WORKSHOP ¥f milano (# MANIAL = “* m™ilanc ; ASSISTENZA TECNICAFOREWORD This manual ie intended for use by workshops belonging to the ALFA ROMEO Service Organization. It contains aif neces sary instructions for tune up, repair and overhaul of the units and systems with which the ALFA ROMEO cars are equipped. It includes procedures conceraing removal and installation, disassembly end assembly, checks and! inspections as well as instructions tor effective trouble diagnosis. Al operations are extensively illustrated so thet the part or unit iavoived. as well as the proper toof 10 be used, are exsly identified. All dete, figures and technical specifications herein contained are up to date at tiie of publication. Any subsequent charige In values or technicel specifications occurring between reprints, wil be included in the Technical Bulletins issued by the Service Department as changes take place: The manufacturer reserves.the right to make - at any time and without notice - all thase changes that it deerms necessary to Improve the vehicle or arising out of manufacturing or commercial requirements. tt further advises that not all models mentioned in this manual will be availeble in all countries. HOW TO USE THE MANUAL This manual is designed as # guide Yor personne! assigned to provide effective service to the mechanical urvits Conceited. The instructions herein contained aré in general common to alt different madels of the same group, when. they are meant for ane partieulsr model, 1 is previously inaicated with a specific detailed reference to be found in the CONTENTS and in the text Alt instructions given for the purpose of restoring faulty components to proper working conditions, do nat necessarily reflect manufacturer's directives: at regards service, but they must just the same be complied with. Furthermore, since most given instructions concern complete disassembly of Components; they should be followed in their entirety only when itis strictly necestary. For easier consultation of the manual, read the CONTENTS carefully. The following chapters are of the utmost importance — SERVICE DATA AND SPECIFICATIONS to be complied with when tuning up and repaicing the vehicle. The specifi ‘ations have been subdivided into four different items: Technical Data, Generat Specifications, Checks and Adjustments and Tightening Torques; — TROUBLE DIAGNOSIS AND CORRECTIONS where Hikely couses of trouble, as well as the relevant recommended corrective actian, are listed; — SPECIAL SERVICE TOOLS designed to allow quick, acourete andi sate repsirs Messurements given in this manual are expréssed in the International System of Units (Si) as well as in the yard/pound systemand in the metric system. Captians CAUTION and WARNING emphasize steps ther must be followed with extreme care to avoid personal injury and/or damage to the vehicle or part of it. Remember to keep the manual up-to-date with the dats supplied by the “Technical Bulletin” periodically sued by the Service Department, PABBASUOO00000 in Marcn 1986eT — WORKSHOP INSTRUCTIONS ° Disassembly and assembly operations should be always carried out using proper tools (general purpose as well as special service tools) since makeshift tools will damage the parts involved. To loosen tight fitting cast iron pars, just lightly strike shem with 2 lead or aluuninium hemmer; use @ wooden or plastic mallet 10 toosen light alloy parts Separate one by one the parts making up each unit and partially tigh ten nuts onto relevant studs or screws, On.dfsessembly, check if parts that should be marked do in fact have the relevant number or reference stamped on it. Hf any previously replaced part is found to be in properly marked, it should be stamped accordingly. Before washing, clean all parts with @ brush and cloth removing most dirt (thus avoiding needless dirtying of the weshing Huid)z then wash them with detergent or special compound, Rernove any residual dirt with a jet of carnpressed air. Dry al! parts immediately after washing to prevent them from rusting. Thoraughiy wash parts: that have been ground or lapped and blow them with a jet of compressed air to remove al! residiaes. Reassembly, clean all parts (especially those that have been ground) with a jet of compressed air or @ clean brush. On assembly also suitably lubricate parts (except settlubricating bushes) to prevent seizure during their running: period, To apply lubricant, use-2 clean brush as well as-clean of! Keeping them eviey from dust and dirt at all times and using them only Far this special purpose. Suitably protect with adhesive tape or clean cloths al! engine parts that after disassembly show orifices or drilling which are likely t0 fet in dust or Foreign matter On assembly, replace all geskets, seal rings, spring washers-and lock rings in-adalition to all. worn or damaged parts. IMPORTANT NOTICE Ver" replacing units or parts the-eo?, be sure.to use only genuine spare parts to ensure intérchangeabil ty as well as proper performance. When ordering, remember to show the part number raked from the Spare Parts Catalogue or from the microfiches Service quality varies according to procedures used, personnel skill, and available tools and parts. March 1986 Iv PA384500000000PA384300000000 QUICK REFERENCE INDEX HEATER v COMPLETE CAR GR. 00, ENGINE MAIN MECHANICAL UNIT GR. 01 FUEL SYSTEM GR. 04 IGNITION, STARTING, CHARGING SYSTEM | | GR..05 ENGINE COOLING SYSTEM GR. 07 CLUTCH GR. 12 GEARBOX GR. 13 TRANSMISSION GR. 15 DIFFERENTIAL AND AXLE SHAET UNIT GR. 17 FRONT SUSPENSION GR. 21 FRONT AND REAR BRAKES GR. 22 STEERING GR. 23 REAR SUSPENSION GR. 25 —— ELECTRICAL SYSTEM GR. 40. cause AN ELECTRONIC GR. 43 GR. 80. March 1986COMPLETE CAR GRouP OO GENERAL VIEWS WHEELS AND TIRES MODEL VARIATIONS SERVICE AND IDENTIFICATION DATA Identification labels Vehicle identification codes LIFTING AND TOWING POINTS Jack Hydraulic jack and safety stands . Towing : SPECIAL SERVICE TOOLS INSTRUCTIONS FOR PRE-DELIVERY INSPECTION Operations in the engine compartment Operations on vehicle exterior and in the passenger compartment Operations.on vehicle lower part Functional tests MAINTENANGE VEHICLE MAINTENANCE SCHEDULE FLUIDS AND LUBRICANTS LAYOUT : RECOMMENDED FUEL AND LUBRICANTS ... Fuel : Fluids and lubricants. APPROXIMATE REFILL CAPACITIES ENGINE MAINTENANCE Engine main mechanical unit Pazsazo0000001 CONTENTS 00-3 Replacement of engine oii and oil 00-4 filter « check, on lubrication system 005 tightness. ois ce eee sees 00-20 Check on bolts and nuts tightening . 00-20 00-6 Tightening of cylinder head nuts... 00-24 00-6 Check and adjustment of valve 006 clearance oo... 6c. eee eee 0021 00:7 Replacement of timing system 007 drive belt. .... 0c cesses es 0025 00-8 Check on timing system and drive 00-8 belt tensioning..........2...... 0026 cog Checking good conditions, replacing and adjusting drive belts of alternator, 00-9 air conditioner compressor, power 008 steetingpump .. 0.2... ... 0.05. 00-28 Check on cylinder compression 00-28 008 Fuel system ....... cece s 00:31 00-11 Cleaning of air cleaner and/or 00-11 cleaner element replacement ...... 00-31 00-14 Gheck and adjustment of idle t.p.m. and exhaust emissions»... ++ 00-31 00:12 Engine ignition ......... 00-33 Check and adjustment of spark 00-13 advance ........ - 00-33 Check, cleaning and/or replacement 06-14 of spark plugs; firing order .... 00-34 00-14 Engine cooling .. eo. 00-36 00-15 Checking and refilling the fystem - 00-35 Exhaust system . ween + 00-36 00-19 Replacement of exhaust gas sensor 00-20 and catalytic: converter 00-36 00-20 Trouble diagnosis and corrections ....- 00-37 sure 1986COMPLETE CAR ‘ CONTENTS (cont.) Engine Ignition... Fuel system Check with BOSCH tester .. Detailed diagnosis for Lambda sensor, on . 0073 EZ-L Ignition system diagnostics (48 mnilane '®. model onty! ..., 00-74 Ignition system diagnostics (M8 mnllane © mode! only! 0078/1 Injection wiring diagram .. . . 0079 MAINTENANCE OF MECHANICAL COMPONENTS AND BODY..... vee 00-81 Clutch .,... - -. 00-81 Check on clutch-brakes fluid level and check cn the system ......... 00-81 Gearbox differential... 00:81 Transmission... 00-81 Front axle and suspension , 00-81 Check, ...-..... bepene .. 00-81 Adjustment of wheel bearings preload... . 2. -. 0081 Rear axle and suspension............ 00-82 Check oes. eevee Check on vehicle height... Preliminary operations. Front height, . Rear height 00-82 00-82 00:82 00-83 00-83 00-84 Height adjustment . Wheel alignment. ... 2. 00-86 Check an front wheels alignment... 00-85 Check on rear wheels alignment -.,. 00-87 Front and rear brakes. ..... ++. 0087 Brake system .... 2... wre. 00-87 Front brakes , sees OOBB Rear brakes ...,....... :+ 00-88 Parking brake. . , + 00-88 Adjustment ....25., soso + 0088 {ABS} Wheel antilock system......... 00-89 Air gap adjustment between front impulse pick-up and impulse emitting December 1987 wheel .. Air gap adjustment between rear impulse pick-up and impulse emitting wheel. . Steering system . Check on the ynit HVE eee + Bocce eee Tire pressure check Body 5.5... seetieae Locks and hinges Seat belts .. Trouble diagnosis and corrections... Transmission... 26... s+ Suspension......... Steering wheel... ,. Brakes . . Diagnosis procedure of the (ABS) MARK Il wheel antilock system .. . Electrical diagnosis of the brake fluid tank for the (ABS} MARK II antilock braking system ...... 5.4 (ABS} MARK lI wheel antilock system wiring diagram .....6.. 55 SERVICE DATA AND SPECIFICATIONS. . Engine maintenance Technical data - Checks and adjustments . Fluids and |ubricants . Wheels and tires . Tightening torques . Maintenance of mechanical components and body oo. ees eee Technical data - Checks and adjustments oo... scat eee ees Fluids and lubricants Tightening torques...2.. 5... SPECIAL SERVICE TOOLS .. 00-89/1 00:89/7 00-89/1 00-89/1 00-891 00:89/1 00-89/2 00-89/2 00-89/2 00.90 00-90 00-91 00-91 00-92 00-93 00.93/20 00-93/22 00-94 00-98 00:84 00-95 00-95 00-95 00-96 00-96 00-97 00-97 00-98 PA384300000003COMPLETE CAR GENERAL VIEWS DIMENSIONS sie: mm tind Dimensions 4 aftele}ofelel}e a Masi! me 8 collans js7er1) hacen} 1690 | 962. | 2510 | 1046] 4618 | 1400°| 5050 154.261 [53-06 |¢64.17)}c33.04)| 98.820] c4n.281| 1790) 165.11 |1968) M# milano (1) withhrims 5 Tyg ta” H2 F= Radius of the circumference described in eprrespondence with ground from driving wheel-outer ed in the max steering, conditions PA3B4I00000002 00-3 Aprit 1987COMPLETE CAR eeeSeSSSSSSSSSSSSSSSSSSSSSFesesee WEIGHTS. AND. LOADS: rit: tb kg? eight aie Lowe Max weight allowed 3686, 11785), ‘Curpweigns 2908 11320) Payload 937 (425) Front 1834 (e392) ‘Max gross weigh per axle allowed Rear 2012 (913) Front 2 Seating capecny Rear 3 WHEELS AND TIRES Winker Tes -sre Balle 300-89-0( 2/3/87 Back spacing. = 13omm Rams 255 Sot > 45mm Cary Prbaction “t 20mm bate 64x16 Tubeles Ties 185/60 VA 14" 185/55 VR 15 A 196; 196.7; 28 (201 6 into rere r 196/196: 78 120) bors Keo; pss Weolem?) (1) & 2165 218.75-31 (2.2) oer oree . 2ab 288;95 (25) As Front (31, Presures mesure on cot tes fhe N+ eth resuce ou anormal some caution: Cs rtulllosd ond hgh seed The whee! nut mest be tighenad 10 98 Wen wr ave Vos ever 190 mah (210 bh aie teie, 10Kpent Aprit 1987 00-4 PA3E4300000002COMPLETE CAR MODEL VARIATIONS oon! vaio \dantitenion Body 4 or sioon Drie us Eaton USA, MY-B7 Idencaon No ‘on semen abel e134 rer6 169.26 tor24 cabal a boxtem of etal at hee - rast on USA. fety “yee seer Ne - - ‘ee op “regulations label eur near ght cor mise wnt armen Heer penn sna on ear ign stot fom From From from assert Juseae comeerne aoorsore | oooseczs | coczso2« | oo960001 oan osnze Ecion tye nd ail No serait From from Aso003 000.001 Paseaso0000062 00-5 Anrit 1987COMPLETE CAR SERVICE AND IDENTIFICATION DATA IDENTIFICATION LABELS VEHICLE IDENTIFICATION CODES Al CHASSIS NUMBERING (VIN- CEE). This consists of two. groups of num. and symbols, bers indicates below; as o a +ZAR161160 + 0000100 + Tone @ (1) Type code: This consists of Ya) Basic type number: This ts allocated for each model range of vehicles. with common con: cept (ie. 161 - 6V-2.5 Milano, (2 176-Alfetta range, 119 - 2500 V-8 range) {bb} Suffix letter for variants; ‘This identities the characteristics. gj within the basle model range (ice: 160- 6V-2.5 Milano 119A ‘Alfetta 6 2800 with manual This consists of two groups of num bers and symbols, as follows’ This: consists of three groups of numbers and symbols, as indicated ‘Break in instructions = Label on bottom side’ glovebon drawer ‘Vehicle identification nurmber — Winginiets plate = 0.0.7. eertticati ‘Compliance with Californie exhaust ‘minions reinderds =_Label on front ieftwinidow Fuel requirement S| = Label near fuel tank fit port ion tate ‘Cobriewtion data 7_ |= Lubrication cata rabe! ‘Compliance with exhaust @miasion imporeation regulations 5 | — ‘Lebel on ime, Prodvetion date & | — DOT. certification bet ‘eauippad care = Fusebox lig inner sie ‘Useful loud Seating capacity - Tire = Fuseoox tid inner side ENGINE NUMBERING a @ AROISTI » AG0007-» Engine number = On crankcase rear side let the teft bank heed joining surtace) ‘Body number Type number: This is aliocated od ont loan ban to.each range with similar tech nical characteristics (i.e: 01911 6V-2.5 Milano - 016.08 Alfetta 1800 engine, 019.13 - 2500.V-6. engine} Progressive engine serial number: This is allocated on # consecu: tive. basis by the Production Department: VEHICLE’ IDENTIFICATION NUMBER (VIN - USA) (1) Vehicle: mode! ‘consisting of Ja} Family (e.g. A: Sport sedan, Br Spider, etc.) 1b} Production variants: (2.9. A: ‘Manual gearbox, B; Automatic transmission, te.) ‘Ach Model variants: @.9.: Body ‘type: (Sedan or Coupe!, engine type (cycle, total displacement, gearbox, 116 C: GTV 25) below: power output, ete.) (2) Progrestive serial umber: This wg a (2) Mode! year is allocated on @ consecutive a 7 (3) Manufacturing plant identifi. aR 7 bssis by the Production Depart @ DANE H'1001001 ‘cation number ment fone Ga (4) Progressive seria! number Jone 1986 00-6 Pazssao0000001COMPLETE CAR LIFTING AND TOWING POINTS JACK PA384300000000 March 1986COMPLETE CAR — WARNING: Never get under the vehicle while it is supported only. by the jack. 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: diagonally opposite to jack oxition, Position the jack, supplied with the vehicle, in the safety points shown in the figure, HYDRAULIC JACK AND SAFETY STANDS WARNING: a. When faising vehicle with the jack, be sure-to support it with safety stands. b. When jacking up the rear (font! of the vehicle, pte hocks in front (back) of the ‘front (rear) wheels, CAUTION: When raising the vehicle, always Place a wooden, black under vehicle lifting points, Position the jack and. the safety stands ina safe manner under the points shown in the figure. TOWING Closely follow the moor vehicle regulations —goncerning vehicle towing. CAUTION: 2, Use suitable towing equipment to pravent. damaging the vehicle, 5. Before towing, make sure that front and raar-axlas 9s well at wtaering wheel are in good ‘Wworkitig conditions. 1 not +o, make use of a dolly, &If vehicle must be towed with its tear wheels raised, the front wheels must be ploced one ‘towing dolly, d. Set the ignition key to. “O° position and de not withdraw it” from ‘the ignition black, otherwise, the steering lock coutd become engaged, #, Before: starting. vehicle towing. release parking brake and shift the gear lever to “neutrat”, {. Do not apply latersi forces. to towing bar. Always keep towing ber, or similar devices, in tine with the vehicle. 9, Remember that when vehicle is being towed. there is:no vacuum in the servobrake; therefore, when braking, exert greater pressure on brake pedal, SPECIAL SERVICE TOOLS Speci imporiant. role ina vehicte’s main tenance since: they are essential to service tools play 2 very ensure accurste, reliable and quick service. To this. effect, it must be remembered that times. taken rele vant tthe. various. maintenance operations are computed assuming that said special tools aré being used All special service tools, made March 1986 expressly on the Manufacturer's design, needed for overhauling, main tenance and repair of models are listed and illustrated! in this manuat ‘The identification number is deter mined by the relevant ordering part number and consists of a letter followed by a five figure number according to the foltowing schedule: 00-8 0.0000 €.0,0000 U.0.0000 Special Service Too! Tester Reamer The listed tools mist be ordered by ‘the authorized workshop according ‘0 the usual systems already followed by each Service - network 4384300000000COMPLETE CAR INSTRUCTIONS This chapter lists andt deseribes the pre-delivery operations. required for the WP miiane Bvehicles, The opera tidn description does not refer to each version, but gives generat information concerning the parts tor which inspection is required, ‘As regards the technical specifi cations related to each operation, and the lubricant products. (and similar), refer to: the “Service Date and. Specifications” present in each. section. CAUTION: Pre-delivery inspection of a new vahiele, prior to customer delivery, consists In carrying out all checking operations and tests hereafter de seribed in order to detect and thus eliminate any damage or mal- function It goes without saying, however, that when Dealer personnel picks up the vehicle, @ visual check. should: be performed in: order to: make. sure that normal: driving conditions, espe cially as. regards level of fluids and controls in general detect any dents or seratehes on body or other damage: to the vehicle interior (uphotstery), 6. make sure nothing is: misting, especially factory supplied acces: sories, spare tire: and any parts that are to be fitted on vehicle as pre-delivery completion. vehicle in in Wf topping: up. is required as ¢ result of the checks, proceed accordingly; this operation is 10 be considered as part of pre-delivery inspection, In the event of interven tions, (malfunctions) different from those indicated, carry out the ad: justments according to. the ‘current technical arid administrative proce ures, Paaea200000000 FOR PRE-DELIVERY INSPECTION As each operation. is being carried. out. the relevant card must be filled: out-and then filed together with the sold vehicle's other documents: the: predelivery card included in the Service Book supplied to. the cus. tomer must also be duly filled out 1 indicate that the pre-delivery checks. have been: carefully. carried out. OPERATIONS IN THE ENGINE COMPARTMENT. Coolant = With engine cold, check: the header tank level. Top up if necessary. with the specified liquid, up to the max. level Engine oi — Check-that level is up. to the MIMAX mark on the dipstick. (carry out this operation after parking the vehicle on a flet surface, and after the engine has been off for a few minutes), If required, top up.with specified oil Power steering oil = Check that level is up to the "MAX" mark on the piug stick {before carrying’ out the check ‘with the engine idling, rotate the steering wheel completely: in both directions in order to carry out bieeding) Brake and clutch fluid = Check that the level in the tank ig up to the "MAX" mark-on the tank, If required, top up with specified fluid remembering that tins must be sealed and opened only when ready to use Be sure-to perform this opera tion’ with utenos! care” and cleantiness 00-9 Battery electrolyte ~ Check that the eieciraiyte covers the plates upper edge by 5 mm 40.197 in), Ef lower, top up with distilled water. Windshied washer liqui Check that this tank: is full. Top up, if necessary. with appropri ate solution, Engine electric fan Connect the thecmat switch cables ‘together and check elec. tric fan functioning, = Check that cables are. firmly con: nected to thermal switch. OPERATIONS ON VEHICLE EXTERIOR AND IN THE PASSENGER COMPARTMENT Exterior cleaning — It required, sdewan the vehicie Using suitable products and procedures; wash the vehicle's exterior with 9 solution of water and shampoo, ringe it thor oughly and dry it Finish cleaning by removing any stubborn spots. using suitable ‘compounds, t = Visually ang: ynorougniy check all painted surfaces and remove accidental’ “or manufacturing flaws, if any. March 1986COMPLETE CAR —. Exterior moldings and fittings ~ Visually check all venicle’s out side ports: bumpers, moldings, grills, headlight rims, letters ana emblems making: sure they are securely fitted, and have no spots.or dents Doors and hoods — Visually check ali weatherstcips for tight fit and make: sure they ‘re not damaged; out of shape or dirty. — See if doors and hoods are aligned and. centered with re levant openings Factory issued accessory equipment ~ Cheek “if following items are in ‘theit proper place in the vehicle tool kit, spare tire, jack, Instruction Book” and Service Book. Locks, hinges, windows — Check proper working conaition Of all door locks: lelasé, lock, ‘pen from inside and outside). Check hood and trunk In the same way. — Check door and heed hinges tor smooth noiseless operation ~ Check if windoine can be optence! and closed all the way withour sticking and noise, Interior finishings = Check all upholstery (root: carpets, panels etc...) removing Postible stains or scratches Seats, seat belt and accessory equipment = Intpect” seats checking if they. slide freely on tracks without sticking and noise. Also check Proper working conditisn of sear and head-rest adjusting devices. March 1986 — Check inside ana outside rear View mirrors making sue ‘they swing easily and stay firmly place when set; also checte shop switch on mirror for day/night driving. — Check if seat ‘belts and relevent retractors are in good working condition, Check, maneuverability of sun visors, ashirays, glove compart ment and any other accessory Heating and air conditioning system — Check correct tunttioning of heater controls and air inlet lids and louvers closing) — Check that electrié fan operates, correctly at the variout speeds — For the vehicles equipped with air conditioner, start the engine and check that, when operating the related control on vehicle the closing of the electro. magnetic ‘coupling occurs. snd, consequently, the eampressor operstion, (opening and. Lights, indicators, electric accessory equipment — With. the ignition key ser te “MAR, check whether lights outside and inside the vehicle, as well as the related warning lamps, illuminate: front and rear parking lights, licence plate Nights, direction and hazarct lights, stop lights, high/low. beams, headlight: flashing, re verse light; engine and luggage compartment lights, passenger compart lights (through manuat cantrot, and-en doors} and’ the related switch. off timer, front and:rear spot lights, cluster lights and related adjust ment. rheostat (or rheostats) glove compartment light. - Check whether the following ‘warning lamps illuminate: alter nator, fuel reserve, engine oi! Pressure, brake fluid level, park ing brake on, starter on, heated 00-10 indow on, engine tempera check correct functioning of ‘the ALFA ROMEO: control warning lamps which illuminate all at the same. time at soon as the ignition switch is set to the “MAR' position, .and then switch off after few seconds = Check proper functioning of horns, cigar lighters, door locking device, power window controls, and: front ‘wats elec trical controls. Windshield wash/wipe and headlight washer ~ After installing the wiper blades, check whether wind: shield wiper works properly at the different speeds, as well-as. intermittently, = Operate the windshield waster and check that nozzle jet. ig uniform and correctly directed towards the upper part’ of the window. — Check that headlight washer jet is correctly ‘directed towards headlights (only: where required by Regulations) Tire pressure ~ Check tire pressure. and, if Fequired, restore to specified values. Use higher pis. for the spare whee! Tightening of wheel. nuts -or screws — Using & wrench, check that Nuts oF -serews of wheels are completely tightened. Check that nuts are appropriate for the type of vehicle and rim, as indicated in the. spare Parts Catalogue PA384300000000COMPLETE CAR OPERATIONS ON VEHICLE LOWER PART Gearbox-differential oi! = Remove filler glug. and check that ‘the lubricant level reaches the lower rim of the related hole, Top up if necestary with the specified oil and re-fit filler plug Systems tightness = Visually cheek for jeaks in the following systems: fuel, power steering, brakes, clutch, engine cooting = Check for oil leaks trom engine, gearbox and differential Maintenance operations consist in checking and restoring proper work ing conditions of-some parts of the vehicle which are.most likely te become worn or out-of-adiustment as 2 consequence. of ‘normal use Aclist of the various operations to be the vehicle's performed at different intervals, os shown in the chart that follows, is PA384300000000 FUNCTIONAL TESTS Engine controls ~ Check that the starter control operates without sticking along the whole travel and that, when the related knob is pushed down, the ‘elated device is completely disengaged. from carburetor. = Cheek that the pedal accelerator control operates’ without sticking “and, with the pedal at the: end of travel, the throttie valve is fully open, Engine start-up and functioning — Check that’ engine starts cor rectly. With engine hot, check: steady functioning of the engine at the specified idle cpm. MAINTENANCE included in the coupons, of the Service Book. which accompanies each vehicle. Coupons will have to be stamped by the Service. Organisation Agency 10 show. that specified maintenance operations have beer carried our. dust as for predelivery inspection, should topping up-or change of fluids and lubricants « as described in the, oo-11 Instruments — With) engine funning, check correct functioning ot alt elec tically operated: instruments: fev. counter, speedometer, oi! pressure gauge, water thermo meter, fuel level gauge, clock Brake, clutch and gearbox controls = With engine running, push -the brake pedal and check that, after the initial empty stroke, it stops without elasticity = Check also proper functioning of parking brake lever, = With. engine running, push the clutch ‘pedal and.check that al! speeds canbe shifted without sticking or noise, ext » become necessary, they will be considered as part of maintenance operations. If damage or malfunc: tions, other than those listed are encountered, they will be taken care of, repaired, ar adjusted according to current technical and administrative procedures. March 1986COMPLETE CAR VEHICLE MAINTENANCE SCHEDULE ‘Mileage covered (x 1,000) —_ Ws peters i | as [7s | 16 |a2e | a0 | ave | + | Change encine at ane Rar Tx|[x|[xi[xix|x Tt 2. Check boots of CV, joints and wearing rout tor sourdnes | X | X |X |x |x | ® I 3 | tpt braking yatem xlxi[xlx|[x|{x | 7 | [eh ben pd tr pn Baap tp red 1 [Lx Tetepe Te Te | mot wate naeie xfe le)? x | 6 | Check parting bake travel and adjust necessary Tx[xix[xixlsx tT 0) eae eon ree ee ‘loctoiye level in tunttery if necssory, T ~ T ee. siecle ke ays 30.| Check vabve clearance and adjust, it necessary x | 1x x € v1] See parce eae enue] | lel | xe 42 | ‘Change ait cleaner element * ~ 13 | Check power steering fluid level 7 Vy x x x x 7 14:| (Change sper plugs - I | - x € 16)| Change engine coolam mixure il T x x 4 76 | Chat genx an atari x) , x 17 | (Check goaitox and crierenial ci'iever ond top up ba netewary x i x ~~ S 18 | (Change bvake tiie’ —_ | x —_ x 6 (Cheek eytinger Revs nuts for proper toraue 20 | Check ole speed and aduist necessary 21 | Check front whee! toe-out and adjust as neccesary 22.) Cheek head lamp beam aiming and adjuey as aquired 23.) Tost vente 24 | Check engine bos for tigminess 25 | Replace exhaust gas-sensor and catalytic nonverer I 261 check trom whee nab bewigs beri x ae x Nore To_be performed at ene stated mieages or once a year whichever occur Sst. Check ol evel move Hegusntly (when retushing). To be cartiag ou at he stated mileages and mare frequently when divig Rar or when diving mainly in mauntainous condltions. ‘To’be partormed more requemty (when retuiing) ‘To.be pertormed athe stated misages or once every two yOu whichever O¢Cur tr. Check ooolant level more frequanty (whan Check gearbox ol more trequenty (when reluaing “Tobe cari out at the staled mileages or once & year whichever octets. Onty for vehicles with ABS ayster, Maintenance require tor proper function of emission control system perfomance. June 1986 00-12 PAB3BA300000001anoa0R0nE rae WE €1-00 9861 42008 Banter, lectrolyee (if necessery) Enoine oF hutch ‘rake Hid Power steering Leet ace ‘every 90,000 fies from 19,000 Sites 1B. Tobe carried out every veo! C.Teibe cerried out every two yeors QO cncex Q woreare ABW Fter corriige — == Strering box boots — = AE Coolant RY - — —— A. Gombox-titterentiat of ~~ Drive shaft boots A Tobe carried out Irequenly wher reluelting LNOAV1I SLNVOINEN1 GNV Saints uva 3L314WOoCOMPLETE CAR ee eessSSSSSSSsSFs RECOMMENDED FUEL AND LUBRICANTS FUEL Octane rating A gasoline’s resistance to detonation knock. is noted by lis octane rating, Pur ‘chate andi use. of correct octane tyel i ‘essential to prevent. knocks which may -¢ventually be harmful to yout cars engine “The higher the rating, he higher the abil- Ay 16 resist sknoeks, Regular fuels have an ‘octane tating range’ trom 94 to 96 RON *Rosearch Octane Number) ar 86 10 90 PON (Pump Octane Numer, PON ratings ‘appeer on gasoline pumps inthe U.S. This rating is determined in the following manner RON + MON" * Motor Octane Number For exemple. Research Octane Number fang Motor Octane Number divided by 2 equals Pump Octane Number. ‘The P.O.N, Setane rating is uaually S:points lees than the RON rating: 91 RON = 85 PON OS RON = 80 P.O.N mporent note for ¥B moilane © Use of fuels with octane ratings lower than 81 RON of 186 P.O.N, should be avoided. Important note for The Xf milano ® - MB nila 16) hes been designed ‘to operate on Pramium unleaded gasoline having a minimum ‘of 80 octane as posted. on gasoline dispensing pumps displaying the Octane Number?.. RON +MON ating method (96 Research’ 2 Ani 1987 00-14 PASBAIOOOQIOZteren No, 2 p = Nene Aponcavion | Cistiction Notes g ve en ae ® sree. ‘other sat rawiso | sm 2000 Sten Fie @ i Motor ‘Aino termoarate Engine 01 arise SAE 10850 ae 1oruA0 10 waver bette 108%) Graton SAE sowis0 | Rowanar sx onvin DS Spirax Ho Anbent tenpeure Biter APiGLs SAE 78/90 sae vowion | aowrao “a0 wo 150% ver (C40 Yo 202%) on fg SAE sowis0 | Ravan ox Ponton HOS Soran nbn noeranve ‘ott ay Piet SAE 7SWIC0 SAE 7690 01790 Flas 150% suspension {40 t0 302) Steering vexnonn — | atroexnows | oFxnon DEXAON 1 ovis 29 287 FLU n tor08- 020197 1397 ‘mic Condlione SUN OIL COMPANY %0 Sania 46 ° oinow cARBIDE $ CHEMICALS COM i PANY: Uson librcant = sone-5100 a MILLOIL: Lubricant toy elastomer sels Engine-01 SiPal AREXONS Sarbo stn or var TSECO, Wolken Paste TSECO: Moiykote @R? GReAse SECO: Moivtow A wena? | Gave ts tate weranen AFC TAniance GOR! Never Seer : engine Borch 5.964 090 05 § Fut System SECO. Mowten Lom = os 'SECO: Moivkore Lang g REINACH: E10 TAG SAINVOIMENT ONY SAINTS V9 3L374WOo9961 yore 3L-00 o00qgc;E Need Type ‘Aphlication Clasitication ‘AGP Grease Engine ignition 05 SHELL REINACH -E10 TAC Engine cooting system +07. Antiseize GORE Never Seer Chutom 42 NLGINo 3 Grease 33 FO Avrogreaie FO Basie Substance Bentonite Polyinene 1SECO: Moivkote BAZ Gearbox 13 NLGL Nod Grease 33 FD Autogrease FO. Fietiaan, AX ESO: Norva 275, Basic substance tonite Polythene TSECO: Molvkate Longerm No? ISECO: Motykote BZ Transmission -15, NALGI.No. 4 Grease 15 Autogrease MP Freuinax G11 ISECO: Motykote BZ ISECO: Molvkore 6 RAPID Ditferentiah -17 ISECO: Molykote VINZ461ic OPTIMOL: Otttamoly | patie Substance! Ls 2LNeRa ISECO! Molykote BR2 From suspension 2 NLGIN03 Greare 29 FO Autogfease FO: Fetinax Ax te Subgtance: ‘Bentonite Polythene ISECO: Molykote GR? 'SECO: Ergon Rubber Greoie No. 3 SSO. NORVA 275 SPCA: Spagraph REINACH: Sterul AAR dO ALaTENODonooqoson reed £t-00 9961 WW Name type Appliention far = wecs J Notws AntimiceR. GORY Never Seez 2 ISECO: Moiykate Longtarm No.2 WAGs. No.1 | Grease 15 Recinge G14 Basie Subétance, AVGe Front and Rese ATE: Bromsevlinder Braker - 22 Paste ISECO: Motykate Longer No.2 NLGI.No.3 | Grease 33 FO Aurogrease FO Retina AX Bisic Substance | Bentonite Polythene REINACH: Storut B2AR, SPCA” Sbagrant Steering box GREASE | Aaet : 23 ESSO.NORVA 275 ISEGO: Ergon Flubber Grease No, 3 ISECO: Motykote Parte G CALYPSOL rear Suspension 8 SPCA: Spagraoh ISECO: Ergon Rubber Greate No. 3 Atiseize Compound GORI; Never Seez MILLA: Protection LT HOUGHTON: Rust veto 1064 REINACH: Sferut azar! avo. aLa1dWOo= Re 3 Type Application: (Chassification had ‘Notes s AGIP oa ‘SHELL ‘Other a & UNION CARBIDE GHEMICALS COM. Wines and PANY: Ucon Ties «28 Iubricant 50 H8:- 5100 MILLOIL: Lubdeant onease tor elestomer seals, UNION CARBIDE CHEMICALS COM. Ali Conditioner PANY. Yeon 6 lubricant 60 HB - 5100 MILLOIL: Lubricant for elastomer seals Antifreeze Antitreeze Ethylene Glyeet (eoncenteated Enaloe.Cootina Std, No, 3681 «69956 S 7 ° Antifreeze i leendly for use | Std, No. 3681 - 69958 ou " Brake Fluia ‘Auto Fluid FR. Brakes Chatch Super HO 22-42 pene ‘Ae Conditioner Freon 12 80 aaonna00R BEE SAE VISCOSITY eartsox- Diferential OF Getet em Gearbox. Differential. Messurenignt SAE 10WSO ‘SAE 9090 cos ~40't-401 - 150000 =20 (4) 2600 cH 40 (1081 165 48 90 11225. 110 - 100 1212, 19 14310153 dvd 3L3a7dWOoCOMPLETE CAR APPROXIMATE REFILL CAPACITIES FUEL TANK 11Gai0) 6707.7) FUEL RESERVE 1 Gals) 81010 (2.1 t028) with titer 6113) ENGINE O1L. SUMP eg tb) Without fitter 581121 CAMSHAFT SUPPORT WELLS (*) a ib 0.450 (0.997 GEARBOX - DIFFERENTIAL OIL, eg ib? 2.07 (4.56) POWER STEERING SYSTEM OIL. kg tt) 0841.78) mint | CONCENTRATED sore) | ANTIFREEZE Harel 381096) pisTiLeo. 20 | water Gets) Banh 4 ANTIFREEZE READY TO USE 1 Gans, 16a COOLANT CONCENTRATED ANTIFREEZE Hate) 601.3) (ln | DISTHLED WATER Hash sina ANTIFREEZE READY TOUSE HGoin) - [+1 Replacement to be carried oUt only in the eve Of disagsemby P4384300000002 00-19 Apri 1987COMPLETE GAR ENGINE MAINTENANCE ENGINE MAIN MECHANICAL UNIT REPLACEMENT OF ENGINE OIL AND OIL FILTER CHECK ON LUBRICATION SYSTEM TIGHTNESS 1. With engine hot, remove the oit filler plug (@) and the oil sump plug (), and drain oil completely (wait 15 minutes at least) YO fuer plus 2 On dipstick 3 OW dain pug March 1986 + & milky oil indicates the pres: nce of coolant leaks in the oil Adentity the cause; and take corrective measures, * An oil with extremely low viscosity, indicates dilution with fuel. 2. By means of @ suitable wrench, release oil filter and remove 3. When. engine oi! is. completely drained, clean the drain plug and tighten it on sump, together with the related gasket, A. Wet the gasket of a new oif filter, then tighten fitter fully, 5. Refill engine with the quantity. and quality of oil specified. ENGINE O1L, Tyee. AGIP Sint 2000 10W50 IP Sintiax TOW40 SHELL Fire & tee Motor 18/50 Quantity: 8.0 Kg (13:2 tb) Cylinder head camshaft support wells (*} 450.9 (1 Ib} ‘Sump at max lever BBkg (124.16) Filter capacity = O.5 kg (4.1 Ib Difference between max and min level on dipstick Zkg (4.4 tb) 00-20 $1) Refituing 10 be carrie’ out tor ach Hipport well when diss sembling. 6. Check oil level by means of the dipstick. 2. Resinsert- filter plug, and start the engine, letting it idle for about 2 minutes. B. Check for fubritant leaks. 11 necessary, replice or tighten any tern with poor oit seal. 9. Switeh off the engine and wait for'a few minutes 10. Remove the dipstick and cleari insert-the dipstick again, remove and check that olf level reaches ‘the MAX reference mark CAUTION: ‘The oil level check is to be carried ‘out with the vehicle parked on a level! surface CHECK ON BOLTS AND NUTS TIGHTENING Check land restore'if necessary! the ‘Tightening of bolts and nuts securing ‘the various parts to body. and those ‘connecting the varlous components to each other. In the case of bolts fittea with spit pin or ealking, 2 visual inspection of tightening con: ditions is sufficient, Take the utmost care in checking the ols and muits that are the most important from the safety point of view, These’ bolts and nuts attach the following components, AS’ regards! the tightening torque values, refer to: Service Data and ‘Specitications - Tightening Torques. 1. Front suspension a Lower levers to body 1b. Upper fevers to body, & -Steutsto body 4. Ball joints to: steering Knuckie +P4384300000000COMPLETE CAR 2 Biakes, @ Calipers 10 related supports b. Rear brake discs to differential shafts AL Steering whee! 2. Steering box to body b. Steering rods to steering whee! levers © Steering rods to steering box arm 4, Steering eaiumn joints ® Bolts securing steering colin to body 4, Rear suspension 4 De Dion axte to cross member b. Cross member to bady Transverse tie rods to Watt patallelograri and body d. Watt parallelogram. to De Dion axle 5. Oher Drive shafts to dlfferem b. Wheels and hubs TIGHTENING OF CYLINDER HEAD NUTS 4. _During first coupon maintenance a Remove the timing system covers. operating. as per: “Check and Adjustment of Valve Clearance Removal of Timing System Covers”, be With engine cold, loosen. the nuts by one turn, and one ata time, according to the given sequence, tay a coat of oll-on the surfaces between washer and nuts, then tighten to: the specified torque, The figure shows the right head, garda the loft head, the tightening sequence is symmetrical, CB emning true feb; 10-1041 kg-m) 364300000002 \a ur Se Techical Bulletins + 01-98-01 Install head covers and the surrounding components, by re versing the order of removal 2 When heads Fesssembling cylinder 2, Lubricate the surfaces between washer, nuit and threads with engine cil and, with engine cold, tighten nuts gradually to the specified torque. @): Hamening toaue weate (65 to 72.3 ft-lb; Gto 10 kgm) by Alter. covering about 1,000 km; proceed, with engine: cold, as per step 1. CHECK AND: ADJUSTMENT OF VALVE CLEARANCE ‘The following operations 1d out with engine cold. to be 00-21 ol- 88-02. OI 88-03 1, Remove timing system covers a Detach the terminal b: Detach connector () from the airflow sensor (8) and release. the negative . bantery felated cable from the securing bracket & Detach, sieeve (3) trom throite bouy CD) Disconnect rose (2) trom the adjusting union on intake air box. Disconnect hose (8) irom intake ait board hose (@} and 48 rom sore @®) f. Detach hose (Band connec tor @ trom the auxiliary ai device and detach from. the. timing svete cone a Detach hose g trom throttle body, and hose from timing system cover, 1. [For 2000 engine}: isconnect hose (18) fri the intake ait box. hi Release the five clipe securing air Gleaner cover and remove it together with sleeve (3) and oil vapor sepa rator (6). Remove also the filtering elementCOMPLETE CAR Thiotte body vacusm nose tor purge conta! valve Auxiliary ai device Fuel vanor cecireuletion howe Oil vabos sepirstor Aiechow sensor (it vapor return hase 10. Auxiliary or piping 1}. Ground:eables or auxiliary air device 12 Supply connector for auxihayy air device 13 Airsteeve 14 Fuel vepor ecveulation hore By-pass-hose for ile m. adjustment Connect: for aitlow vendo novenviozneter Vaccum intake nose oF inition dst’ weeuwm e660! ene Yor 3000 engine) 48 Hose for air delivery 10 AC. solanne thor S000 engi 18. Hose fr sir aetvery o intake ir box tom A.C. kalena iar 36H engine i Detach the spark plug caps, disconnect. the high voltage cable from coil, remove the ighition distributor: shell covers;: then release ‘cover and remove it. 1. Unscrew the screws securing the timing system. covers and remove covers. 2. By means of a syringe, suck the il from lubrication tanks. 3. Clean the spark plug seats, temove spark plugs and plug the holes, so as to prevent. foreign matter fram entering 4. With engine cold, check that the Clearance between the cams resting radius and cups crown is within the specified values. Aptt 1967 To check the intake valves clearance use fesler gauge C:6.0197 INTAKE VALVES CLEARANCE MEASUREMENT ¢.6.0197 a EXHAUST VALVES CLEARANCE MEASUREMENT Valve clearance (on old engine} tntake Gq = 0.478 10 0.500 mm {0.018 10.0.020 ini Exhaust Ge = 0.235 100.250 mm (0.008 to 0.010 in) 5. Should intake valves adjustment be required, proceed @ follows 4. Toke note of the clearance on each exhaust valve b. Engage the Sth speed, move vehicle forward so as to cause eran shaft to rotate until notch P Amarked fon engine. pulley! mates with re ference pin Paseeso00 Rae‘COMPLETE CAR ‘8. Unscrew the three screws, which secure hub, shown in the figure 1 Reference pin Netches (2) on camshaft will. then bbe aligned with the corresponding reference notches (1) marked on the related caps. f. Seoure tool A30527 to hub, and withdraw hub itself from the ‘toothed pulley. 1 Comshett cap oieh 2 Garnansty noxen ©. Remove the cover which pio ‘tects the timing system belt gd. By means of tool A.2.0367 keep comsiaft sti, and unscrew the rut securing camshaft pulley. Pasbe300000000. 00-23 8. Disassemble the camshaft caps; withdraw camshaft by lifting it trom rear side WN. Withdraw cops and recover aps, i. By means of tool €.1,0108, measure the caps thickness; ‘then select. the. most suitable one among the set of caps, to restore the correct clearance, 61.0108 i install caps and: cups lubricating them with engine oil, m., Position the camshaft and instalt the releted caps complying with the sequence, and following the. arrow marked on them — Right heed! cap: arrow towivts af ‘ine roar sic, = Left head cap! arrow Swardson: ‘ine front side fi Tighten the nes securing. caps to the specitied torque. Maren 1986COMPLETE CAR Tightening torque Nuts securing camshaft cape (in ‘engine ot) 1610 18 Nm (11.8 10 93.2 te; 2.610 .8 kgm) 9. Rotate camshah 3° that the notches marked on shaft ave aligned with those marked on caps. Also check that notch P is: aligned on crankshaft pulley. P. Install hub complete with a new O-ring, and screw the three securing screws without. tightening them q. Sciew the nut which secures toothed pulley ta camshaft; use too! 2.0361, to prevent pulley trom Totating and lock the nut to the ‘specified torque. Also tighten com pletely the three screws. securing ub. @ + Tightening torque Nut securing camshaft front tub 9710117 Nem (71 t0 B6 ft 9.9.10 11.9kgmi tb, Engage the 5th speed and move vehicle $0 as to rotate crankshaft Until the piston of first cylinder is at the T.D.C., during the expansion stroke. This position is identified by the motion reversal of comparator index. & When in this position, check that © notches (2) on camshats are in line: with those (1) in the re: lated caps. 1 Gornsnsie esp eben 2. Camihstr noten + the notches Fon engine pulley in line with. the reference pin (1) on engine block, 2 Adjuring eerie 6 Should adjustment of tie en 7, Before reassembling, position aust valve clearance be required, camshafts correctly, as follows. proceed af follows a, Install tod! €.8.0183 fitted with By means of ‘too! A.6,0220, comparator, into the. seat of tot loosen lock nut (TF) opersting on cylinder spark plugs toa! intermediate lever b. By means of the same tool, ‘operate the adjusting screw (2) until the ‘specified value. Is: measured on the feeler gauge e. Tighten tock nut (D) and re check clearance 1 Reference pie 8, Reassemble, by reversing the order of disassembly ‘Api 1987 00-24 PABA IDOGKNIO?COMPLETE CAR REPLACEMENT OF TIMING SYSTEM DRIVE BELT Removal 1. Detach the fegative ‘terminal 2. Remove the timing system covers (refer to: Check and Adjust ment of Valve Clearance - Removal ‘of Timing System Covers) 3, Remove the drive belts of alternator coolant pump: and power steering pump. (refer to: Checking Good Conditions, Replacing and Adjusting Drive Belts of Alternator, ‘Air Conditioner Compressor, Power Steering Pup). 4 Disconnees sieves (9) and 3) of thermostat (3). battery Recover the coolant drained. from the system, S. Detach connartors () and (B) from thermostat 6. Unserew sender (@) trom theemostat unit. 1 Coolant delivery sleeve ta-ediator Thermonet Coolant temperature tender Coolant temperature sander coniecior Coolant reuien sleeve to thermortat Connector for thermo-kime switch 2 a 4 8 7. Clean the spark plug. seats Femove spark plugs and. plug. the holes to prevent foreign matter from entering B. Unscrew: the bolt and screws which secure the timing: belt case over; remove the ‘timing belt case. 8. Engage the Bth speed and move vehicle forward $0 98 to rotate crankshaft until natch P (marked fon engine pulley) isin tine with reference pin G), When in this position, notches (1) and marked on camshafts, will be aligned” with the corresponding frotches marked on the related caps In addition the piston of Ist cylinder is at the T.D.C, with both valves dlosed (compression stroke); also check that rotor atm (@) of ignition distributor is towards the reference notch marked on distributor body P4.384300000000 Notehes of right camanott Notehes of lett camahett Roference pin Tgnition gisteibutor rotor ater 00-25 March 1986COMPLETE CAR 40, Litt arm (4) of belt tightener and insert pin 2.0363 to keep the belt tightener atm lifted 1 Bert aigntener arr 1, Loosen nuts CF) and CB), ores the belt tightener downward, up. to en of travel, then tighten ut 1 2 Nut 3 Bei tightener sem 12. Remove the touted belt ie moving it from pulleys. March 1986 Reassembly 1. install tool €6.01B3, fitted with comparator, into the spark plug seat of st eylinder and check engine correct timing by checking thet notches are aligned, as described in Removal - step 9, CAUTION During the belt reissembly opera. ‘tions, check that the notches ar always correctly aligned, 2, Fit the timing system drive bett fon pulleys, Keeping the belt parts already installed taut, and complying ‘with the following sequence. 8. crankshaft toothed pulley bb, left head toothed pulley 5. right head toothed pulley 4. ignition distributor ‘toothed pulley ‘2, belt tightener puliey- 3. Looser the belt tightene’ se curing nut. 4, To bed the timing system drive belt, engage the. Sth speed, move vehicle forward in order: to rotate crankshaft by two turns, stopping when the pisten of first oylinder is at the T.D.C., in the compression stroke {all notches. are “aligned, refer to. Removal «step 9). 5. Keep belt taut, press the beit tightener pulley against belt itsetf; then tighten the two: nuts which secure belt tightener. Litt the belt tightener arm slightly, remove pin €.2.0363 and celease the arm, 7. Terminate the. reassembly by feversing the. order of removal and complying with ‘the following indi cations 8. Lubricate the threading of cool ant tempereture. sender with the “specified antiseize product. Antiseize: R. GORI Never Seez LOCTITE Anti Seize comroi Tighten the following compo rents. to the specified torque. 00-26 ©): Tightening torque Goolant temperature sender on thermottat container (with ‘specified enti-seize product) 2010.25 Nm (15 t0 18 fib; 210 2.5 kgm) ©. Gary. out the Belts tensioning (refer to: Checking Good: Conditions, Replacing ard Adjusting Drive Belt of Alternator, Air Conditioner Corn pressor, Power Steering Pump] @. Restore coolant correct level (referto: Engine Coating) See Tedsaicel Bulletia Ol-8 9-083 CHECK ON TIMING SYSTEM AND DRIVE BELT TENSIONING (A) Check and adjustment of timing system This check is to-be carried cut with valve’ ¢learancé to the specified value and timing system drive belt normally taut. 1. Disconnect the negative battery: terminal 2, Remove’ the timing. system ‘overs (refer to: Check and. Adjust. ment of Valve Clearatice} 3. Clean the spark plug seats, rermove spark plugs, and plug the holes in order to prevent foreign ‘matter from entering 4. Check the correct adjustment of timing. system. as follows. 4, Install probe C6.0183; fitted with dial gauge, into. the spark plug seat of first cylinder b. Engage the Sth speed and move vehicle. $0. sto rotete crankshaft Until the piston of 1st cylinder is at the T.D.C, in the expansion: stroke This position is: indicated by the motion reversal of dial gouge index. & When in this position, ensure that © The notches on camshafts are in line: with ‘those on: the related caps. + Notch Pon engine: pulley is in line: with the reference ‘pin on engine block. +#:4384300000000COMPLETE CAR 1 Notenes on tight cummsnatt & Reterence pen 2 Notches on let camshaft 4 Ignition disebutoe rotor aren 5. Ifthe notches on. camshatts and those on the related caps ate not aligned, carry out the adjustment ‘operation by proceeding as follows, ‘a. Use tool A2.0361 to keep camshaft still, ard unscrew the nut ‘which secures pulley to shaft b, Unserew the “three securing & Secure toot AS.0521 to hub, Screws of hub (they are shiown inthe and withdrew hub itself from Figure’. toothed pulley: recovering the re fated tongue: PA3B4300000000 00-27 Merch 1986COMPLETE CAR Rotate camshaft until its notch is aligned with the reference notch ‘on cap, and. check that, at the same time, notch P on crankshaft pulley is aligned with the reference Bin, Refit the hub complete with « new Osting and screw the three Securing screws without tightening ‘them. f. Screw the nut seeuring toothed pulley to. camshaft; use tool 2.0381 to prevent pulley from rotating, and tighten. the nut to the specified. torque: Also. tighten the ‘three screws securing hub. @: Tightening torque Nut securing from hub to camshaft 87 10.117 Nm (71 10 86 feb; 2.910 11.9kam) €. Check that all notches are cor rectly aligned and, using a dial gauge, check that the piston of first eylinder is at tts TD. the expansion stroke, 7. Install by reversing the order of removal 4B) Check and adjustment of timing system drive belt tensioning This adjustment is to be carried out ‘with engine cold, and after tightening ‘the head securing screw, 1. Detach the ‘terminal negative. battery March 1986 2 Detach connectors (7) and (4), then unscrew sender (3) from thermoster(2) Recover coolant Connector for wherme:tiens satel ‘Thermonat Cootant temperature cena Connector for coolant termoature sender ‘ 2 3 4a 3. Detach the soak pl cas, disconnect the high voitage cable from eo, and esleese the buncle of cables ftom the panic. clamps 4. Unscrew the bolt and screws tech secure timing belt ease, ten remove 5 Disconnect belt _tahtene tern) and ise pin 82.0363 into the Ale of arm fel, in onder to keep the belt tightener. arm lifted. 41. Ben sighener gem 60-28 6. Looten nts (F) and @), press the ben agheener agsinat Te Bele then tighten nuts. ‘The loosening of nuts, should allow ‘the possible belt backlash to be recovered. Neverthaless, it it good practice to press tightener against the bolt, Ch if GF A] pad Nut 4 2 Nu 3 Belt vightener am 2. Lift ‘the: beit tigntener arm enough 3c remove pin A.2.0363, ‘then release belt tightener. 8. Terminate the reassembly by reversing the srder of removal, and complying with the following indica tions. 8. Lubricate the threading of coolant. temperature sender with the specified antisselze product. LOCTITE Anti Seize Tighten’ the following compo. ent to tne specified torque. ©: Tightening torque Coolant tempersture sender on ‘thermostat container {with the specified antieize product) to 2 Nm (15 to 18 feb; 210 26kgm) & Restore coolant correct ievet 4384300000000COMPLETE CAR CHECKING GOOD. CONDITIONS, REPLACING AND ADJUSTING DRIVE BELTS OF ALTERNATOR, AIR CONDITIONER COMPRESSOR, POWER STEERING PUMP 1. Alternator drive belt a. Tensioning adjustment Tensioning is correct when, applying 147 10204 N (33.1 to 66.1 Ib; 15 to 30 kg) joad in the middie of belt, this Sefiects by 16 mm (0.63 in}. To adjust. the tensioning, unscrew screws. 1) and (2) on adjusting arm, ther loosen boit Move the alternator away, $6.5 10 increase. the belt tensioning, and tighten screw (2); re-check the belt tensioning, then tighten bolt 2) and screw (1) b, Belt replacement Remove drive belt of air cohditionér compressor and power steering pump (reter to steps 2_and 3). Loosen sevens Ci) and B) and bolt (3) Move the alternator inward and remove the worn belt, Fit the new belt on the three pulleys and. move alternator until the belt tensioning required is obtained, Tighten screw. (2) completely and check the tensioning: tighten bolt () and serew (1). Fit the drive belt of ir conditioner compressor and power steering pump; then tension them (cefer to.steps2.and 3} Power stearing pump drive belt Tensioning adjustment Tensioning is correct when, applying 167 10. 294N (83.1.0 66.1 Ib; 15 1030 kg) load in the middie of belt, this deflects by 13 mm {0.61 in). To adjust the tensioning, looser: serews (1), @ and (8), on the front adjusting bracket, and the rear bracket securing bolt. Move the Dui avy s,s to increase the Bt Tensioning, than tighten screws (1) and). Fe-check the bet tensioning, Tighten screw ind the reer bracket securing Salt bh Bet replacsinnt Remove the drive belt of air condi: tioner compressor {refer to step 3). Loosen serewa (1), (2), (3) ane the rear bracket securing bolt, move the pump. inward: then remove, belt Fit the new belt on the two pulleys and mcve the pump: until the re: i tending iota Tighten screws (1) and ‘com: pletely, Re-check the tensioning and: tighten screw (B). and the bot securing rear bracket, Fit the belt of air conditioner com presor (refer to step 3} 3. Air conditioner compressor drive belt 8. Belt tensioning Tensioning is correct. when, applying 196 to 343.N (4 x0 77 ln; 20-10 98 kg} toad approx. in the middle of beit, ‘this deflects by 14 mm (0.56 in), To ist the tensioning, unscrew bolt om the-belt tightener pw: ley). To increase the tensioning lower the belt tighténer pulley and tighten bolt (1), Bele repiacernent Release bolt of belt tightner. Move the belt tightener puliey up wards, than remove the’ worn belt. Fit the new belt on the three pulleys, and move the belt tightener pulley downwards, until the belt tensioning required is obtained. Tighten bolt (1) completely and check’ the tensioning 1 Bor 2 Bele ughcene’ pulley CHECK ON CYLINDER COMPRESSION When checking poor engine perfor mance because power is nox up to specs, itis advisable to test cylinder compression using the related tester ‘The check is to be carried out as follows. a. Start the engine. and warm it up to the normal running temperature. b. Remove spark plugs, Merch 1986COMPLETE CAR ©, Detach the coil supply cable (418). d. Detach the connectors on the injectors. 8. Apply the compression tester in the seat of 3 spark plug March 1986 4. Crank the engine briefly; keep ing. the accelerator. pedal fully pressed, $0 that the accelerator throttle is fully open {check tor leaks from pressure. gauge union} Repeat the test to meesure the compression value of the remaining ylinders taking. care, to reset the writing end of tester each time, ther) comparé the values measured 00-30 hi I the difference between: the pressure values measured in the cylinders is considerable, Identify the cause starting from the valve tight ness check and, if necessary, check ing the compression rings, ‘8384300000000COMPLETE CAR ee FUEL SYSTEM CLEANING OF AIR CLEANER AND/OR CLEANER ELEMENT REPLACEMENT 1. Cleaning & Release the tive clips (4) which secure air cleaner cover ()to eon: tainer, and lift cover enough to re move. cleaner glement, without dam- aging sieeve (1) and the surrounding components. b, Clean the’ element thoroughly, ‘blowing low pressure compressed air ‘onelement lower side, © Clean cleaner element container. d. When reassembling, take-care to position cleaner element) correctly (on. the filtering element, there is @ mark indicating the. upper side} e- Fit filter cover and lock it with the chips, 2. Replacement The cleaner element. must be re Placed periodically, according to the Pefiods indicated .in: Vehicle Main: tenance Schedule, 1 Sieve 2. Aittlow sensor 3 Filter cover % clip Paaeaavoovo0a2 CHECK AND. ADJUSTMENT OF IDLE APM. AND EXHAUST EMISSIONS 1. Adjustment of idle rpm; ‘This adjustment is 10 be carried out with engine at normal running tom. erature, gearbox in neutral, and all the ancillary devices excluded. Proceed as Follows & Loosen lock nut. (7) and rorate serew (2) unt the specified p.m value is obtained: {For 2500 engin: 1950 = 50 rpm up te 1200 m {4000 ft) A.S.L. £00 10 900 .pim, cover 1200 m (4000 fa) AS. value indicated is acceptable FFer 2000 engine) 280280 p.m upto 3200 m (4000 fy A'S. 700 10 900. sver 1200 m 400) 8. value Indlerted in acceptable b. Tighton lek nut (8) 1 Lock nut 2 Idle... adjustiaterom 2 Check and adhustment of ex haus emissions (carbon. monoxide Percentage CO‘) ‘This check is performed. by analyzing the exhaust gas taken from the tap fon the exhaust piping up stieam of the catalytic converter using NOIR equipment, This check is to be-carried Out with engine at normal running tempera- ure [after the electric fan has 00-31 switched on and offh and after car ying out the idle r-p.m.adjustment. Also the following preliminary checks are to'be carried out: = Checkon engine oit ievet = Cleaning on-air cleaner element = Ignition system efficiency + Ignition timing & Disconnect connectors. (1) Le Dot te tome a 1 Lamba sensor, resistence connector 2 Lambe sensor connector bi Using! too! “A.5.0212, unscrew the tap screw to take. some of the exhaust gases, fit tool €.2.0081 in its place and connect it to the- analyzer; the CO value must. be within: the specified values: %CO = 0.5 10 0.7 {for 2500 angina) CO = 0.5 t0 0.9 (for 9000 engine) (with Lambda sensor disconnected) 1 Cambde sender 08 1987COMPLETE CAR © If the CO percentage is not ‘ith the spcitled range of valu, adjust the. adustingserew (2) lo tated on tirflow sensor under sealingplug @ Remove ating piu @) as tollows a Remeve the airflow sensor from the vehicle and: secure Ion 4 suitable tool or in @ ice with proleeiee ors ‘CAUTION: hot to damage or deform the airflow tensor body. — ‘Using a drill, make a'hole in the ‘alum iniurn plug CAUTION: Do not drill through completely es ‘this may damage adjusting screw underneath Remove eny bits’ with 2 jet of corn pressed -air and. tap the previously made hole until sufficient thread bite has been obtained, Mater 2966 — Screw a'screw in the hole and pull it outwards to remove plug @) = sta the: antow sensor on vehicle. Start the engine, and run it unt feaching normal running temper ture, then adjust adjusting screw C3 according. to the following. indies tions: — screwing increases the CO per centage — unscrewing decreases: the CO percentage. f. After adjusting, insert the new sealing plug 1G Then check that idle speed is within the specified values; if not, repeat adjustment as described in step 1. Ih. Reconnect the Lambde sensor wiring connectors and refit the plug ‘on the exhaust gas manifold, 1 Auction sentor 2 Sealing plvg 2 Adjumting sere 00-32 Pages 300000000COMPLETE CAR ENGINE IGNITION CHECK AND ADJUSTMENT OF SPARK ADVANCE CAUTION: ‘The checking of idle «p.m. timing, must be carried out with the utmost ‘care; ‘correct timing, in tact, is the most important fector at tar as the emission levels are concerned. Aya sooeu000e 7, Detach the vacuo ihiske hse for vacuum advance, from the ignition distributor 2, Conncet the stroboscopic gun to tHe terminal related to the spark pluy ‘of cylinder a. 1, “on the: ignition distributor; connect both positive and negative terminals of strobo: sopie gun to the related battery terminals, 1 Reference pin 2 Engine pulley 00-33 | 3. Connect an elacuoic rev counter to engine. 4. Fun the engine to normal running temperature and, at idle check that notch F (marked on engine pulley) is aligned with the reterence pin — (2° 41° batore 7.0.6.) (tor 2600 engine) = (7 #1° detore 7.0.C.) (tor 3000 engine} Apa 1987COMPLETE CAR ————— 5. If required, adjust timing as fol- los a. Unscrew rut/@) a the ignition istbutor securing bot b. Rotate distributor body, (7) anti notch Fis aligned with the reference pin Tighten the nut, cheeking tha: cistibutor body has not been moved, 4. Re-check the timing, 6. Reconnect the. vacuum, intake hose for the vacuum advance. 1 lgninén shitrbuior bea y 2 Bott securing dtnbutor CHECK, CLEANING AND/OR REPLACEMENT OF SPARK PLUGS; FIRING ORDER The standard plugs fitted tothe engine are: SILVER LODGE HL-E and as. altemative, CHAMPION RNIIYC. The LODGE HL-E spark plugs are of the surface a0 type. with foar points: ano 2 central electrode; these plugs require nO. routine adjustment of the gap between the electrode and points. The CHAMPION RIN1TYC spark lugs feature a central electrode faced by 2 single. ground elec trode; the gap between thé. wo March 7 986 Ignition distributor advance graphs Vacuum advance disgram 2 10° Distributor sdvance degreet ° 100 200 sectrodes should be adjusted feguiarly 0.7 to 0.8 mm {0.028 t0 0.031 in) = Use of spark plugs having different features or dimensions, can cause serious engine damage and alter emission levels. — Clean or replace the:spark phags periodically, according 10 the routine checks contained in the: Vehicle. Maintenance Schedule — if the insulator is cracked. or electrodes are too worn, replace the spark plugs: ceramic 00-34 Replacement a With ‘engine cole, rot us tne Fubber cap, withdraw the cables anc remove the spark plugs. Lubricate the threading with 1SECO Molykote A grease, ang tighten the spark piugs to the torque: 25 to 34 Nem (18 t0 26 frib; 2.5103. kgm) ©, Check for good mechanical anc lectrical connection between ‘spark plug cables and couplings Hf in doubt, slide the rubber cap along cable, tighten the coupling Page«z00000000COMPLETE CAR ——_—— fully, and refit rubber cap above coupling, Connect. coupling to the spark plug. CAUTION: ‘The spark plug cables are to be reconnected according to. firing order Firing order: 14:25:36 ENGINE COOLING CHECKING AND REFILLING THE SYSTEM 1, System check: 6. Cheek that the coolant tevel in the filler tank is within the MAX and MIN reference marks b, Check for good conditions and leaks in the Sleeves and piping, ©. Check the filler tank plug, fensuting that springs, gesket and valves are in good condition d, Test the electric fan functioning, = Detach the two cables of ther mastat and short circuit them, = Turn the ignition key and check that elecntie fan starts PA 384300000000 @. Check: radistor. referring 10 Group 07 - Radiator. f. Should considerable amounts of coolant be required, identify any possible leaks in the cooling system, in order to eliminate thern, 2 System refill Drain the systern, thier vetill it wink ‘the fotlowing quantity and quality of liquid. Concentrated. | amittesze (Gat Std, No. 2681-69956 Dilution distitied. 1 waver Gaisy ‘Antiteeeze teady | rove (Gate) Std, No. 9681 69958 To increase antifreeze protection at temperatures below —30C (-22°F) without draining the. system com. pletely, replace 7.5: (0.4 gels) of the mixture with the same.amount of concentrated antifreeze, For tem peratures below 45S (~49F replace 3.3 1 (0.87 gals) of the mixture, CAUTION: Products hermful to paint. Avoid contact with painted surfaces, Retilling is to be carried out throughy tank filler, complying with the following indications: a, Sat the heater control knob te ‘the fully open position. bb. Fill the system until reaching the max index of header tank. €. Run the engine to the. normal 00-35 running temperature, so that the residuous air contained in the sytem flows through thermostat ‘opening. With engine cold, top-up up to ‘the level corresponding to. the max Index of header tenk. Retin wank plug, March 1986