted on upper
the indications provided in table. ornament of central console (see:
Location Group 66 - Consoles).
The switch is mounted on the
REVERSE LIGHT SWITCH relevant bracket of pedal assembly.
Check.
Verify switch functioning by check-
Check ing whether continuity between
terminal occurs in accordance with
Connect a tester to terminals of stop
the indications provided in table.
light switch and verify the following
resistance values.
REMOVAL AND
INSTALLATION
With reference to the exploded view
proceed as follows.
1. Operating from engine com-
partment inside, disconnect harness
from cover 0.
2. Remove grille (see: Group 75 -
Grille).
3. Unscrew the two nuts securing
combination lamps to body.
(3) For installation of transparent 6. For installation, reverse order of 1. Operating from fender inside,
cover, reverse order of removal. remova I. compress the two springs securing
transparent cover of side direction
LAMP REPLACEMENT i n d i c a t o r @ to fender @, t h e n
CAUTION: remove it.
Do not touch with the hands glass of 2. Withdraw lampholder @ from
Headlights and front side lights
1. Operating from engine com-
headlight halogen lamp 2 . If this 0
direction indicator 1 _
occurs, wash the glass. 3. Replace lamp @ by pulling
partment inside, rotate cover 0 the relevant bulb.
clockwise, then remove it. 4. Install direction indicator by
Front direction indicators reversing order of removal.
1. Operating from engine com-
partment inside, rotate lamp- SETTING OF HEADLIGHTS
h o l d e r @ counterclockwise, then LOW BEAM
remove it.
Carry out the following procedure to
2. Press lamp bulb @ and rotate
adjust headlight low beam.
it in order to withdraw lamp.
1. Check that tires are inflated at
3. Replace the lamp and install
the right pressure and that car is free
lampholder 0.
from any load excepted those of
service supplies and of one passenger
equivalent.
2. Position the car and the possible
test equipment on an horizontal
plane. If no test equipment is avail-
1 Cover
able, place the car in front of a clear
screen.
1 Supply connector
2 Halogen lamp
3 Securing spring
4 Lamp
5 Lampholder
1 Combination lamps
2 Lamp
3 Lampholder
1. Open back door and lift rear 3. Press bulb of lamp and rotate it
trim. in order to remove.
2. Press on lampholder side 0, 4. Replace lamp and refit lamp-
pull; then remove it. holder.
5. For identification of lamp loca-
tion, refer to diagram of the follow-
ing figure.
4
0-J
Diagram refers to the left rear
combination lamp. 1 Rear fag light
The right-hand one is specular with 2 Side light
respect to the left-hand. 3 Stop and side lights
4 Direction indicator
5 Reverse light
The rear fog light is present in the 6 Number plate light
left rear c o m b i n a t i o n l a m p o n l y .
1 Lamp
2 Lampholder
INSIDE LIGHTING
1200 and 1350 model
0 H4
O-
Gl
--I
P
z h nz
0
A l -%
‘=-
it*
Nl
1500 a n d 1 6 0 0 Quadrlfogllo m o d e l
Al Battery
G30 Power window and door lock connector
61 Ignition switch
G86 Passenger compartment roof lamp connector
F3 Passenger compartment roof lamp
H4 Roof lamp switch on passenger compartment pillar
F16 Ignition switch lighting lamp
NlO Passenger compartment roof lamp timer
Gl Fusebox
ROOF LAMP
Lamp replacement
1 Cluster
2 Connector5
3 Cover
4 Bracket
5 Screw
Check
1. Set the ignition key to the MAR
position.
I m---J
r- -
PI9
0’
I n I
L--
+3
r--l
Al Battery
Bl Ignition switch
82 Windscreen wiper control switch
83 Windscreen washer and/or headlight
wash/wiper pump control switch
Gl Fusebox
WINDSCREEN WIPER
IO Brush
6 Bush
1 Motor 11 Bush
7 Cowl top cover
2 Motor cover 12 Spacer
8 Nut
3 Linkage 13 Nut
0 Wiser arm
4 Nut
7. Unscrew the three screws secur-
5 Spacer Remove cowl top cover 0
4. ing motor 0 to linkage @ and
REMOVAL AND (see: Group 75 - Cowl top cover). nut securing motor shaft to linkage.
INSTALLATION 5. Withdraw bush @) , unscrew
Disconnect motor 0 harness. nut 8, then remove it together
1.
0 from with spacer @ .
2. Withdraw brushes 0
0
wiper arms 9 .
6. Unscrew the three screws secur-
ing linkage @ to body, then re-
3. Lift covers of nut @ securing
move it.
wiper arms @, unscrew nuts, then
remove wiper arms.
May 1983
40-29
ELECTRICAL SYSTEM
Windshield wiper does not l Faulty auto-stop device Replace auto-stop device
stop correctly
l Faulty wiper motor Replace motor
Washer fluid does not eject Clogged washer nozzle or hose Free nozzle or hose
(washer motor operates)
Wiper does not operate inter- l Faulty wiper switch Replace combination switch (right lever)
mittently but operates at low
l Faulty wiring Verify wiring
and high speeds
l Faulty intermittence Replace intermittence
Intermittent speed is too long, l Line voltage below 10 volts Restore voltage
for proper wiping
l Faulty intermittence Replace intermittence
40-31 M a y 1983
ELECTRICAL SYSTEM
HEADLIGHT WASH/WIPER
1500 Quadrlfogllo model
Bs
I;
1
I 1 1 ’1 r I!jI1
!
I
i
I
i
1w--B 1I
HEADLIGHT WIPER
1500 Quadrlfogllo m o d a l
1 Motor
7 Nut
2 Bracket
B Wiper arm
3 Headlight wpsher hose
9 .Headlight washer hose
4 . Grille
10 Bracket
5 Wiper arm
11 Motor
6 Nut
40-33 May 1 9 8 3
ELECTRICAL SYSTEM
Refer to
Tool number Tool name
Page
1 Harness 3 Bracket
2 Nut
I
Only one side operates l Faulty hose Replace horn
Poor tone quality on one side Tone adjustment not good Adjust tone by operating on the relevant
adjusting screw 0
Both horn volume reduced l Low battery charge Charge battery or replace
1 Filament 3 Rule
2 Interruption 4 Ruling pen
POWER WINDOW
1 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
Al Battery 821 Right front power window control switch I1 2 Front power windows relay
Bl Ignition switch 822 Left front power window control switch PI4 Right front power window motor
B9 Heated rear window control switch Gl Fusebox PI 5 Left front power window motor
812 Hazard lights control switch G36 Power window switch cable connector
I I I 1
I I I I
r e-- 1
LOCATION
The door lock control unit is located
inside passenger compartment, in the
gear lever console, behind Check
Control and Trip Computer.
REMOVAL AND
INSTALLATION
1; @wi;ydisc;;;ey;e “,“,:“,I
vant harness.
2. Remove control unit @ by
unscrewing the screw securing it to
Trip Computer 0.
1 Door lock control unit
For control unit installation, reverse
2 Trip Computer
order of removal. 3 Instrument holder
4 Check Control
REMOVAL AND
INSTALLATION
1. Withdraw instrument holder 3
from console and disconnect the
relevant harness.
2. Remove Check Control 2 and
Trip Computer 1 by unscrewing,
for each one, the two securing screws
to instrument holder.
1 T r i p C o m p u t e r 3 instrument h o l d e r
2 Check Control
2 Medium consumption for the covered distance in L/100 km 8 Engine oil level warning lamp
starting from zeroing by red Key (Start Key)
9 Engine coolant level warning lamp
3 Fuel consumption in litres since trip start, starting from
zeroing by red Key 10 Cluster warning lamp
5 Drive time in h/min since trip start, starting from zeroing 12 Side lights warning lamp
by red Key
13 Main red warning lamp
6 Time in hoursjmin
14 Main green warning lamp
PASSENGER COMPARTMENT
HARNESS LAYOUT
GENERAL HARNESS
ENGINE COMPARTMENT
May 1983
ELECTRICAL SYSTEM
Bl Ignition switch
F8 Air ventilation controls lighting lamp
82 Windscreen wiper control switch
84 Control switch for headlight, flashing, low beam and full beam G5 Connector
B5 Horns control switch G6 Cluster B connector
B6 Direction lights indicator switch G7 Cluster R connector
B9 Heated rear window control switch G86 Passenger compartment roof lamp connector
Bll Rear fcg light control switch H3 Stop light switch
B12 Hazard lights control switch H13 Choke switch
.
821 Right front power window control switch N13 Hazard and direction lights intermittence
822 Left front power window control switch 06 Cigar lighter
C7 Clock Q4 Air ventilation heater fan control
HANDBRAKE INDICATOR
handbrake indimtor as shown in
SWITCH figure.
(1500 Quadrifoglio) 3. The following resistance values.
shall be read.
Check
1. Set the ignition key to the MAR Brake engaged: 0 a
position. Brake disengaged: &
2. Connect a tester to terminal of
CIRCUIT DIAGRAM
I
I
ELECTRICAL SYSTEM
CONTENTS
May 1983
BODY -SHEET METAL PANELS
GENERAL INFORMAi-ION
IDENTIFICATION DATA
LIFTING POINTS
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
BODY CONSTRUCTION
BODY CONSTRIJCTION
BODY SEALING
DESCRIPTION
The following figures, show the body areas which are possible sealing faults.
sealed by Manufacturer.
The scalings applied to these areas, must be smooth and ICIR: Paraflex Alpha 3M
free from scratches or gaps. 8531 IE
8536/E
Take care not to apply too much sealing and not to Alternative: part. no. 3522-00014
allow other unaffected parts to come in contact with the
sealing.
Sealant for bolted joints
Body components sealing Sealant for joints between panels assembled by bolting.
Paint seal, after priming or painting, and then sleek by
means of a brush along all sheet joints in order to remove 3M - Autosealer 8573E - part. no. 3522-00045
Detail M
BODY ALIGNMENT
MEASUREMENT OPERATIONS
MEASUREMENT POINTS
May 1983
BODY-SHEET METAL PANELS
1. Spot welder
Before starting welding operations, carry out the follow-
D=Zt i-3 (mm)
ing checks in order to obtain welding sufficient strenght:
(1) Welder arm adjustment
a) Keep the arm as short as possible in order to obtain
welding maximum pressure. D= Electrode end diameter
,
t =Sh;thickny ; ~
b) Tighten arm and tips securely so as they do not get
loose during soldering operations.
1
3. Cautions during spot welding
I I
(I) Spot welding selection
Use the direct welding method (for the parts this method
can not be applied to, use the MIG welding method).
May 1983
BODY - SHEET METAL PANELS
MIG welding
01 1. Conditions of panel to be welded.
1 CORRECT By means of belt sander or wire brush, remove any
f
It must form an opening of
foreign matter from surface.
about 3 mm dia., when stressing Paint films, rust or oils present on sheet surface, causes
decrease of welding strength, thus generating blow holes.
i
INCORRECT 2. Cautions during welding operations.
(II Plug welding (of pre established holes)
a) Make a hole, having 6 to 6 mm diameter (0.20
t
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 to
(2) Test to be carried out after welding, by means of
sheet, then fill metal into the hole.
chisel and hammer.
Each time welding is stopped, on the surface an
. Insert tip of a chisel between the welded sheets and
oxide film generates which causes blow holes. If this
slightly tap on chisel until, between sheets, it is
occurs, remove oxide by means of a wire brush.
obtained a 3 to 4 mm clearance (0.12 to 0.16 in); if,
c) Make sure that welding between upper and lower
on the welded part, no strain is present, test result is
sheet is perfect.
then positive.
. If sheets thickness is not equal, clearance between
sheets must be limited to 1.5 to 2 (0.059 to 0.079
in).
Take into account that the above value is only a
reference one.
. The mentioned clearance changes according ta Part around the hole
Panel edge
Plug welding
Reference value: 3 to 4 mm
(0.12 to 0.16 in)
I Butt weldiirg
-.
BODY - SHEET METAL PANELS
REPLACEMENT OPERATIONS
In detail:
(1) “HOODLEDGE. PANEL WITH RADIATOR CORE The parts Tepresented by chain line, set in evidence the
SUPPORT REMOVED” components which must result to be removed or for
In the title it is indicated the element to be removed which it is required the preliminary removal, accordingly
(hoodledge) specifying, if required, the operative to step (I 1.
condition (in this case, radiator on core support
removed). If the element is not in the required
conditions, it is necessary, to execute preliminary (III)PARTS TO BE WELDED
removal of the other components; in the present case, A list is provided relevant to the components which
it is necessary to remove the radiator core support, are to be welded using the methods indicated in step
referring to the specific replacement procedures. (II).
(II) “SERVICE JOINT”
(IV)REM~NDER WHEN REM~V~NG/INSTALLING
Any information concerning the welding operations
to be carried out is shown in the figure indicating the Indication is provided, relevant to the main opera-
welding method and the spot numbers, together with tions to be carried out, with special care in identifica-
accurate location of spots on the elements to be tion of the areas concerned in the cut operations,
joined. selection of the equipments to be used and definition
of welding methods to be adopted.
Example: a l 3 -Welding spot number
Welding type (spot welding:
see simbology on page 2 1)
LL Parts to be welded
Spot welder
ed by means of air
..
m MIG seam weld/point weld
Spot welding
May 1983
BODY -SHEET METAL PANELS
Welding - brazing
May 1983 4 9 - 2 2 - -.
BODY -SHEET METAL PANELS
flJ!lJ
not allow a reliable drive of drill.
. As a rule, punching must be executed from sides of
the components that are to be removed.
1
?
:i
Tools required:
. Chisel
. Hammer
Recommended paint:
Part. No. 3540-44401
SAVIU: Zincovid No. 7949
SCHRAM LACK: Extrinom Punktschweifarbe
GLASURIT: Glassomax 7 F 4625 (red color) *
INSTALLATION
(1) New service parts temporary installation.
Tools required:
Holes must have 5 to 6 mm . Vise pliers
(0.20 to 0.24 in) dia . Convex rule
. Tracking gauge (sight)
. Centering gauge
(3) Remove paint from components to be welded. . Port power
Tools required: . Jack
. Belt sander . Spot welder
. Disc sander . Mig welder
Cautions during operation: (3) Grind MIG welding by means of a sander machine.
. Position components as per figures provided in “Body Tools required:
Alignment”. Into body compartments, install the . Air sander .
movable parts (i.e. windscreen, doors, hood, back- . Cl isc sander
door) in order to carry out check of clearances,
grades and parallelism. If necessary, adjust sheets
until correct alignment is obtained.
. Clamp parts to be welded by means of pliers and
some welding spot.
CORRECT INCORRECT
m Area to he protected
) Front
R EM I N D E 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 of
drilled sheets.
MIG welding
Service joints
Parts to be welded
a. Upper part hoodledge and lower part hoodlege
Overlapping
tolerance
Service ioints
Parts to be welded
a. Plate and replaced side member
b. Plate and present side member
CENTRAL PILLAR
Service joints
SECTION A-A
Parts to be welded
a. Pillar and pillar inner reinforcement C. Outer pillar and inner pillar
b. Outer pillar and inner pillar d. Inner pillar and roof panel side member
1 Reinforcement
2 Body side ring
===T===
Overlapping 7
I
tolerance
I
=F
Overlapping
tolerance
Parts to be welded
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
Precaution during cutting of outer side member l The continuous welding areas of outer side member
. Cut outer side member aligned with non-replaced to central, front and rear pillar, must be tinned.
panel part
Overlappine
tolerance
Welding indication
l Use MIG welding method to weld the three over-
lapped sheets along the whole perimeter from both
sides.
.d
REAR FENDER
Service joints
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 Take care not to cut frame of rear fender.
. By means of air chisel, cut the area shown in figure.
Sealer application
. Apply sealer to wheelarch outer side.
Parts to be welded
a. Drip and rear fender inner frame
b. Drip and rear panel,
Parts to be welded
a. Cross member and rear panel
b. Cross member and floor
c. Cross member and side member
I+1
Centml area
Service joints
Parts to be welded
a. Rear panel and drip
b. Rear panel and outer fender
C. Rear panel and outer fender
d. Rear panel and floor
REAR PART OF REAR FLOOR WITH REAR FENDER AND REAR PANEL
REMOVED
Carry out replacement after .Rear Fender and both Lower and Upper Rear Panel have been removed.
Service joints
: -4~ e -6mb
1
-
s
F
Parts to be welded
a. Rear floor and rear side member d. Rear floor, rear side member and inner rear wheelarch
b. Rear floor and rear side member e. Rear floor and rear seat cross member
C. Rear floor and central cross member f. -Rear floor and outer fender
CONTENTS
May 1983
DOORS
FRONT DOOR
@II* 1 3 5 21
(1.36+2.2
9.83 + 15.9)
1 Door
15 Tie rod
2 Door lock device
16 Hinge
3 Lock block clamp plate
17 Window regulator device
4 Lock block 18 Panel lower clamps
5 Handle 19 Seal
6 Molding and weatherstrip 2 0 Sealing screen
7 Molding 21 Upper trim and weatherstrip
8 Molding 22 Door lock control
9 Glass velvet seal with trim 2 3 Panel
10 Glass 24 Window regulator handle
11 Door mirror 2 5 Arm rest
12 Ring nut 26 Power window switch (1500 and 1500 Quadrifoglio models)
13 Rubber 27 Power door locks device (1500 Cluadrifoglio model)
14 Hinge
DOOR ASSEMBLY screws, then remove it. 3. Unscrew the five nuts securing
2. Remove ornament covering the window regulator @ to door, then
REMOVAL AND door securing screws, then remove remove it.
INSTALLATION window regulator handle @ .
With reference to exploded view 3. Remove plastic rivets securing
proceed as follows: panel @ to door. Remove panel
1. Disconnect door from tie rod by bending it.
a n d f r o m h i n g e s @ and @ b y 4. Remove plastic rivets securing
unscrewing the six screws, then upper trim @ to door.
remove it. 5. Remove hook of door lock
la. Only for the 1500 and 1500 control rod. then remove upper
Quadrifoglio models. t r i m @) ,
Disconnect harness and then proceed
as per step 1.
6. For upper trim and panel 3a. Only for 1500 and 1500 Quadri-
installation, reverse order of removal. foglio models
Disconnect harness of window
regulator motor, unscrew the five
WINDOW REGULATOR nuts securing power window @
to door, then remove it.
DEVICES AND
GLASSES
2. For door installation reverse
order of removal and tighten screws
REMOVAL AND
securing .hinges t o d o o r t o r h e
INSTALLATION
prescribed torque.
1. R e m o v e p a n e l @I upper
@ : Tightening torque trim @I and sealing screen @ .
Screws securing hinges to door 2 . L o w e r g l a s s @j) c o m p l e t e l y ,
1 3 G-21 Ndm unscrew the two nuts securing
(I .36 + 2.2 kg-m w i n d o w r e g u l a t o r d e v i c e @ to
9.83 + 15.9 ft4b) glass, then remove by rotating it.
INTERNAL FINISHING
PANELS
Cover end of the tool used for
removing plastic rivets in order not
to damage or scratch the body.
REMOVAL AND
INSTALLATION
Lift ornament of arm rest @ 4. Install window regulator and
1.
and unscrew the three securing glass by reversing order of removal.
DOOR LOCKS
AND HANDLES
REMOVAL AND
INSTALLATION
1. Remove panel @I upper
trim @I and move sealing
screen @ .
2. Lift glass @J completely in
order to avoid damage.
3. Remove plastic fasteners secur-
ing levers to door.
DOOR MIRROR
6. Withdraw clamp plate of lock
block @ by means of proper tool REMOVAL AND
and remove lock block @. INSTALLATION
1. Remove panel @ and upper
trim @J _
2. Withdraw rubber @I and un-
screw the two screws securing mir-
ror @I to door.
3. Unscrew ring nut 1 and
O@
remove door mirror 11 .
4. Install door mirror by reversing
order of removal.
4. 1500 Quadrifoglio model
-Release connecting rod between
lock @ and door lock electric UOLDINGS AND
device 0 . To remove it, if neces-
7. Unscrew the three screws secur-
SEALS
sary, disconnect harness, and un-
screw the two nuts securing it to ing lock @ to door then remove
Cover end of the tool used tor
door. lock.
removing moldings in order not to
8. Unscrew the two nuts securing
damage or scratch the body.
handle @to door, then remove
hand le.
REMOVAL AND
INSTALLATION
1. Operating as per figure, remove
molding with weatherstrip @.
2. Remove molding 8 .
3. Remove panel 8 and upper CAUTION:
trim with weatherstrip @ . Apply proper grease to hinges, tie
4. Remove door mirror 0 . rod and door lock device.
5. Remove molding 7 .
6. Remove glass 8 0 and glass
velvet with trim 8.
7. Reposition moldings and seals
by reversing order 05 removal.
8. With reference to the following
figure take care to secure glass velvet
seal on clamp @ of glass guide 0
located inside the door.
1 Glass guide
2 Glass velvet seal clamp
REAR DOOR
3 N-m
(kg+n
ftw
1 Door 14 Hinge
2 Spacer 16 Window regulator device
3 Ooor lock device 16 Hinge
4 Rubbers 17 Panel lower clamp
5 Handle 18 Seal
6 Fixed glass 19 Sealing screen
7 Melding 20 Upper trim and weatherstrip
8 Fixed glass guide 21 Door lock control
9 Molding 22 Window regulator handle
IO Glass velvet seal with trim 23 Arm rest
11 Glass 24 Panel
12 Molding and weatherstrip 25 Door lock electric device (1500 Duadrifoglio model)
13 Door lock control
Cover end of the tool used for 3. Unscrew the screw securing
removing plastic rivets in order not fixed glass guide @ to door frame.
to damage or scratch the body. 4. Slightly detach the glass velvet
seal @I in correspondence with
fixed glass guide @ and remove 4. Remove fixed glass guide @
REMOVAL AND and fixed glass @.
guide.
INSTALLATION 5. Remove glass 0 .
5. Remove fixed glass.
1. Lift ornament of armrest @ 6. Install fixed glass by reversing 6. Install glass and window re-
and unscrew the three securing order of removal. gulator by reversing order of re-
screws, then remove it. moval.
MOLDINGS A N D
SEALS
4. Unscrew from door the door 7. Unscrew the three screws secur- REMOVAL AND
lock control rod @ securing screw ing lock @ to door, then remove INSTALLATION
and remove it. lock. 1. Operating as per figure, remove
8. Unscrew the two nuts securing molding with weatherstrip @ .
handle @ to door, then remove
handle.
1 Glass guide
2 Glass velvet seal clamp
TIGHTENING TORQUES
Screws securing hinges to front door 13421 1.36 + 2.2 9.83 f 15.9
Screws securing hinges to rear door 13+21 1.36 + 2.2 9.83 f 15.9
I I I
CAUTION:
. During installation of hood
8
hood 1 come in contact with
body 3 ; if not so, properly
change hood bumper height
.
hood lock opening control.
Lubricate hood lock mechanism
with proper grease.
lock @ make sure that striker by screwing or-unscrewing them.
CAUTION:
In case of breakage of hood opening
control cable, it is possible to open
the hood by pulling the nylon-made
emergency cable @, lowted in the
,passenger compartment inside.
1 Cable 4 Bracket
2 Hood lock device 5 Hood opening control
3 Cable retaining ring 6 Nylon-made emergency cable
BACKDOOR
CAUTION:
. Lubricate the cable with proper
oil letting it slide into sheath.
. Do not bend excessively cable
sheath in the luggage room, in
order to prevent opening stress
1 Cable 4 Bracket
increase.
2 Backdoor lock device 5 Backdoor opening control
3 Cable retaining ring
TRIM
ROOF TRIM
1 Roof
2 Taps
3 Sun screen
4 Sun screen
5 Passenger handle
6 Passender handle
7 Roof lamp
8 Passenger handle
9 Inside mirror support
10 Roof lamp
11 Inside mirror
C A U T I O N :
For installation, it is recommended
to position roof trim starting from
2. By means of proper tool, remove rear side and then use a cord to
taps 0. reposition windshield seal in its place
3. Disconnect harness and remove (see: Group 75 - Windshield - 1 Roof trim 4 Cord
roof lamps @ and @I . Installation). 2 Front righr 5 Windshield
4. R e m o v e i n s i d e m i r r o r @) in pillar 6 Body
order to gain access to the t h r e e 3 Windshield seal
FLOOR TRIM
INTERNAL TRIMMING
a*27 f f 4 3
(2.8 +f
(2.8 + 4 4.4
.4
20.25 f 31.8)
1 Door opening seal p::
2 Door opening seal
3 Central pillar trim
4 Safety belt
5 Safety belr anchor on tunnel
6 Central pillar trim cover
REMOVAL AND
INSTALLATION
With reference to exploded view and @ in the part where they cover 4. After removing protection, un-
above, proceed as follows: central pillar trim 0. screw the screw securing safety
1. Move front seat completely 3. Lift protection of screw securing belt @ anchor bracket to body.
forward. safety belt @ suppot~, unscrew it
2. Remove door opening seals @ and remove the support.
@ : Tightening torque
Safety belt anchor screws
27 + 43 N.m
(2,s + 4,4 kg-m
20.25 + 31.8 ft-lb)
CAUTION:
If the vehicle is collided or over-
turned, replace t h e e n t i r e b e l t
assembly regardless of nature of
accident.
REMOVAL AND
INSTALLATION
With reference to the exploded view
above proceed as follows:
1. Remove movable shelf under
rear window.
2. Unscrew screw securing seat
back fixed part @ to body, lift seat 6. Install trim by reversing order of
back and remove it. removal.
REMOVAL AND
INSTALLATION
1. Remove door o p e n i n g s e a l @ 2. Detach plastic cap @ and 3. Install trim by reversing order of
in the part where it covers trim 0. remove pillar trim 0. removal.
REMOVAL AND
INSTALLATION
1. Remove seat back clamping 2 . By means of proper tool, remove 3. Install side trim by reversing
device @, seat back fixed part @ plastic rivets securing side trim to order of removal.
and trim of fixed part shelf under body, then remove it.
rear window @ (see: Trim of fixed
part shelf under rear window).
REAR SEATS
1 Seat
2 Seat back fixed part
3 Seat back
4 Shelf under rear window fixed part
5 Seat back clamping device
6 Luggage room and seat back trim
7 Seat back
8 Seat back hinge
1 Seat back
2 Kick plate
3 Door compartment seal
1 Seat back fixed part 4 Body
2 Seat back
3 Body
4 Door compartment seal
5. Carry out same procedure for
3. By means of proper tool, with- removal of the other seat back.
draw plastic rivets securing luggage 6. Install seat backs and seat, by
room upholstery to seat back. reversing order of removal.
CONSOLES
REAR CONSOLE
REMOVAL AND
INSTALLATION
1. Remove rubber bellows located
on parking brake.
2. Remove ashtray, which is pres-
sure secured.
3. Unscrew the screw securing
console and remove it by moving it
first forward in order to withdraw
it from clamp located on floor
tunnel.
CE:NTRAL CONSOLE
DASHBOARD
/I \
Low view
CAUTION:
To remove the whole dashboard, two
(2) Open cover @ pressure in- operators are required.
set-ted, disconnect harness; then
remove cluster 0 . 8. R e m o v e the whole dash-
4. Operating as per figure, remove board @ and @.
spring securing center ventilation 9. If necessary, disassemble dash-
d u c t @ control cable to heater b o a r d c o m p o n e n t s @ and @.
control assembly. (1) By means of a drilling machine
fitted with suitable drill, countersink
the four rivets securing upper dash-
board @ to lower dashboard @.
TIGHTENING TORQUE
Unit
N-m kg-m ft.lb
Item
FRONT SEATS
CONTENTS
May 1983
EXTERNAL TRIMMING
FRONT BUMPER.
REMOVAL AND
INSTALLATION
With reference to exploded view
above proceed as follows:
disconnect fog 3. Unscrew the four screws secur-
1. If present,
ing brackets @ and @ to sills.
light @ and @ harness.
2. Operating from engine com-
partment inside, disconnect harness
of the two electromagnetic horns,
unscrew the nut securing each horn
t o b r a c k e t , a n d remove horns.
May 1983
75-2
EXTERNAL TRIMMING
REAR BUMPER
1 Bumper 4 Bracket
2 Bracket 6 Nuts
3 Bracket 6 Bracket
REMOVAL AND
INSTALLATION
W ith reference to exploded view
above proceed as follows:
1. Lift luggage room upholstery
and rear trim.
2. Unscrew the four screws secur-
ing bumper brackets @ and @ to
brackets @ and @.
4. Remove bumper.
5. If necessary, unscrew the eight
3. Unscrew the two screws securing screws securing brackets @ and @)
bumper @ to body. to rear floor.
GRILLE
1 Badge 3 Hood
2 Grille 4 Screw
REMOVAL
With reference to exploded view remove, by means of proper tool p i l l a r t r i m 0, then remove it.
above proceed as follows: ornament 0. 5. Operating as per the following
1. Remove wiper arms @ and 3. Remove door opening seal @ figure, set end of tool A.9.0051 out
move cowl top cover @ forward in the part where it covers pillar of every 10 cm (4 in), starting from
(see: Cowl-Top Cover). trim 0. centre of windscreen upper rim;
2. Operating from vehicle inside, 4. By means of proper tool, remove between body and windscreen seat.
May 1983
EXTERNAL TRIMMING
REAR WINDOW
INSTALLATION
CAUTION: allow an easy insertion of weather-
Do not damages filaments of heated For installation; two operators are strip on body.
rear window with tool A.9.0051. required.
1. Into seal rim @ inset-t two
4. Carefully pull upper part of rear CAUTION: cords (A and B) arranged as per
window, release it from back door By means of silicone, lubricate rim of figure in order to allow repositioning
and remove. rear window weatherstrip in order to of weatherstrip on back door.
May 1983
AIR VENTILATION
CONTENTS
c:
May 1983
HEATER
.-
WIRING DIAGRAM-~
G1.5
111213141 r i
I I@
I I,i,i 1 I I
I1 G1,5 B
I---d
M I
A l Battery
El Ignition switch
84 Control for headlight, flashing, low beam and full beam
F8 Air ventilation control lamp
G I Fusebox
Ql Air ventilation heater fan
Q4 Air ventilation heater fan control
(IV - Low speed)
(2V - High speed)
REMOVAL AND 5. Loosen metal clamps securing (2) Remove or cut seals.
INSTALLATION pipings @ to air ventilation unit; (3) Separate the two shell cov-
then remove pipings. ers 0 and @.
CAUTION: (4) If necessary, with reference to
. Remove battery ground cable. exploded view above, release control
. Before removing components cables of doors @ and @ b y
fitted with harness, make sure operating with suitable wrench on
the relevant connections have the screw securing levers to door
been disconnected. hinges as shown in figure.
. Be careful when removing air
ventilation unit pipings, other-
wise liquid leakages from heater
core may occur.
Insufficient heating performance b Cooling water temperature too low Check thermostat: replace if necessary
(No heated air flow to ducts)
D Heater care plugged Clean heater
Insufficient air flow to floor l Blower motor speed too lo w Check blower motor and:
-- restore poor connections
- replace blower motor if necessary
Insufficient air flow to defroster l Blower motor speed too low Check blower motor and:
(Refer to: Group 66 - Dashboard) - restore poor connections
- replace blower motor if necessary
Noise from blower motor l Loose bolt in blower motor Check and tighten