1991 to May 1998 (H to R registration) Petrol

iaynes.' Service and Repair Manual ~

, Includes Roadside Repair! and MOT Test Checks ..

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es Publishing 196 ' ~,

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 Contents
LIVING WITH YOUR RENAULT CLlO
- ----t-b
h3
A

I
lntroduct~on
Safety first!
to the Renault Clio Page
Page
0.4
0.6 1
Roadside Re~airs
If your car won't start Page 0-5
I
Jump starting Page 0.7
Wheel chang~ng Page 0.8
Towing Page Or9
ldentifytng leaks Page 0*10

' 'Weeklv. Checks 2 -,

lntroductlon Page 0-11
Underbonnet check polnts Page 0'11
Engine oil level Page. Qt12
'
Coolant level Page 0.18
Brake fluld level & Page 0.13

.rin
Power steering fluid level
Tyre condlt~onand pressure
n Page 0 4 4

Battery
-
Wiper blades
Electrical systems w a g e 0.17
Screen washer fluid level h g e 0.17
P

- Lubricants, fluids and tyre pressures

MAINTENANCE
.I.$
Y
Routine maintenance and servicing i~. (

- ~ 2" models (models up to April 1996) Page 1A.1

'+Phase
~ ~ 1" ~ . "Phase
- and
~

, .-.- .
. ~

- .
Sewicina s~ecifications i - Page 1A.2
Maintenance schedule
.
i ". ~

Page 111.4
Ma~ntenance orocedures 1 .' pa -- ~~~

"Phase 3" models (models from May 1996) Page 18*1

?
Servicing specifications . . Page 18.2
I -
Maintenance,&fieddie !%ge 18.4
~aintenanceprocedures
.~
f' ,' L , - . Page 18.7
~
C
REPAIRS AND OVERHAUL
Engine and Associated Systems , .
1108 cc (C-type) engine in-car repair procedures Page 2A-1
1149 cc (D-type) engine in-car repair procedures Page,.@*l
1171 cc and 1390 cc (E-type) engine in-car repair procedures Page 2C.l
1764 cc, 1783 cc and 1794 cc (F-type) engine in-car repair procedures Page 2D.1
Engineremoval and overhaul procedures Page 2E.1
Cooling, heating and air conditioning systems Page 3.1
Fuel and exhaust systems - carburettor models Page 4A.1
.
Fuel and exhaust systems - single-point fuel injection models
~

Page 48.1
Fuel and exhaust systems - multi-point fuel injection models Page 4C.1
Emission control systems ~ = -
Page. 4D.l
Starting and charging systems ~ : P i e 5Ari
--

Transistor-assistedcontact breaker ignition system (C-type engines) Page 58.1

Electronic ignition system Page frF'1

Transmission
Clutch Page 6.1
Manual gearbox Page J&?i
Automatic transmission Page 7B'l
~riv,&affs Psse -:PA,
- -
~.- ,

Brakes and suspension

-.
.' J.3 , -.
k. .<{
Braking system ..
, .. ~ ~ , , '.bl >. .
Suspension and steering Page 10'1 -. .
-.
'Body equipment . . , . r..ll i.. ~
7k ;
r ;.
Bodywork, trim and fittings Page l j * l
Bodv electrical svstems
, , , ~: -
Paae 1 2 ~ 1
--~~-
Wiring diagrams - .- .... Page 12-22

REFERENCE h .,*

Convers~on factors
-
Dimensions and we~ohts -
Paae REF01
~age-w~-2
.E

General repair procedures Page REF03

Buylng spare parts Page REF04
Vehicle and Engine ~dentlflcat~on Page REF*4
Jack~ngand Veh~cleSupport - REF-6
Paae
Disconnect~ngthe battery Page REF-7
Tools and worklng faclllt~es Page REF08
MOT test checks Page REF-10
Fault iind~ng Page REF44
Glossary of techn~caiterms Page REF.98

Index .,$, .,,> ., Page REF-27

 The Renauir Clio range coverec by lnls manual was first introobced .n
France in May 1990,and to m e UK 'n March 1991, to replace the popular
Rena~lt5 range of cars. Th s manual covers models fitteo w tn petro,
engmes, h i other moam n the range were ava.lable w tn Dlese eng.nes.
The Cllo range was prodJceo w.rh 1.I,1.2. 1.4, 1.7, and 1.8 I'tre
slnole overnead camshaft (SOHC) lypes, and a 1.8 I tre d o ~ o l e
ovs;head camshaft (DOHC) type, which is fitted to the performance-
orientated 16-valve modei. Apart from the 1.Ilitre unit, all of the engines
availabie in the UK used fuel-injection, although carburettor engines
were availabie in other markets. All the engines are of a well-proven
design and, provide3 regular maintenance is canied out, are unlikely to
give trouble.
The Clio was availabie in 3- and Bdoor Hatchback and 3-door Van
body styles, with a wide range of fittings and interior trim depending on
the modei spwdfication.
The range underwent a minor cosmetic facelifl in March 1994, and
these revised models are known as "Phase 2" models. The range
I The Rendult Clio Team
Haynes manuals are produced b y dedicated and
enthusiastic people working in close co-operat~on.The
team responsiblefor the creation of thls book included:
Matthew Minter
Steve Rendle
Sub-dioy Sophie Yar
M~@&P
Editor & &-J! Steve Churchill
Workshop mahager Paul Buckland
Photo Scans Steve Tanswell
John Martin
1 Cover illustration & LineArt Roger Healing
I Wiring diagrams Matthew Marke
We hope t h e b o o k will help y o u t o get t h e maximum
enjoyment from your car. B y carrying out mutine
mdntenance a s described you will ensureyour car's
reliability a ~ preserve
d its resale value.
Fully-mdependenl front wspenslon 1s fitted, witn tne components
anacned to a subframe assemb.y, and the rear.suspension is semi-
ndependent, with trailing arms and tors;on oars.
Four- and five-speed manJal gearwxes, and three and fourspeed
auromatc transmiss~onswere available, ahhodgn Me three-speed ado-
marlc vansmlsslon was not avai.aole in me JK. The four-speed automatic
transmission is eiectronicaily-contmiled.
A wide range of standard and optional equipment is available within
the Ciio range to suit most tastes, including an antl-lock braking
system and driver's airbag.
The Clio is conventional in design, and the DIY mechanic should find
most servicing work straightforward.
Ranault Clio 16V
Your Renault Clio Manual
The alm of this manuai is to help you get the best slue from your
. . It can do so in several wavs. it can h e i vw
vahlcla ~ deoide what work
mJst be done (even should you choose to getjt dine by a garage),
orov.de nnformatlon on routlne maintenance and s e ~ c i n g ,an0 glve a
ioolcal
-" course of action and diaanosis when random faults occur.
~ ~
dowever. .t .s noped tnar you will i s e the manual bytackling the work
yo~rseaf.On s.mpter .obs, It may even be quicker than booking the car
inlo a garage and going there twlUe, to leave and collect it. Perhaps
most .mportant, a lot of money can be saved by avoiding the costs a
garage mJst charge to cover its labour an0 overheads.
Tne manud has orawlngs ana descriptions to show tne function of
the various components, so t h i t th,@ FaF~utcan be understood. Then
the tasks are described and photographed in a clear step-by-step
sequence.
References to the 'left' or 'rigW ate m the sense of a person in the
driver's seat, facing forward.
Acknowledgements
Thanks are due to Champion Spark Plug who suppiled the
tllustratlons showlng spark plug condittons. Certaln other iliustratlons
are the copyright of Renault (UK) L~mlted,and are used with their
permission. Thanks are also due to Draper Tools Limited, who
provided some of the workshop tools, to John and Sally Brooks for the
use of thew car, and to ail those people at Sparkford who helped in the
production of this manuai.
Technical authors who contributed to this pmjeot ~nclude
and Mark Coombs.
Andy Lsgg
We take areat oride In the accuracy of infomation given in this
manual, b u i vehicle manufacturers make alterationsand design
changes during the production run 01a particular vehicle of whlch
they do not inform us. No liablllty can be accepted by the authon
or publishers for loss, damage or injuw caused by any m r s in, o i
omission8 from, the Information given.
 Safety first! 065
Workino- on vour -
. car can be danaerous.
This page shows .dsl some of tne potentia
Ma~nsvoltage is aiso dangerous. Make
sure that any mains-operated equipment is Special hazards
risks and nazards, wttn the aim of creating a correctly earthed. Mains power points should
safety-conscious attitude.
Hydrofluoric acid
be protected by a residual current device
(RCD) circuit breaker. 'This extremely corrosive acid is formed
General hazards Fume or gas intoxication
when certain Woes of svnthetic rubber. found
n some 0-rings, oil seis, fuel hoses wic, are
Scalding
Don't remove the radiator or expansron
tank car, while the enaine is hot.
Exhaust fumes are
~~

poisonous: they often

contain carbon
~

.a ..
exposed to temperatures above 400CC. The
rubber changes into a charred or sticky
substance containing the acid. Once formed,
* ~ n ~ i noil,
' e automatic transmission fluid or monoxide, which is the acid remains dangemus for yeam. /fit
power steering fluid may also be dangerously rapidly fatal if inhaled. gets onto the skin, it may be necessay to
hot if the engine has recently baen running Never run the amputate the limb concerned.
engine in a When dealing with a vehicle which has
Burning confined space suffered a fire, or with components salvaged
Beware of bums from the exhaust system such as a garage from such a vehicle, wear protective gloves
and from any part of the engine. Brake dlscs with the doors shut. and discard them after use.
and drums can aiso be extremely hot Fuel vaoour Is also The battery
immediately afker use. poisonous, as are the vapours from some
cleaning solvents and paint thinners. Batteries contain sulphuric acid, which
Crushing attacks clothing, eyes and skin. Take care
When work~ngunder or near Poisonous or irritant substances when topping-up or canying the battery.
a raised vehicle,
& Avoid skin contact with battely acid and The hydrogen gas given off by the battery
always with anv fuel, fluid or lubricant, esoeciallv is highly explosive. Never cause a spark or
supplement the antifreeze, braKe hydraui c f J I and
~ ~1e6e1 allow a naked light nearby. Be careful when
lack with axle fuel. Don't syphon them by mo~th.If sdch a connecting and disconnectingb.altBty
stands, or use substance is swallowed or gets into the eyes, chargers or jump leads.
drive-on seek medical advice. Air bags
ramps. Prolonged contact with used engine oil can
Air baas can cause iniurv if thev ao a
Never
venture
Undera car which
-- cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oii-
soaked clothes and do not keep oily rags in
accidenjal y. Take care.when re&vlng tne
steer ng whee andlor facia. Special storage
is only supportadby a jack. your pocket. instructions may apply
Take care if loosen~ngor tiqntenfno hah- Air conditioning refrigerant forms a Diesel injection equipment
toque nuts when the vehicleis on sianis. polsonous gas ifexposed to a naked flame
Initial loosening and flnal tightening should be (including a cigarette). it can also cause skin Diesel injection pumps supply fuel at very
done with the wheels on the ground bums on contact. high pressure. Take care when working on
the fuel injectors and fuel pipes.
Fire Asbestos

I Fuel 1s hlghly flammable, fuel vapour 1s

explos~ve.
Asbestos dust can cause cancer if lnhaled
or swallowed. Asbestos mav be found in
/\
fi
Wamlng: Never expose the hands,
face or anv other fflri of the biiv -
I Don't ler fdel spill onto a hot engine.
Do not smoke or allbw naked lights
gaskets and in orake ana cidtch linings.
Wnen dealing with such components it s
Ito lnjectoisprey; ihe fuel can
penetrate the sldn wtth potmW!y fatal

1I
(lnoluding pilot lights) anywhere near a
vehicle beino worked on. Aiso beware of
creating sparks
safest toasume that they contain asbestos. re8uIts.

(electrically or by use of tools).

1 Fuel vawuris heavier than a~r.so don't
work on the fuel system wlth the vehicle over
an inspection pit. DO ~?
Another cause of fire is an electrical 9 buss-
pmt8EtianmUsftlg~ Dbn't-tfoaffsWm
overload or short-clrcult. Take care when toQ$*wdaffienmUWWW ~hl*WbheyMd~&l&-
repairing or modifying the vehicle wiring.
Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock , ( ,
:
@ .
eb : : : : ! $ dangerous,
:
especially to

people with heart J

r r oowqri- c

*bm(I~69.-eto
r
r
rga
ng w I M ha~r
~ va~i
out s b W W @ M A Q m % Wp*,
befrxre
~
D0nZb-a~bak a m lying around
~
vpaalna~spars&onos.
~ ~ MOP
~
I .

problems or a
pacemaker. Don't , -\
-
\
I w~onhw;sho(e-e4peolr&the
64w~Wcasystem.
Don't anow c n m or p&s to play m
~ e s5
r V&ICI~ bdng worked on

..
work on or near the \
lgnltlon system wlth r . . I\
t h i & runnino or ) I J i'
the ignition switched on.
I 0
.
6 Roadside repairs
The following pages are intended to help In deailng with
common roadside emergencies and breakdowns. You will flnd
more detailed fault findlng information at the back of the
I manual, and repalr ~nformationin the maln chapters.
I*

I I
l1 If your car won't start If your car won't start
I and the starter motor even though the starter
I doesn't turn motor turns as normal
If it's a model with automatic transmission, make sure the is there fuei in the tank?
selector is in 'P' or 'N'. Is there moisture on electrical components under the
Open the bonnet and make sure that the battery terminals bonnet? Switch off the ign~tion,then wipe off any obvious
are clean and tight. dampness w~tha dry cloth. Spray a water-repellent aerosol
Switch on the headlights and try to start the engine. If the product (WD-40 or equivalent) on ign~tionand fuei system
hsqdiights go vety dim when you're ttying to start, the electrical connectors like those shown In the photos.
battery is probably fiat. Get out of trouble by jump starting Pay special attent~onto the ignition coil wiring connector
(see hekt page) using a friend's car. and HT leads.

A Cl~eck'me~smdition
baflery.connedtions.
and security of the Bsecurelyiconnecrd~byplugpushingleads
EWMth;?t4Ite-W
'
HT
them
are
onto the ignition coil or DIS module (as
c '
module (as eppliWF+wiriitg plug is
p-ljm,

applicable).

C . . . . ._... .. _. and spray them

wi~i&@rdispersant spray like WD40 if you suspect a problem due to damp t n d been activated (fuelinjection
models).
 <. .
. ., g@$t@e!engine using the 19osstar.,..~

7
---
4----- i----.-iiii--i--i--i&i~-i
ba'ttgand run it at IQe speed,SWm
demi(%&d ,A
iair'ttielights, ~ w k i d o w
heater bl?Wmotor,thew Jiw.~nn(y:t
thed~mpleads-inthe reverseorderof
y-
conmution. Turn off the lights sic.
 0
.
8 Roadside repairs
Wheel changing
A Warning: Do not change a wheel in a situation whem you risk being hit by another vehicle. On busy mads, try to stop in a lay-
by w a gateway. B e wary ofpassing trafic while changing fhe wheal if b easy to become distracted by the job in hand.
Preparation
0 When a puncture occurs, stop as soon as
it IS safe to do so.
Parn on f i n leve, ground, if poss ole,
and well om of the way of otner traffic.
Use hazard warnlng ghts if necessary.
Changing the wheel
..
ket on the laft-hand side of the
compartment. On models with
el covers, the key for the covers is
to the wheel brace.
applicable, remove the wheel trim
foracPBSS to. the wheel bolts then, using
@~Bi;8C.~~~lligMlyloosenthe wheel bolts.
I
1 b&, woMng in pro~ressiv;stages and
in SWKgonal sequence. Refit the wheel
trim, where applicable.
-
If you have one, use a warning tr~angleto Chock the wheel d~agonallyopposite the
alert other drlvers of vour
. .~resence. one beins removed - a couple of large
App y the nandorane and engage firs1 or stones wll oo for this.
reverse gear (or Park on models w.tn iftne ground is son, use a flaI pece of
a~tomat~c transm ssion. wood to Spread the load Jnder the jack.
Remove the spare:U;kee~fromthe cradle
2 the
Remove the jack from its location under
r~ght-hand access hatch in the 3 under the rear of the car. To lower the
cradle, use the end of the wheel brace to
windscreen cowl panel. To remove the
jack, open the bonnet and lifl the access loosen the cradle securing bolt, located in the
hatch. Loosen the securing nut, then release luggage compartment flwr. Support the spare
the clamp and lift the jack from its location. wheel cradle, then pull back the safety catch
under the rear bumper, and lowwthe cradle to
the ground. Uft thesoare whael from the uadle.
~ & t e the jack head inihejacking point 6 $hen! the. wheel is clear of the ground,
5 nearest
- ~ =
-~
'
to the wheel to be changed. Note remove the bolts and lift off thewhwi. Fit
that the l u g on the jack head must the spare wheel, and tighten the bolts
engage wlth the cut-out in the jacking point. moderately by hand, then lower the vehicle to
Engage the end of the wheel brace with the the ground.
jack, and tum the wheel brace to raise the car. f
I
0 then lift the cradle sharply upwards until Have the damaged tyre or wheel repaired
the safety catch engages, and tighten the as soon as possible.
cradle securin,g bolt with the wheel brace.

When all else fails, you may find yourself
having to get a tow home - or of course you,
may be helping somebody else. Long-distance
recovery should only be done by a garage or
breakdown service. For shorter distances, DIY
towing using another car is easy enough, but
observe the following points:
Use a proper tow-rope - they are not
expensive. The vehicle being towed must
display an 'ON TOW' sign in Its rear window.
Always turn the ignition key to the 'on'
position when the vehicle is being towed, so
that the steering lock is released, and that the
direction indicator and brake lights will work.
Only attach the tow-rope to the towing
!eves~rovided.
~rkore being towed, release the handbrake
end select neutral on the transmisslon.
Front o -
tmexe42) models with standard front spoiler
Note that greater-than-usual pedal
pressure will be required to operate the
bakes, since the vacuum sewo unit is only
o$?rational with the engine running.
On models with power steering, greater-
than-usual steering effort will also be required.
The driver of the car being towed must
keep the tow-rope taut at ail times to avoid
snatching.
Make sure that both drivers know the route
before setting off.
Only drive at moderate speeds and keep
the distance towed to a minimum. Drive
smoothly and allow plenty of time for slowing
down at junctions.
Note that it is strongly recommended that
cars with automatic transmission are trans-
ported on a trailer, or towed with the front
_ Ront towing eye (2) -model
% Rear towlng eye (I)
Roadside repairs 04
Towing
wheels off the ground. If it Is necessary to tow
a car with automatic transmisslon with the
front wheels on the ground, the following
recommendations must be observed.
Towlng may be carrled out w ~ t hall four
wheels on the ground, or wlth the rear
wheels ralsed a max~mumof 15 cm off the
ground, proviaea that the speeo does not
exceeo 25 mpn (40 ~mlh),and tne distance
does not exceed 15 miles (25 km), when
towlng.
Warning: To prevent damage t o
A the catalytic converter, a vehicle
must not be push-started, or
started b y t o y i q when the engine Is a t
operating temperature. Use lump lea@
(see "Jump starting"). i
wlm deep from
., . ..-,+
. .,P.@$lei>snthe gaiage fioor ordrlve, or
.q@vjqp "R'ness under the bannet or
ind@Tle@ the oar, suggest;a@k that needs
g. lt.can sometimes be difflcult to
re the lwk is wming from. :
f the engine bay is veiy dirty
king oilor flyid oan also be blown
, & , t h e h e of air under the car.
giving, 'e false. Impression of where the
pWlern lies.
k*,;,,.x5.7 -. ,, :,,
>'. . 1: , 1.
 0.12 Weeklv checks
Underbonnet check points
Note: Refer to "Engine identification"on page REF.4 for dstails of engine Identification.

F7P
(16-valve) engine
A Engine oil level dipstick 1
B Enghe oil filler cap
C Cooient expansion iank
$ Brake flud reservoir
E Washer fluid reservoir I
Power steering fluid reservoir

I'.r -.

I -.~
dbi~mect
. . oil
6&+.qlngs @acegreat demands on their
oil. It i$9e&pomnt that the correct oil for
vour car.tsa%ed (5ee 'iubiicants and Fluids"

Car Care
m:lr.yau have to add oil frequently, y@&shmuld
W k Whether you have any oil leal(s,,RlaaB
$ome clean paper under the car ovepi@Q$
end check for stains In the morning. there
hre no leaks, the engine may be burning oil
f6w "Fault Flnding"J.

*Always maintam the level between the

3 dipstick, wFiqh$.hodcl..be
-5;,,-.,&=I.= ".a;--~ ~~~-
between the 4 unscrew the filler cap, then top-up the
IP.

upper and lower dipstlck marks (see photo 3). upper ('MAX'? mark and the lower ikve(. A funnel may help to reduce
If the level 1s too low severe engine damage ("MIN") mark. spillage. Add the oil slowly, checking the level
may occur. Oil seal fa~luremay result if the on the dipstick often. Don't overfill.
englne Is ovemlled by adding too much oil.
 Weekly ~ h , l e @0.1~3 k
Coolant level I-

Warning: DO NOT attempt to

remove the expansion tank
pressure cap-when the engine
is hot, as there is a very great
&k of scalding. Do not lesve
open containers of coolqot
about, as it is poisonous.

Car Care
With a sealed-type coollng system, addlng
coolant should not be necessary on a regular
basis. If freauent t o.~. ~ i-n a .- U1sDreauired. ~t1s
likely tnere is a iean. Check tne radiator, ali
hoses ana joint faces for signs of staning or
wetness, and rectifyas necessary
It is impottant that antifreeze is used in the
cooling system all year round, not lust during
the winter months. Don't top-up with water
alone, as the antifreeze will become too
diluted.
4 Tne ~oolaritlevel vart
I
.. - . the
erature of tne.englne. The ievel snould be L engine is cold.. ~lo&ly'unscrew and
checked in the expansion tank, wnich s remov~.~b~s tank
i ocap
n to release
located at the left-hand rear corner of the any pr&sukin'the,system. Add a mixture of
englne compaltment. The ekpanslon tank has water and antif-ze to the expansion tailk,
"MAXI" and "MINI" level marktngs. When the '.MAX mark. R a t
englne isaold, the ievel should be between
the two marks. Whbn the engine is hot, the
ievel may rise slightly aboveZhe'MAXI" mark.

Brake fluid level

Weming:

A Brake fluid can harm your

eyes and damage pahied
surfaces, so use extreme
caution when handling end
pouting it
Do not use fluid that has
been standing open for some
time, as it absorbs moisture
fr& the air, which can cause a
dangerous loss of braking
1 The -MH~ ana -F1IiN" marks are
Indicated on the side of the reservolr.
which is ocated at the r~ght-handrear
corner of the engine compartment. Tne f i. d
ievel must be kept between these two marks
(make sure that the car Is parked on level
ground when ntkking2he~eck).

Before YOU &a@

cieanilness is of great iniportance wheh
dealing wlth the braking system, M, take care
to cban around the reaetvoir aap before
topping-up. Use only clean brakbfluid

Safety First!
If the reservolr requlres repeated topplng-
up thls is an indlcatlon of a fluid leak
somewhere in the system, which should be
lnvestlgated immediately.
If a leak is suspected, the car should not be
driven until the braking system has been
checked. Never take any risks where brakes
are concerned.
3 ~arefbliyatltlku'fd,'@oldWg aQllilng7f 3n
surrounding paintwork. Use only the
sowifled hvdraulic fluid: mixina dkfferent
types of fluld -can cause damaie to the
system andlor a loss of braklng effectiveness
Bear In mind that the level In the reservoir w~ll
rlse slightly when the oaplfloat assembly is
refitted. After filling to the correct levei, reflt
the cap securely W~peoff any split flu~d.
4 .When checking WRUld leva ~tis a good
Ideato check tt16 operation of the low fluid
levei wamlng light. Switch on the lgnmon
and ask an assistant to press the test blmon on
top of the brake fluid reservoir cap. When the
button is pressed, the brake fluid levell
handbrake "on' wamina liaht should come on -
if not, the level sw1tch;wiing or bulb may be
faulty. If the warning l~ghtcomes on and the
fluid levei is not low, check that the handbrake
is not on. Swltch off the lgnitlonafter testing.
 0.14 Weekly checks
Power steering fluid level
start:
Bkf~re~~yl?kb
4 p@@e*&@ble on level ground.
I
1 S&.tlwS&iing Whed .&tai&t-@:ead.
i fl Ws;&&i@$?dbciuld b@tum& off;

I Wfety First!
*+he need for frequent topping-up indicates
a leak, which should be investigated
irfrmedi*iy.
The shape and looation of the power

to model.
reservoir vanes from model

a) On E-Wne enalne models not ebuiooed

' witn ai~'condrtionlng, the reservorr ;s an
integralpart of the pump assembly, and is
mounted on the fmnt rrght-hand comer of
2 awithn E-Qpe engine models not equipped
air conditioning, w i ~ ethe wea
around the reservo; fliler cap, then
unscrew the cap and wlthdraw it from thefluld
reservolr. Wipe the d i i c k ciean, then insert
~tinto the
~~~- rffiewoir
.~.- ~ and hvlthdraw it and check
the fluid level. ~ h @ i i i d g h @ lba
d between the
the cvlinder head. marks ("A" and :*B) &kp:Oipstick. If not,
~1 On NPengine models equrpped w~thair top-up to the highe~;~iilsingthe,sp~cifled
conditioning, the reservoir rs an nntegral type of fluid, tfien::f$~~@e+t&rpir oap,
. , . F
oart of Zhe electric D U ~ D
assembly, and is tightening it s$cufwl~' :
Ytuated by the srde of the nafteG
C) On all other moaels, the reservorr rs errher
circuiar in shape and situatedat the hont
-
of the enoine comnartment. or is
rectangular in shape and is mounted on
tne right-hanbside 01 the engrne
compartment, just in front of the
suspension tumt.

3
..
..,, >,
& 4 c ~ ~ ~ t i @ , @ ~ # i ~ 6 f ~ i circular
fh-the 4 On models equipped with the rectangular
fluid reservoir, wlpe the area around the 5 On all modeis, ta&e great wre not tv
allow any dirt or foreign matter to enter
reww@ivwhi& iwmauntad'in the light- cap ciean, then unscrew the cap. The the hydraulic system, and.do not overfill
hsnd corner of €I%e ~ ~ m c o i n ~ a r t m ethen t , fluid level lndlcator is in the form of a block the reservoir. When the level is correct, refit
fluid level is v~sibleth;ou8h the transl~cent fixed to the centre of the filler neck filter. The the cap. Note that the need for frequent
material of the reservolr. The level should be f l ~ i dlevel s n o ~ d be oeween tne Lpper ("A") toppihg~upof thasystem indicates a leak,
I between the "MAX" and "MiN" level lines cast and lower ("6'7edges of tne block. If not, lop-
..
which should be i n t e s t e d immediately.
,%
on the slde of the reservolr. If necessary, wipe UD to the uDDer edue of the indicator block ,
the ama around the reservolr cap ciean, then using tne sd&ifea Gpe of l l a,~then refit the
..
remove the cap and top-up to the "MAX" reservo r cap, tignten ng il secLrety.
mark using the specified type of fluid.

Tyre condition and pressure
It is very important that tyres are in good
conaltoon, and at the correct pressure - having
a tyre failure at any speed is nigh.y dangerous.
Tyre wear is influenced by drivlng style- harsh
braklng and acceleration, or fast cornering,
will all produce more rapid tyre wear. As a
qeneral rule, the front tvres wear out faster
chan the rears. lnterchahglng the tyres from
front to rear ('rotat~ng the tyres) may resun In
more even wear. However, if this Is
completely effective, you may have the
expense of replacing all four tyres at once1
Remove anv nails or stones embedded in the
tread before they penetrate the tyre to cause
deflation. if removal of a nail does reveal that
mark on thetyre sidewall (A).
Twe .tread wear patterns
Underinfietion (weer on:bah ddwJ
Under-~nfhtlon will cause ovefheatlng of the
Me, because the lvre wlll flextoo much. and
the tread will not sii correctiy enme mab
-
I
1
surface. Thls will cause a loss ofgrip and
excessive wear, not to mention the danger of
sudden lyre failure due to heat build-up:
oh& and adiustpressurea
lnwnnot wheel camber (wear on one side)
Repair or renew suspension parts
Hard cornering
Reduce speed!
the tyre has been p~ncturea,refit the nail so
that '1s point of penetration is marked. Tnen
mmediatelv cnanae the whee , and have the
tyre repaired by aim dealer.
Regularly check the tyres for damage in the
form of cuts or bulges, especially in the
sidewalls. Perlodicallv remove the wheels.
and clean any dirt or Aud from the inside and
obtslde sbrlaces. Examlne tne wheel nms for
signs of rusting, corrosion or other damage.
Light alloy wheels ere easily damaged by
"kerbing' whllst parking; steel wheels may
also become dented or buckled. A new wheel
is very ohen the only way to overcome severe
damage.
&$,&& ; F': .~ = -
, :-
, r,- nf)mdh *u*: . !
&'rcld .&@f&
ithe if
centre part of tne lyre wad. cliupled wnh
wheel miSalianment. Most tvradealers and
reduced gnp, harsher r ia arid the-&gw of
shock damageaccurrin$ In 6be tyre w i n g .
Check and adlust p m w m s
, -
If you sometimes have to PhWBts your bar's
tyres to the higher pressures specified for
m i m u m load or sustained high speed, don't
forget to reduce the pressures to normal
affewem's.
Weekly checks 0.15
New lyres should be balanced when they are
fitted, but it may become necessary to re-
balance them as thev wear. or if the balance
we8ghtsf Wed to the whee r m should fall otf.
Unbalanced ryres will wear more q ~ ~ c k las y,
will the steering and suspension components.
Wheel Imbalance Is normallv -
, sionified bv
vibration, particularly at a certain spee;
(typically around 50 mph). If tnls v~brattonis
felt onlx through the steering, then it is likely
that justthe front wheels need balannng. l f , t
however, the vibration is felt through the
whole car, therear wheels could be out of
balance. Wheel balancing should be canled
out by a tym dealer or garage.
Tyre pressuresare Aown on pag&o*l8.
Frdnt t y k may wear uneuenly as a result of
garages can checb and aijllrst the wheel
alignment (or 'lra.cklng )tor a modest c h q e
lncennct camber or Gastor
RepaC or renew swpension par&
Malfunctioning auspenslon
W r or renew suspenuon parts
. .
.-
Unbalancedwheel
Balanm trres
Incorrect toe setting
Adiust front wheel alignment
Note: me feathered edge of the treed which
typifies toe.wear is best checkedby feel.
 Battery
I%LItlOII:Before canying out any worX on the
VehiCie battery, read the precautions given In
"Qfsty first' at the start 01this manual.
H W s s u r e that the battery tray 1s in good
,& W B n , and that the clamp is tight.
@3h'&WI~n9n the tray, retaining clamp and the
m w f can be removed with a solution
W e r * n d baking soda Thoroughly rinse all
@& areas
%i@ wlth water. Any metal parts
ed by corrosion shouid be covered
k@.azinc-based primer, then palnted.
I"Perlod1oal1y (approximately every three -, ""
1 side ?f thi, engine comp^artmmt. The ';
Clamps' %3 ensure good ieledricai
R1981hsJ.check the charge condlr.on of the exterior of $he battew should be
LWddeswlbed in chapter 5 ~ . c ~ n W i v n s .m
. u shouid not~Wable
. 20.
inspected periodically for damage such as a move them. &so ohecK each cable for cracks
hitS?ryisflqzand you need tojump
cracked case or cover. and frayed conduetors

wire brush: then *it them. Automotive stores

.
sell a tool for cleaning the battery post. .

1 :the wN8ltic lewlper 0,ades;

are CracKed ow any signs of
deterioration, or if the glass swept area s
smeared, renew them For rnaxlmum clarity of
vision, wiper blades should be renewed
annually, as a ma* of course.
2 TO removea windscreen wper b.ade, p ~ l l
the arm fully away from the screen until t
-.--
locks. Swivel the blaoe Inmuah 90°. than
depress the looking clip at the base of the
rnountlng block, and slide the blade out of the
hooked end of the arm. Where applioabie,
don't forget to check the tallgate wiper biade
as well. The blade can be removed by
swlvelllng the blade through 90°, then pulling
the biade from the arm.
Electrical systems

kinoie than.p&.i@icatar s&bt.:w beadlght

1 ifheadlight has failed, it is likely that a bulb 2 haiisiiiiecl, it.6 likd$ t h a ' e i t h k i hse has
a single.indlgatoi light, brake light or

has blown and will need to be replaced.
Refer to Chapter 12 for details. If both brake
lights have failed, it is possible that the brake
light switch operated by the brake pedal has
failed. Refer to Chapter 9 for details.
blown or that there Is a faun in the circuit
(see "Rectrcd it%/! findingg"hil~hapter 1)The
.
main fuses are in the fusebox under the
passenger's side of thafecia. For accessto the
fuses. Dress the two ~iasticsecurins tabs, then
owe; ine fusebox panel from thaiacia. Tne
c rc J ts protected by t b fqware marked on a
sticcer at me bottom of the fusebox panel.

3 a.@ha& fiig& under the. bpntmt,

beneath thg hinged flap - ih the pro@i@wd, Fit a new fuse af the same
windscreen caw1 panel on the. left-hand side. rating?evaiUbb from car acces$oly shops. It
For access to tGqe.fuses, ifi the cowl panel is i m p o r t p that you find the reason that the
flap,lhen unclip the cover frob tpbusebox. fuse blew (see "EleotWeal feuR fwd@? In
The circuits protected by the fuses are Chapter 12): ,
marked on the.inside of th6-pami cover. The
~ ~ is mounted
fuse for t@ r a d l . 0 1 player
on the rear of the un%

Screen washer
fliuid l'evel
Screenwash addrtives not only keep the
winscreen clean during foul weather, they also
prevent the washer system freeztng in cold
weather - which is when you are likely to need It
most. Don't top up using plaln water as the
screenwash wlll become too diluted, and wlll
freeze dunng cold weatner. On no aciount use
molant anMreere h the washer system -
thk coukl discdour or damagepaintwork. ~he.k~ndscreen/taiigat~ea'dlight washer g-up t1 n-
fluid reservoir 1s located under the left- re sho he
hand access hatch in the windscreen qLanrltles recommendedon the bottle.
cowl panel at the rear of the englne comparl-
ment. If topplng-up 1s necessary, open the
hatch, then remove.tM@ from the resefvolr.
 0.18 Lubricants, fluids and tyre pressures
Lubricants and fluids
Engine ... .,:. ;.; .............. ... < .........
; .. I.;. Multigrade engine oil, viscosity 15Wf40 to 15W150i.U . ,

-. . . ACEAA2/A3
.. ...<- . puckhams QXR Premium Petrol Engine Oil, or
54. ..
&lral gearbox .............. ............. .-:,~5
'
: .
Duckhems HypergradePetrol Engine Oi/)
Tranself TRX J5W 80W
&itom+. transm.miw . .
.
. .Net
. .%?i
. @drive
l ::., .
%2.i.. ... ...........
. . ,...*....:. ...
~ -
Elf Renaultmatic 02, Dexron type ATF
, ~ ' .-= -.
.-
.~
.
.
; (WKhmsATFAutotrans 111)
I

nnsI drive .... :........................:........... Tranself TRX 80W

d o w a r steering reservoir ............................. Elf Renaultmatic D2 or Mobil ATF 220
(Duckhams ATF Autotrans MI) A -*
z -
&ooling sy&em .......... .................. Ekhylene-glycol based antifreeze (AL Glaecol type C d k a g
br
@rake fluid m o i r ...... ....
(Duckhams Antifreeze and SummerCoolant)
Hydraulic fluid to SAE J1703, DOT 3 or DOT 4 .,
fl (Duckhams UniversalBrake and Clutch Fluid)

3' Choosing your engine oil

i a.1 8

Cleaning ffte englne internally

-
ICKHAMS ENGINE OILS
Good quality englne oils clean the inside of the driver who demands a premiul
your engine, collecting and dispersing ~iityoil for complete reassurance, w
Combustion deposits and controlling them >mmend synthetic formula Duckham
until they are trapped by the oil filter or flushed R Premium Engine Oils.
e confugiin and made it easierforyou out at oil change.
the driver who requires a straigh
se thed~htoil for your engine.
OIL CARE FOLLOW THE CODE - vard quality engine oil, we recomman
:khams Hypergrade Engine Oik.
To handle and dispose of used engine oil
saferel*pp further information and advice, caii fh
, - Avoid skln wnlect :kharns UK Helpline on 0800 212988.
with used ennine oil.

w p o n s i i i manner in an
a Cooling hot-spots authon'ped disposal site.

'P pamtures inslde the engine can exceed

WOD C. The engine oil circulates and acts as
'a coolant, transferring heat from the hot-spots
b w
Call a800 S63366 to find
the one
Never oil downtodrshs
UDnearest You.
to the sump. or onto the gmund.
7
-- 7

.
C
cl45/M R 135 tyres .................................. 2.4 bars (35 Ibfhnz) 2.4 b& (35 Ibfbnz)
155Ii"i' R 13s and 165165 R 13Ttyres .... w . . ............ 2.1 bars (30 lbf/in2) 2.3 bars (33 Ibfhnq
145180 R 135 and 155180 R 13T tyres .......... ..,, ., 2.1 bars (30 lbflinq 2.1 bars (30 Ibflinz)
165/60 R 14H tyres .............................t ... : 2.3 bars (33 lbflinq 2.3 bars (33 lbflinz)
185160 R 14V and 185155 R 15V tyres .................... 2.2 bars (32 Ibflinz) 2.2 bars (32 Ibflinz)

or models equipped with automatic transmission, add 0.1 bar (7.5Ibflinz)

 Chapter 1 Part A:
Routine maintenance and servicing .
"Phase 1" and "Phase 2" models (up to April 1996)
1 Contents
Air cleaner air temperature control system check (carburettorand
single-point fuel injection engines) . . . . . . . . . . . . . . . . . . . . . . . .25
Air filter element renewal .................................. 21
Automatic transmissionfluid and filter renewal .................27
Automatic transmission fluid level check ..................... 4
Handbrake adiustment check ..............................29
.
Heaa ght Deam a gnment check ........................... 16 4
Hearing and air conditioning system check ................... 20
Hinge and lock lubricat~on.................................33
. ~ rotor arm check ..................23
HT lead distributor c a and

i
I
Auxiliary drivebelt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bodywork and underbody condition check .................... 15
Brake fluid renewal ...................................... 30
oncheck ................................... 11
points check (Gtype engine) . . . . . . . . . . . . . . . . . 9
...................................... 36
eck ...................................18
-a1 ................................ 3
eck .................................... 12
......................................... 5
anddisccheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
t check ............................... 31
. 26
..................................... 1
tale speed ana mlnure cneck .............................. 7
lgnirion t.m.ng cnec6 (C-type engine) ........................10
Intensive maintenance .................................... 2
.............................
Manual gearbox oil kvel check 34
Rear b r h e pad and disc check .............................'14
Rear brake shoe and drum check............. ..... .......
;; 1 28
Road test .............................................. 24
Seatbellcheck ......................................... 32
mparlcm check .........................................8 !
Spah plug renewal ......................................... 22
Steering and suspension wmponent check ................... 17
Timing belt renewal ......................................35
Wheel bolt tightness check .................................19

1 Degrees of difficulty
.

1 Easy. suitabbfor
mb?*hliie
-m
&
.-
Fai~lyww.
al@rbeginnmvih
Q
suitable
suRablefor mmpetent
%,
R
%-
WScult, suitablefor
expen- ON
&I
%, VerycMadt,
sultahlef o r m DN
I
 I
1n.2 Servicing specifications - "Phase 1" and "Phase 2"
Note: ~ e f etd
r "Engine identirication"on page REP4 for details of engine identification.
~ubricantsandfluids
Refer to "Weekly checks"
Capacitiesi
Engine oil
Excluding oil filter:
'Gtype engilie ...............................................3.0 iitres
........................... 3.5 litres
F3Pengind ....... ......
F7P (16-val+) engine:
:. 1
1171 ccan 1390 cc E typeenglnes
............................... 4.7 litres 1
Engines vyith steel sump................................. 3.5 litres
............ .-............. 4.2 iitres

I
;

................................ 0.5 litre

0.2 iitre

:
C-type e n g y . .... .........................................1.0 litre
E-type engi es ........................ ,....*...,.......... 1.5 litres
F3P engine4 ........................... ..; ........
~. ......... 2.0 litres
marked dipstick. ....................... 1.1 litres
........................................ 0.6 litre
...................
,.. :.,..............
: ...........
..........
5.4litres
5.2 iitres
............... ....... :. ............
?. 6.4 litres
1.. ....................................... 7.0 litres

Cooling system
Anfifreeze mixture:.
Protection to 4&%,.,. .......................................... 35%
Protection to -46Q......................................... 50%
 Servicing specifications - "Phase I"
and "Phase-
Fuel system
Air cleaner element type:
C-type engine ............... ................ ...........
... >. Champion W145
E-type engines ..............................................Champion W190
F3P engines ................................................ Champion V429
t"

F7P (16-valve) engine ... .; .... ............................. Champion W251

?
Fuel filter element type:
Carburettor engines ........................................ Champlon L101
....................... Champion L206
Fuel injection engines ................... : -
-;.If)- ,,!
Idle sped: 3:. ,- . .
J - :2'2
......................
Carburettor .............................. : 700 * 50 rpm
... .....................................
Fuel injection models .. : .+:, , L :' * .- Not
.
8 '

ldle mixture (CO content): ' ' ' ; ,&;$h&

Carburettor models ........;.................... .-.:...... 1.5 * 0.5 %
;,: ;.L
... -
t
+,-
, ..-.;!..~.~jr. : j.

Fuel injection models:

;.... "....... 0.5 % maximum (not a 4
Models with catalytic converter ............ A,.
,. ....
F7P (16-valve) engine models without catdytlc WilVelier ; 1.5+ 0.5 %

Ignition system - general

.; .........-;.
'Firing order .................................. , ..,. 1 . :i 1-3-4-2
Location of No 1 cylinder .............. .........I.....n
; . .r. ~ '.:; .....
Transistor-assisted contact breaker ignition sYt3WIl-
.....................: .... .:.
Contact breaker points gap
Dwell angle (percentage) .:I.
:
..........:. .......... .
, .............*&
.-..,?
...:.: :.
~. : i . ;o.

..
.:,,...:.. . ..,......., <.-
lgnitiontiming': , , I ,
etatic .-........................ ; et
....,.... .... . .. ;;..
: 8

At idle (vacuum hose disconnected) .:. : ..':; ' .... '

Qt%we value stamped on clip fastened!k&W&ffW%% '#Mmd

Spark plugs: 4 :~,
, . ..
Type ................................. .; .........
....:, . r . . Champion N12YCE
Electrode gap ........................................... .....
.,, s W
0.80 ~ 8 : @mm .
,,,
Electronic ignition system'
... - .
...... .; ....... .... .
................ 8 ,
Ignltion timing ::.
spark piugs:
Type:
:1 . . ;

:
L.
.
.,. : , .
21; :
. ,,

.......,!.,......,..,.> ., .:.,.;.. ......................

4 . .

E-type engines
F3Pengines ............., ........... .;.......... .$..:. ... ;
.................................... .&.., .
............+...;...;.......<E~.;-. . .,. ; r.. .. .
1764 cc (RP! engine
Electmaegap
@rakingsystem ...... .. S T....
Friotion lining minimum thickness: . : , , - 8 -. I v; . :.
..,-.
,bnt.brake pad (lncludlng bacMng pl&tshr%h,.,, :+.,.s..;-;(+d.&>.
&I$@@ake pad (illaluding backing @
+i p .&a &$

. ,%&&shoe (includingshoe) ;. . m + > s l i . : is 2.5 mm

-.-. - . . . . .
wiper b&cke&
- ,
.
. . . .
.. . models
"Phase Is$ ~lw
-
~ ~

hndscreen .................................................. . .
Tailgate ..................................
..
,:., . . - ...............,.
, , . ~. ............
,

TOrque wrench ' ~1 ;': 1'.

EnginesumpdrainpiUg . ..,?.......;.,,. ......... ........

E..:.:. i..
Spark plugs:
Taper seat plugs ..............................................
Plugs with sealing washer ........ ...................%.....
;
Automatic transmission gauze filter .., ..... ,......, ............ I

Automatic transmission sump pan ..................................

Roadwheel bolts . . . . . . . . . . . . . . ...............................
 1A.4 Maintenance schedule - "Phase I"
and "Phase 2"
The maintenance intervals in this manual perform some of these procedures more more frequent maintenance intervals are
are provided with the assumption that you, oflen. We encourage frequent maintenance, recommended.
not the dealer, will be carrying out the work. because it enhances the efficiencv. When the vehicle is new. it should be
These are the rn nimum rnantinance tntervais performance ana resale va ue of yo,r veh c d servlcea oy a factory-authorlsed dea er
recommended by us for veh ces arlven dally if the venlcle 8s dr ven in d ~ s t yareas. ~ s e d sew ce aepartment, in order to preserve tne ,
If you wish to keep your vehicle in peak to tow a trailer, or driven frequently at slow factory warranty.
condition at all times, you may wish to speeds Odling in traffic) or on short Journeys,

itim and mcuflly c# the exhaust

., ~

1-4mg)e-sand iwks (~ra~tian

33)
i nual gerabox oil IevA &Q"if+hn Q

I
I
the stewing and sospensiMt mmnQ
d'kion and security (Sect'ion i7)
the concfifiion of the d r i w M gaitgrs

. .,.= . . i . .*!
;-sf
.,,--,-
!!'
,.,. ,,, ,
... .. - ~ , ..
I.>..I .,
 -. .
. 1
2
VINplate
Suspension stmt up*
mounting

i
3 Jacklocation
4 MAP sensor
5 Brake fluid resewoir
6 Engine oil flller cap
7 Throttlebody unit
8 Bonnet lock assembly
C 0 Coolant axpansion tank
10 Washer ~ ~ ~ ~ ~ . F B S B N O P ~
Ioc~tJan
11 f@nfrionmodwle

f6 Enginaojl~eueldipsti&
19 Oil S/@
ma ~ ~ ~ e g s o r ~
4 .rRaQ'iafoF:@phose
22 .AcceIwator:&e.
iB @WemaIo$:

.. I ( :'.
--.. --II .
:Fi'ont underbody view
1 'WhWI'archsplash shield
2 Sump drah plug
9 Brake.diper
47 , Lower suspension arm
5 Tiacli-iod bailjoint
@ flntimllhar
d 6mMsubfmme
8 Gearchangeselector rod
8 CaZa(yfc converter
&&pi,
1.I.. Wst d ~ w n p i w
#$.~ w ~ ~ ~m~ w i o n
wq@e2:. .: ..,
$8.Gk?~k&t~me~.wnstant
veloci~@ #... ~ .~.
8 Eh@inereahowntin# link,
i
rg ~&arbo*~@u€!r . "

t@jY@Qn&&M~x.tie-har
?A-6 Maintenance - component lacation
Underbonnet view of FJP (16-valve) etfjtne model

This Cnapter is des~gnedto he.p the nome
mechan c ma ntan nlsiher venic e for safety.
economy, long life and peak performance.
The Chaoter contains a master
Maintenance procedures 1A.7
The first step in this maintenance
programme is to prepare yourself before the
actual work begins. Read through all the
Sections relevant to the work to be carried
out, then make a list and gather all the parts
and tools required. If a problem is
encountered, seek advice from a parts
specialist, or a dealer service department.
~~-
compression test indicates serious internal
engine wear, conventional maintenance as
described in this Chapter wiil not greatly
improve the performance of the engine, and
may prove a waste of time and money, unless
extensive overhaul work is carried out first.
4 The following series of operations are those
most often required to improve the perfor-
mance of a generally poor-running engine:

malntenance icheduie, followed by Sectlons . Primary operations

deallng spec~flcailywlth each task in the
schedule. Visual- checks, adjustments,
component renewal and other helpful items
are included. Refer to the accompanying
illustrations of the enaine ComDartment and
the underside of the vehicle for'the locations
of the various components.
Servicing your vehicle in accordance with
the m;leag&&ne malntenance sched~leand
the follow~ngSect.ons w I proviae a P anneo
, a) Clean, inspect and test the battery (refer
to "Weekly checks").
. . . *
b) Check all the engine-related fluids (refer
1 If, from the time the vehicle is new. the to 'Weeklv checks?.
routlne malntenance scneo-le 4s follonrea cl Checx the condrbon and fenvon of me
c80seay, an0 frequent cnecks are rnaoe of it-10 auxrlrary dnvebell (Secrron 6)
levels and high-wear items, as suggested d) Renew the sDa&DIu.os (Section 81.
throuahout this manual. the enoinLwili be e)
~.Check the~~-~~cbnditjonbf- ihe alrfiher and
n
kept relatively good n n n ng coidit on, and
tne nee0 for aodt onal work w~lloe rn.n mlsm.
~ ~ ~ - ~ ~~ ~

renew rf rlecessaly (Sec1,on 21).

maintenance programme, which should result
in a long and reliable service life. This is a
comprehensive plan, so maintaining some
but not others at the specified service
intervals, will not produce the same results.
As you service your vehicle, you will
discover that many of the procedures can -
and should - be grouped together, because of
the palticular procedure being performed, or
because of the proximity of two otherwise-
unrelated components to one another. For
example, if the vehicle is raised for any
reason, the exhaust can be inspected at the
Same time as the suspension and steering
components.
2 It is possible that there will be times when
the engine is running poorly due to the lack of
regular maintenance. This is even more likely
if a used vehicle, which has not received
regular and frequent maintenance checks, is
purchased. In such cases, additional work
may need to be carried out, outside of the
regular maintenance intervals.
3 If engine wear is suspected, a compression
test (refer to Chapter 2A, 26, 2C and 20 as
applicable) wiil provide valuable information
regarding the overall performance of the main
internal components. Such a test can be used
as a basis to decide on the extent of the work
to be carried out. if, for example, a
f ) Renew the fuel frlfer fSection 26,.
b) Check the condition &a// hose;, and
check for fluid leaks (Section 5).
5 If the above oDerations do not Drove fuilv
effective, carry out the following secondaj
operations:
Secondary operations
Ail items listed under "Primary operations",
plus the following:
a) Check the charging system (refer to
Chapter 5Al.
b, neck the 8gnlllon sfstern (refer to
Chaprer 58 or 5C)
c, Cneck the fuel srsrem (refer to rhe
relevant Part of chaptek4).

Every 6000 miles (10 000 km) or 6 months --

a

I
aovisable to wear ruooer gloves ~ h e n '1. tnen slacnen t tlalf a t l r n .sng a specla
carryng o ~ tr n s work. Access to tne oran p l ~ g 6ey (8 mm sqLare, (see
1 Jnderslde of tne ven c e wi I oe greatly illustrations). 01poss8D.e. 1ry to keep lne p l ~ g
'
improve0 11 t Can oe raised on a 0 fl, arlren pressed ,nto the sdmp wh e bnscrewlng t by
I onto ramps or lacneo LD an0 sc.~~orteaon nano the last c o ~ o l eof 1-ms. As the otdo "
axle stands (see "./ahking and vehicle re eases from tne tnreads. move s away snarply
suppofl. Whichever method is chosen, make so the stream of oi s s ng ~ from the sJmp nns
sure that the car remains as level as possible, into the container, not up your sleeve!
to enable the oil to drain fuilv.
2 Remove the o I ii er cap f&m the va.ve cover,
then poslt!on a s4itaoe contamer oenealn tne
sump. Clean the drain plug and the area around

1 Before starting this procedure, gather

together all the necessary tools and materials
(See illustration). Also make sure that you
have Dlentv of clean rags and newsuaoers
m n b t o m b p up any sp -s Ideal y, mieng ne
01 Should be warm, as it w I oram bener and
mofe built-up sludge will be removed with it.
Take care, however, not to touch the exhaust
or any other hot parts of the engine when
working under the vehicle. To avoid any
possibility d scalding, and to protect yourself
-
~

from possible skin irritants and other harmful 3.1 Tools and materials necessary for me 3.2a Engine sump drain plug location (I)
Contaminants in used engine oils, it is engine oil change and filter renewal all except F7P (16-valve) engines
 1A.8 Every 6000 miles
3
.
- Engine sump drain plug location (1) - uns&ew the sump drain plug
WP (I€-valve) engine
B Allow some time for the old oil to drain,
notlng that it may be necessary to reposition
the container as the oil flow slows to a trickle.
4 Afler ail the oil has ora~ned,wlpe off the
&n oQo with a clean raa and renew its
siding &her. Clean the area around the
draln plug opening, rnen refrt and t,gnten rhe
pltig to ti+ specified torque setting.
5 Move the container ,nto pos.tlon under the
oil filter, locate0 on tne front of tne cy1,nder
M:&&.
B.On.the-F7P (16-valve) engine there Is only
limiisd toom between the subframe and the
sump, and it Is very difficult to reach up to the
oil filter. However, it is possible to gain access
through this space, and it is not necessary to
I w o v e any body or engine components.
9'
L.
Note that the oil fiiter on F7P (16.-valve)
snalnes Is mounted
~~ ~on. an oil
-cooler.
~
7 Usmg an oil fiiter removal tool, slacken the
fiHer'ln!tiallY (on the F7Pl16-valve engine, try
to unsoreG the fiber bv hand first). Looselv
wrap some rags around the o I falter, then
unscrew it and lrnmedlately post on lt wltn 11s
open end uppermost to prevent further
spillage of oil. Remove the oil fiiter from the
englne compartment and empty the oil into
the container.
8 Use a clean rag to remove all 011,dlrt and
sludge from the fliter seallng area on the
engine. Check the old filter to make sure that
I I
4.6 Automatic transmission fluid filler
tube (D)and vent
3.9 Applying a imCIRNI*JUI.USMI VI~
t o the'seallng tlng beforefttling the new
- oil finer
the rubber sealing rlng hasn't stuck to the 14 Dispose of the used engine 011 safely with
engine. If it has, carefully remove It. reference to "General repair procedufes"' in
9 Apply a light coating of clean oli to the the Reference sectlon of th~smanual.
saal~ngrlng on the new ftlter, then screw it lnki
position on the engine (see Illustration).
Tighten the filter flrmly by hand only - do not
use any tools. Wkpe clean the exterlor of the
oil fiiter.
10 Remove the old oil and all tools from . .
under the car, then (If appilcabie) lower t h e w Note: The fluid level checMn9 r~mcedureon
to the ground. the eutomatlc transmission-1s particularly
11 F~llthe engine w~ththe specified quantity complicated, and the home mechanic would
and orade of oil. as described In "Weeklv be well advised to take the car to a Renault
chici;~". PoLr tne o,l in slow y, otnerwlse it dealer to have the work camed out, as special
may overflow from the top of me va.ve cover test equtpment is necessafy to carry oui the
C h k k that the oil ievei is up to the maximum check. However. the followina procedure is
mark on the dipstick, then refit and tighten the gben for those who may hav&iccess to this
oil filler Gap. equipment. Note that the final drive 011 level is
12 Start the enQine and run it for a few not checked as a routine maintenance W. as
minutes, checking that there are no leaks ~tis sealed for life.
around the 011fiiter seal and the sump drarn -
plug. Note that when the engine 1s first Main transmlsqi"n
started. there will be a delav of a few seconds 1 First add 0.5 IitreDYthe smcltred fluld to the
befoe tne 011pressure warnlng i,ghr goes oJr transm~ss%nby removing the vent from the
wn le tne new 11ter falls w~th08, Do not race top of the fliler tube and using a c l a n fdnnel
the engine while the warnlng llght Is on. with a fme-mesh filter. Refit the Vent.
13 Sw~tchoff the englne and wait a few 2 Poslhon the car on a wmp, or jack ~tup and
rnlnutes for the oil to settle In the sump once support on axle stands (see "Jacking and
more. With the new 011c~rculatedand the fllter vehicle suppoff].
now completely full, recheck the ievei on the 3 Conneot the Renault XR25 test meter to the
dipstlck and add more oil if necessary. dlagnosbc socket, and enter "D04" then
number "04". With the selector lwer in Y ~ & .
run the engine at idle speed Until the
temperature reaches 60°C.
4 W~ththe engine still running, unscrew the
topping-up plug on the transmission. Allow
the excess fluid to run out Into a calibrated
container for 20 seconds, then refit the plug.
The amount of fluid should be more than 0.1
lltre: if it 1s not, the fluid ievel in the
transm~sslon1s incorrect.
5 If fluld is to be added, pour 1 litre of the
seeclfled fluid through the filler tube after
removing the vent (see illustration). Allow the
transmission to cool down, then repeat the
checkina procedure aaain as described in the
prev~ousparagraphs. -
---
Final drive
4.8 Automatic transmission flnal drive 6 This IS not a rout~neoperation, but it may be
oil ievel plug (GI considered necessary if there Is reason to
 suspect that the oil level is incorrect - for
instance if there has been an oil leak.
ramps, dr jack it up and
nds (see "Jacking and
vehicle suppoe). Make sure that t h e i a r is
level.
8 Unscrew the final drive level piug located
behind the nght-hand driveshaft on the r~ght-
hand side of the transmission (see illusbation).
9 Check that the level of the 011is up to the
bottom of the plug hoie. If not, lniect oil of the
wrrect grade lntothe hoie ~ n t iiiovelt.ows.
i
10 Wipe clean the .eve1 piug, then refit and
tighten it.
11 Lower the car to the ground brake hose
partlcuiar attention to the vent pipes and
hoses, whlch often loop up around the filler
neck and can become blocked or crimoed.
Follow the lines to the front of tne vehbie.
carefully nspecting them ail tne way. Renew securing wets o i certvn models -.
oamagea sections as necessary. S.miiarlv. 3 Check the or~vebelt(s)for ma&, spfithng,
1 Visuallv tnsDect the enoine ioint faces.
whdst the veh~cle 1s raised; take the fray~ng or damage, -whilst rotating ttre
gasketeind &is for any signs oi water or oil
opportunity to Inspect ail underbody brake crankshaft cto&iG wsinoea sukbt@&her
imb. Pay particular attention to the areas
fluid pipesand hoses. appl~edto the crankshatlTpuflieybo~t,-$othat
a w n d the valve oouer. cviinder head, oil filter
7 From within the enalnecomoartment. check tne ent re lengtn of each belt 1s examfad lsee
and sump Iolnt faces. B&r in mino that, over
the securlty of all fue~vacuumand b&e hose illustrationl. Cneck aiso for signs .of gla&g
a period of time, some very slight seepage
attachments and pipe unlons, and inspect ail (sh~nyparches) and for separation of the belt
hom these areas is to be exoecreo - wnat vou
hoses for kinks, chafing and deterioration. pl es. Renew tne oelt if worn or oamageo, wth
are really looking for 1s any indicat~oni f a
8 Check the condition of the power steering reference to the appropriate paragraphs later
serious ieak. Should a ieak be found, renew
fluid pipes and hoses and, where applicable, in this Sbction.
tb offinding gasket or oli seal bv referrlno to
the appropriate Chapters 'n this manual. - the automatic transmission fluid cooler pipes
and hoses.
C-fype engine
2 Also check the security and conot on of all
the engine-related pipes and hoses, an0 a i Removal
hydraulic and brakina svstem oioes and 4 Working at the top of the alternator. loosen
hoses (see illustrationj ~nsbrethat'a~~ cable the alteriator tensioner nut whilst counter-
Ues or searing clips are in p.ace, and in good hoid~ngthe bolt (seeIllustration).
condinion. Clips which are broken or missing 5 Slmllarly, loosen the alternator mounting
can Idad to chafing of rhe hoses, ppes or nut (located at the bottom of the alternator),
Note: Disconnect the battew neaative lead
wirlng, wnch could' c a s e more serious then p ~ otheiltemator
t towards the engine to
before yoMlng in the aria &und the
problems in the future. relieve the tenslon in the drivebeit.
alternator. 6 Slide the drivebeit from the pulleys.
3 Caretunly cneck the radiator hoses ano
heater h o w along their ent.re engrh. Renew General iaWrmation Refitting
any hose whlch is cracked, swollen or 1 The tvoeand number of aux~i~atv drivebelts
-~ ~- 7 Fat tne oet aroLnd tne pulleys, ensurlng that
deteriorated. Cracks will show up better if the rmed v- depenoingon modei. Tb check tne the oeit is of the correc? type .f it s be.no
hose is squeezed. Pay close attention to the conoition of tne dfiueoeit(s), proceed as fokows. renewed. T,&e6:up the si5ck7'i0 the belt bjy
hose clips that secure the hoses to the 2 Apply the handbm&e then.lack UD the fmnt swingin$dti6 alpmator away fmm the engine
cooling s w e m comoonents. Hose cl~oscan of the "ehlcle and support li on aiie stands and, ,lfbhtJy tiqhtening the mqunting and
pinch G d ~ u n c t whoses, resulting in Aoollng (see "Jack~ngand vehcle support"). Remove tension&uts ahd bolts.
system leaks. If the crimped-type hose cilps the right-hand ftont.madwhealai$ ,where
are used, it may be a good idea to replace
8 6ns1onthe drivebeit as described in the
necessary ths wh&. $arch splash shield. following paragraphs.
them wlth standard worm-drive clips.
4 Inspect ail the eooilng system components
bosas, ioht faces, etc) for (see Havnes
Hint). Where any problems are found on
System wmponents, renew the component or
gasket with reference to Chapter 9.
5 With the vehicle raised. insoact the fuel
~7 ~~ ~ ~

tank andfliler neck for punctures, cracks and

otner damage. The connection between the
flllw nedk and tank is especially cr~ticai(see
ih&aWn). Somerimes a rubber filler neck or
conneoting hase will ieak due to ioose
retalriing cramps or detenorated rubber.
0 Carefully check all nbber hoses and metal
fuel lines leading away from the fuel tank.
Cneck for ioose connections. deteriorated
h o w , erimped llhes, and other damage. Pay
ofthe rubber'hose (amwed) which
ccnneois the fuel filler necK to the tank
6.3 Checking for driW&~if'Vvsar
multi-rlbbed W 8 R b ~ n
-
 to drill out the emrinalclvets on certain

.-
- *:
-
tensloner bolt (A) and
~ ~ n t l i i r n(B)a tc . w engw
4 W ~ W , ~ m r w l t ~ . ~ ethb
g rpulleys,
rd ensuriNg
~ a ~ ~ ~ *if ~ :it.is beirig~ ~ : ~ ~ ~ a &
of the, drtvehelt will ~ h & w W TaWrup+ the el%elc In the belt,by
a long life. Beware, swin@ing:.W&$lt8matobBwey frav the engine
nlna, as this can .muse and llghtly tightening ,€he rnwnting and
ve wear in ihe altehator trniOlWfflut5.&i@ beif&.
@-'metwit shwu bo tensioned so thatmere ?@ T&bibnfhecdrl~&eit as desm'bed in the
1B1 wprwimately 4 mm of free mavOVewnt,folbWRrg.paqrwhs.
osde&m thumb pnenrsureat thewibpointaf
@&m.;m between the. water pbmp pulley ~eneiarRng'
..m .&,alternator pulley (see illwtmtNon):
thsmwnting and.ten@.F.ern!&%iust
2Q Proce&as dessflbed in paragraphs 14
and 16. ifnot elwdy,dene.
Rw, l a v e r ~ ~ ~ b m a~ Wi oErY 21 Correct tensioning of the drivehe~will
:$f,@::&$.@ag,ine untll the. correct ten$@n6 ensure that it has a long life. Beware,
however, of averfighteninra. as this can, cause
e m e m h / e d & W 4 r i t ~ ~ -~ , t ~ r ~

The b e k - s ~ o b esoothat 'there

ia,btymw 4 2 and 4;7 mmof free movement,
under firm thumb pressuw at the mid-point of
the.beR.run.btwwn the pulleys.
2?1 YUjhthe rneuntlng,andtensionerand.nSio nut8 Just
&quid be as described previously in holdim the unit f i n , levsr We altmatcr.sway
from ;he eng~neunttl tha wrrect t e n s e
achieved, then tighten We nJts and bolts.
24 When a new belt nas been fitted, ti will
pmbW@stretch ellghtiy whewthen engffle ts
run. After flwng a new belt, run 'thmmglne
unttl the coollhg fan euts in, then stoQ the
enoine and Wch& the !At t-loil.
&-with theengine w m ,the bit dbfleetion
6hwld be behween 6.2 and 7.7mm, usingthe

of fhfi pums loosen

nut (@I& secures
ster strut) whlist

8.37 Alr condltloning compressor drivebeit
tensioner pulley bracket bolts (F) and
-
adjuster screw (G) E-type angines
Without power steerlng
Remting
40 Flt the belt around the ouilevs. ensurino
that the belt is of the correci typeif'it is being
renewed. Take up the slack in the belt by
tightening the adjuster ndt.
41 Tension the drivebelt as described in the
following paragraphs.
Tensioning
42 Correct tensloning of the drlvebelt wili
ensure that it has a long iife. Beware.
however, of overtightening, as this can cause
excessive wear in the comoressor.
43 At the time of wntnng, no informailon was
available for the recommended belt tension.
b ~ at reasonable approximation would be
aDDroximateiv 4 mm of free movement. under
firm thumb pressure at the mad-point of the
belt run between the crankshaft and
compressor pulleys. Consuit a Renault dealer
for recommendations if in doubt
- --.
44 With the tensioner puiiey bracket securing
bolts just holding.the bracket firm. turn the
adiuster nutkntil the correct tension .is
~ ~~~
a c h i e v ~ t h e ntighten the adjuster nut,
iocRnut and puiiey bracket securing boits.
€-type englnes -
alr condltronlng compressor/
power steering pump ddvebe/t
45 On models fitted wlth both power steering
and air conditioning, the procedure for belt
removal, refitting and tensloning is as
described previously for models with air
conditlonlng. Consult a Renault dealer for
details of the belt tension recommendation.
F3P englnes - ground, and refit the headlightasdescribed in
models without power steering
or a/fconditioning
Removal
46 Remove the right-hand headlight, as
described in Chapter 12, Section 9.
47 For tmproved access, apply the
handbrake, then jack up the front of the car
Every 6000 miles IA.II
and support securely on axle stands (see
"Jacking and vehicle support?.
48 Remove the right-hand roadwheel, then
remove the engine spiash shieid from the
subframe to improve access. Where
applicable, unciip the brake pad wear sensor
wiring from the spiash shieid, takhg care not
to strain the wiring.
49 Working at the bottom of the alternator,
loosen the lower mounting nut (which seoures
the aiternator to the adjuster strut) whilst
counterhoiding the bolt. Loosen the adjuster
stmi locknut and adjuster nut. Also loosen the
bolt securing the adjuster strut to the engine. 6.50 Loosening the alternator upper
JO Working at the top of the alternator, mounting nut- F3P engine models without
loosen the upper alternator mounting nut, www aeerhrg or a t condtnonlng .
again counterhoiding the bolt (see
62 Slacken the b d l in the centre of the
illustration).
iga. 7 mm Alien key or bit.
tensloner pulley. /,ngn
51 Back off the adiuster nut to relieve the
tension in the drivebelt, then slip the drivebeit
63 Using an open-endedspanner on the flats
provided, turn the tensioner pulley clockwise
from the pulleys, taking note of its routing.
to relieve the tension in the drivebelt.
Refitting 84 Carefully release the drivebeit from the
52 Fit the belt around the pulleys, ensuring puileys, notlng its routing, and wlthdraw the
that the beit is Of the correct type ifIt is being belt.
renewed. Take up the slack in the belt by Refitting
tightening the adjuster nut. Ensure that the 65 Fit the belt around the pulleys, ensuring
belt is routed as noted before removal. that the belt is of the correct type if it is being
53 Tension the drivebelt as described in the renewed. Make sure that the belt is correctly
following paragraphs. routed round the puiieys, as noted before
Tensioning removal.
54 Proceed as described - in naragraphs 46 gs Tension the drivebelt as described in the
to 50, fi not already done. following paragraphs.
55 Correct tension~nQof the drivebelt will Tensioning
enwre that it has a long life. Beware, however, 67 Proceed as described in paragraphs 61
Of oveltightening, as thls can cause excessive and 62. if not already done.
wear In the alternator and/or water pump. 68 Correct tensioning of the drivebelt wili
56 The belt should be
~~ - - tensioned
-~~ .. so that there ensure that it has a long iife. Beware,
s between 2.5 and 3.5 mm of free movement, however, of overtightening, as this can cause
under firm thumo pressure at the mio-point of excessive wear in the alternator and/or
the belt rdn between
~ -~
the
~~. crankshaft ano pumps.
aiternator puiieys (see illustration).
57 With the mounting nuts just holding the I
alternator firm, turn the adjuster nut until the
correct tension is achieved, then tighten the
adjuster nut, the locknut, the bolt securing the
adjuster strut to the engine, and the alternator
mounting nuts and bolts.
58 When a new belt has been fitted, it will
probably stretch slightly when then engine is
run. After fitting a new belt, run the engine
until the cooling fan cuts in, then stop the
engine and recheck the belt tension.
59 With the engine warm, the belt deflection
should be between 3.5 and 4.5 mm, using the
method described in paragraph 58:
60 On completion;, refit the .engine splash
shieid and the madwheel. Lavver the carto the
Chapter 12, =!on 9.
F3P engines -
models with power steering
I
and wlthout air conditioning
Removal -
6.56 kuxillary drlvebelt tension checking
point (F3) F3P engine models without
power steering or air condiioning
61 Proceed as described in paragraphs 46
to 48. F3 = 2.5 to 3.5 mm coldM.5 to 4.5 rnm hot
 76 Slacken the bolt in the centre of the
tensioherpulley, wsinga 7 mm Allen b y or bit
(@a illmn).
76 Using amopen-endedspanneron the flats
Provided. t u n the Wnsioner putlev clockwise
io relievethe tenelon in R e d&ebelt.
TT Carefully Feleam the drivebelt from the
pulleys, nOtfng its routing, and withdraw the
belt.
Reflaing
78 ~il.the
bsli.around the pulleys, ensuring
thatihe 6% Jsof me corm@ type if it is being
ren~yqds:~a@,.sure.~aff the belt is correctly
r~.@p&@und.t& pulleys;. + noted before
rspoval*. . . '
' nqiqn the. dri&belt as described in the
Je
$6b AuxWy drlvebelt tension checking follawingparagraphs.
(F2) 1F3P englne models wlth power KW8Rhg;
stwdng and wlthout air condmoning
T &~,PG&%BB~
as described In paragraphs 74
A water pump p u l y D Power steering and 'I'f..ti61a h d y done.
B. Cranksha# pulley pump pulley 81 Correct tensioning of the drivebeit d1 l
C Alternator pulley F Tensioner pulley smsure tt@ it has a long. life. Beware,
hmweusr, of qv.ertightening,.as this oan oause
m ~ e a s i v awear in the alternator and/or
W Tne bek sho~labetensloned so that there com(3resord
is between 3.5and 4.5 mm of free movement.
82 the ~elt snoLla be tensioned so that there
under flnn thumb pressure at the mid-point of
IS between 1.6 and 2.5 mm of free movement,
#e hePun between the alternatwmd Dower
stwmg pump pulleys (see illustration)' under f l n thumb pressureat the mid-point of
70 Turn the tensloner pulley clockw'se using the belt run between the air conditioni~g
+ spanner on the .flats. provided until the compressor and alternator pulleys.
@en& tension is achieved. Leek the & T&m enbloner pulley clockwise usihQ
mnsioner pulley in position by t)pQnjng.;the a spanner on the fitits provided until Fe
@@$boltwhilst count&oiding the pulley. 5 6 j i d t .tensido i s achieved. Lock tiie
ri kun'fhe &gine f o r approxtmatptly.,$ ,&,sioiiet 'ntille'y in pb'sitton by tightening the
mint$% end recheck thedrhrebelttensioh'as i911w~dRGhiM c6unte[noiding the pulley.
dhh ,mfi
b e d ilip a r w p h 69. 84 .R$i t h e enphe for aT-xPnzfeIy 5
mine warm, the belt defl&%lon m!h&% a d id-th-eck the dfi belt tension as
shau~dbe betineen5.5 and 7.0 mm, usingihe &eS&i&" pakwapphs2.
m&t&od dascribeil in paragraph 69. ti5'
:I- .@&It-,the 'hehqltght, wlth reference to
73 On comDletion. refit the enolne sbiash Chap%?Y2, $?ti% ?:
shield and tne madwnee . ~owart i e car to the n lz ~ ~ Z ~ ~ * Y B Aengine
M,J
gmJnd, an0 retlt the headlight as described ln !.
Chapter 12,Section 9. Removal
,FgP eriqlnes -
mm#els with air ~onditioning
W .Remo,ve , the righi-hatd haadli@kt, as
desaribed in.Chapter 12, Ssc7ionOr : -,

87 On modeis Wed with a chamru canister,

Remy4 unscrew the two securlng bolts, remove the
74 Rem'vy e right-hand headlight as shield from the f ~ e tenk-w-canisterhose,
,
$
d e s c d I@ 'apter 12, Seciion 9.

~@~.FmmYhTg
the right-hand%@?&
-. -S@jgI&.;-&-vahre).gngine
 I03 Where applicable, r e c ( ~ m e g 4 t h e 1 q ~ I
canister hose, m d r@fit@eh
rpa Refit Wgzhssdllght.
- t@&i - -
Chapter.lZ 96stlon9.

Warning: Do n

;a4 neloaslng m e onveoelr rmm me

-
srnator pulley F7P (16-valve) engine
Refitting
S5 Fit the belt around the pulleys, ensuring
that the belt is of the correct type if it is being
renewed. Make sure that the belt is correctly
A a confinedspace (risk of carbon
monoxide ooisoninnl. Do not
remove tamperpro& caps ;here this i s
forbidden by law (risk of pmsecufion).
Canburettor models
Note: A tachometer and an exhaust gas
analyser mll be requlred to cany out ths
procedure accurately.
~ ~
-
6.99 Auxillaty drivebelt tension checking
pointif) PIP (*@-wive) engine
~-

1 Before carrying out the following

routed round the pulleys, as noted before
removal.
98 Tension the drivebeit as described in the
following paragraphs.
Tensioning
97 Proceed as described in paragraphs 86
to 8D,if not already done.
p Correct tensioning of the drivebelt will
ensure that it has a long life. Beware,
howaver, of overtightening, as this can cause
ewesslve wear in the alternator andlor
pump(&).
BS The belt should be tensioned so that there
is W e e n 1.5 and 2.5 mm of free movement,
under fin thumb pressure at the mid-point of
thebelt run between the power steering pump
or idler pulley (as applicable) and the
alternator pulley (see illustration);
1M)Tumthetensioner puiiey clockwise using
a spahner on the fiats provided until the
correct tension is achieved. Lock the
tensioner puiiey in position by tightening the
Aiien bolt whilst counterholding the pulley
kee illusbmtlonl.
101 With the drLebel correctly adj~sted,refit
and tighten the screw securlng the wiring
Dracmet to tne inner wing panel
102 Run 'the engine for approximately 5
m i n u t e s , e n d ! ~thednveoeit
~ tens80nas
dssnribed in parapph.99.
adjustments, ensure that the spark plugs are
in good condition and correctiy gapped. Also
ensure that the contact breaker points and
ignition timing settings are correct.
2 Make sure that ail electrical components
are switched off during the following
procedure. ~fthe electric coiling fan operates.
wait Lntii it has stopped before contnbing.
3 Connect a racnometer lo the englne in
accordance with the equipment
manufacturer's instructions. The use of an
exhaust gas anaiyser (CO meter) is also
recommendedto obtain an accurate setting.
4 Remove the tamperpmof cap (where fitted)
from the mixture adjustment screw by
hooking it out with e scriber or small
screwdriver.
5 Run the engine at a fast idling speed untii it
reaches normal operating temperature
(indicated by the cooling fan cutting in and
out). Increase the engine speed to 2000 rpm
7.6 Carburettor adjustment screws -
Solex 32 BIS carburettor (C-type engin
A Waterpump D Powersteering
pufley pump or Idler
B Crankshaft- ' 1 t L *I ipulley
pulley , , .&;Tmsio~arpulley
C Alternatorpulle~, 5r 1.5 to 2.5mm
procedure. This will enslie that any excess
fuel is cleared from the inlet manifold.
6 With the englne idiing, turn the idle speed
screw untii the engine is idiing At the specifled
speed (see illustration).
7 urn the mixture adjustment sctew
clockwise to weaken the mixture, or anti-
clockwise to richen it, until the CO reading is
as given in the Specifications. if a CO meter is
not being used, weaken the mixture as
described, then richen it untii the maximum
engine speed is obtained, consistent with
even running.
8 Re-adjust the idiing speed if necessary,
then check thiCO reading again. Repeat until
both the idling speecl and CO reading are
correct.
qehbvad (see illustrattcm] The gentre 13 Spmlal sparlc plug electmere gap 4s R&WJ~~W:~FS~~@~~W mrWhten the
electrode should n e w be bent, as this may and adjuang tools are available rjrw t&?.@d&
measuring
q, $ &%rra udw the spark
W k the lnsulatron and cause plug tailure, d
nothing wow.
from most motor acceesory shops ( s e ~ Plug so&$ ~,g@.
UluJaatl4n81.
& '$rrw+
.,
. . wrench [see
Refp@#i'iem@ini!tgspark Nugs
tl~ustmti~n),
14 Before fitting the spark plugs, chmk that in-fhesawC!v&@fg* . ~

the threaded oonhector sieew are trgM, and 17 Wipe dgan 1- .,, !gads,,than o r ~ n e c t
that the plug extenor sqlfaces and threads are them in their c a n e @ $ o ~ w ~ # & r ~ ~ @ @ m
clean. Apply a ltttle anti-se~zecompound to refa the e@tne~p,~:p$g&. . ,
the threads.
15 It is often difficultto insert spark plws into
thair halee Whout cross-threadina them. To
avoid thlsposslb~ljr,fit e short length of hose
over the end of the spqrk plug (seaTaolTin).

1 Rekeae the two spring cl p and lltt off the

dismbutw cap. P ~ lthe l rotor arm off the shaft
andrmove thepksiic shieldfseeIllostration).,

It'b v u y offen difficult M msert s

plugs into fheir holes wtthout
2 With tne tgnitioh switched off, use a
snewdri~ t o oplen the contact breaker
poinp,.&w visudly oheck the points surfac+s
for pitting, mugtinass and dl&ol&tlan. ~fthe
I
points.bavebeen q@Jng,mere will @ a build-
UP cf nrstal on the. movi,ngcontact and a
~ q in me &ea contaor: if
c o n e s p ~ holl~pr
this l s t h p m 5 f @r j o r p , s ; ~ . ~ l ' ~ p e . r e n e w ~ .
3 TO m p u q % . ~ & t % ~ r f buwyew. .t the
' adiclstiwin~k$0lb tf~e,.s@dithe distributor

S.1 Removing the rotor annfmm theoentaet breakev d n t r i W

 IA-~S Every 6000 mil(

9.5a Prise oul the plastimplug ... 9.5b ...to gain:aeoessto,thes@tiinIng

BPml clip (errowedl . ..
4 Unhook the end of the adiustment rod fmm points open, there is no sparking across them, nut at the LT terminal post and slip off the
the fixed contact, and slide the rod and spr.ngwhich would cause wear of their faces and lead. Unscrew the condenser retaining screw
dut gf the distributor body (see Illustration).prevent the rapid collapse of the magnetic and remove the unit from the side of the
6 -Primout the small plug and then remove fiela in the coil. Failure of the condenser distributor body.
the retaining clip, noting that the hole in thewould cause a reduction in coil HT voltage, 14 Refitting of the condenser Is a reversal of
clip is uppermost (we illustrations). and uitimateiy lead to engine misfire. the remod procedure.
6 Slacken the LT terminal nut and detach tne 11 If the engine becomes very difficult to 15 To fii the. opw,Gontact breaker pdnts, first
start, or begins to misfire afier several miles check if there 1sany.flr~y:deposit on them,
7 ~emovethe spring retaining clip from the of running, and the contact breaker points and ifn m a w clWTbn.wingmethymed
top of the moving contact pivot post, and take show signs of excessive burning, the spirit.
aff the flbre insulating washer (see condition of the condenser must be suspect. .a
16 Fit the points using @em&! qi' the
ilwbtlonl. A further test can be made by separating the removal procedure, thim edjm %&xi@ 9s
aU' e thsspring blaae away from its ny~on points by hand with the Ignition switched on. follow. Turn the engiria o v & : W q @ q : ~ t
&rt, and lift the moving contact upwards If this is accompanied by a strong bright or spanner on the crankshaff:pgIlg$j~.WI
and off the . .
. ~. i v o~t o s(see
t Illustratlon~. flash, it Is indicative that the condenser has the heel of the contact bmaker 9rm %Aon.he
b unscrew the retaining screw, and iemove failed. peak of one of the four cam lobes.
the flxed contact from tne baseplate (see 12 Withoutspecial test equipment, the only 17 With the points fully open, a clean feeler
s.$e wayto diegnose Condenser trouble is to bladeMual to the contact breaker ~olnts -.aa~.
J . 10 'lhe pu.rpose of the condenser (.ocared fit a new Qne, and note if there is any as giVen'ln the Specifications, sho"ld nowjust
exlbmally on the side of the distrtoutor body) improvement. Rt between the contact faces (see
Is tp ensure that when the contact breaker 1G Td .Mniove'~fhecondenser, unscrsw the

0.6 Slacken the LT termlnal nut (A) and

d.tach the leed (0)from the connector

pints gap Usinge

9.8 YIISINI-W L.I r n n ~ ~ Contact
mg fmm the 9.9 Renwvin~
me nwu m r - d fmm the feelerblade.Adfust M,neoasaaryW
pivot post baseplate turning nut (Al
 I
- Every 6000 miles i n * ~ r
18 if the aaD is too larae or too small., turn the
~~~
adjusting-nut on the side of the distributor
body using a small spanner untii the specified
gap is obtained.
I 9 With the points correctiy adjusted, refit
the plastic shield, rotor arm and distributor
cap. Check the ignition timing as described in
Section 10.
20 if a dweii meter is available, a far more
accurate method of setting the contact
breaker points is by measuring and setting the
distributor dweii angie.
21 The dweii angie is the number of degrees
of distributor shaft rotation during which the
contact breaker points are ciosed (ie the period
from when the points close after being opened
by onecam lobe untii they are opened again by
the next cam lobe). The advantages of setting
the points by this method are that any wear of
the distributor shafl or cam lobes is taken into
account, and aiso the inaccuracies of using a
feeler gauge are eliminated.
22 To check and adjust the dweli angie,
Connect one iead of the meter to the ignition
coil "+" terminal and the other iead to the coil
"-"terminal, or in accordance with the meter
maker's instructions.
23 Start the engine, allow it to idle and
observe the reading on the dwell meter scale.
if the dweii angie is not as specified, turn the
adjusting nut on the side of the distributor
body as necessary to obtain the correct
setting. Note: Owing to machining tolerances,
or wear in the distributor shaft or bushes, i t is
not uncommon for a contact breaker points
gap correctly set with feeler oauaes. -
- . to give a
dwell angle outside the specified tolerances. If
this is the case, the dwell angle should be
regardedas the prefened setting.
24 After comoietina the adiustment.
, ~ ~ ~.
switch
-~
on tne eng.ne and oiconnect the dwel meter.
Cneck tne ign lion t mng as describe0 in tne
Section 10,
1 in order that the engine can run efficiently, it
is necessary for a spark to occur at the spark
piug and ignite the fuellair mixture at the
instant just before the piston on the
compression stroke reaches the top of its
travel. The precise instant at which the spark
occurs is determined by the ignition timing,
and this is quoted in degrees before top dead
centre (BTDC).
2 The timing may be checked and adjusted in
one of two ways, either by using a test bulb to
obtain a static setting (with the engine
stationary), or by using a stroboscopic timing
iight to obtain a dynamic settina - ,(with the
11
engine running).
3 Before checkingor adjusting the ignition
timing, make sure that the contact breaker
II I points are in good condition and correctly
adjusted, as described previously.
Static setting
4 Refer to the Specifications at the start of
this Chapter, and note the specified setting for
static ignition timing. This value wiil aiso be
found stamped on a clip fastened to one of
the HT ieads (see illustration).
5 Pull off the HT lead and remove No 1 spark
plug (nearest the flywheel end of the engine).
6 Place a finger over the piug hole and turn
the engine in the normal direction of rotation
(clockwise from the crankshaft puiiey end)
until pressure is felt in No 1 cylinder. This
indicates that the piston is commencing its
compression stroke. The engine can be
turned using a socket or spanner on the
crankshafl puiiey bolt, or by engaging a gear
and pushing the car along.
7 Continue turning the engine until the mark
on the flywheel is aligned with the appropriate -
notch on the ciutch bellhousing (see 10.4 Ignition timing setting P(" BTDC) is
illustration). -
stamped on clip C-type engine only
8 Remove the distributor cap, and check that ROWD00=
the rotor arm is pointing towards the No 1 Advance cume reference number
spark piug HT lead segment in the cap.
19 Po~ntthe tlming i~ghtat the timing marks.
9 Connect a 12-volt test iight and ieads
They shouid appear to be stationary, w~ththe
between a good earth point and the LT
mark on the flywheel aligned with the
terminal nut on the side of the distributor
approprlate notch on the ciutch beilhouslng.
body.
20 if adjustment 1s necessaw lie the flvwheei
10 Slacken the distributor ciamp retaining
mark does not ilne up withihe appropriate
nut, and then switch on the ignition.
notch), slacken the distributor ciamp retaining
11 if the test light is on, th'k shows that the
nut and turn the distributor body either ant;
points are open. Turn the distributor slightly
clockwise to advance the timing, or clockwise
clockwise untii the iight goes out, showing to retard it. Tighten the clamp nut when the
that the points have closed. setting is correct.
12 NOWturn the distributor anti-clockwise 21 Gradually increase the engine speed while
untii the test iight just comes on. Hold the Still pointing the timing iight at the marks. The
distributor in this position and tighten the mark on Jhe fiywheei should appear to
clamp,retaining nut. advance further, indicating that the distributor
13 Test the setting by turning the engine two centrifugal advance mechanism
complete revolutions, observing when the functioning. if the mark remains stationary or
is
iight comes on in relation to the timing marks. moves in a jerky, erratic fashion, the advance
14 Switch off the ignition and remove the test mechanism must be suspect.
light. Refit No 1 spark piug, the distributor cap
and HT iead.
Dynamic setting
Note: A stroboscopic timing iight wiil be
required for this procedura.
15 Refer to the Specifications at the start of
this Chapter, and note the setting for ignition
timing at idle. This initial value will also be
found StamDed on a ciio fastened to one of
the HT leads. To make s;bsequent operations
easier, it is advisable to highlight the mark on
the flywheel and the appropriate notch on the
ciutch bellhousing with white paint (typist's
correction fluid is ideal) or chalk.
16 Connect the timing iight in accordance
with the equipment manufacturer's
instructions (usually interposed between the
end of No 1 spark plug HT iead and No 1
.
SDark oiua
, - terminal). ,~
~
17 Disconnect the vacuum advance pipe
from the distributor vacuum unit, and plug its I" Timing marks Onfl*lll.n'
end. and scale on beiihousing) -
18 Start the engine and ieave it idling at the
specified speed (refer to the Specifications).
C-type engine only
0 = TDC
 1A.18 Every 6000 miles
ad~ustments, switch off the engine and
d~swnnectthe timing light.
Not= The follbwing check is not specHied by
Renault. but is indude0by the author.
1 Check that the clutch pedal moves
smothly and easily through its full travel, and
that the clutch itself functions correctly, wtth
no trace of slip or drag. If the movement 1s
uneven or stiff in places, check that the cable
Is routed correctlv. wlth no sharo turns.
2 Inspect the ends of the clutdh Inner cable,
- both at the gearbox end and .nslde the car, for
signs of wear and fraying.
1 With the engine cold (at least an hour after
the vahlcle has been driven), check the
. complete exhaust system from the englne to
the end of the talipipe. Ideally, the inspection
should be carried out with the vehicle on a
hoist to permit unrestricted access, but if a
hoist is not available, ralse and support the
vehicle safelv on axie stands (see "Jackina - the specifi;d thickness or iess, all four pads
and vehicle sbppof).
2 Check the exhaust pipes and connections
for evidence of leaks, severe corrosion and
damage. Make sure that all brackets and
mountings are in good condition and tight.
Leakage at any of the joints or In other parts
Of the system w~llusually show up as a black
sooty stain in the vlcinity of the leak.
3 Rattles and other nolses can often be
traced to the exhaust system, especially the
brackets and mountings. Try to movc the
pipes and silencers. If the components can
come into contact w ~ t h the bodv or
suspension parts, aecdre the system wdh new
mountings or if posscb~e,separate the jo,nts
and twist the pipes as necessary to provide
additional clearance.
4 Run the engine at idling speed. Have an
assistant place a cloth or rag over the rear end
of the exhaust doe, and listen for anv escaoe
of exhabst gasiithat wou d indncatea leak:
5 On completlon, lower tne car to tne grodna.
6 The insioe of the exhadst talo.oe can oe an
indication of the running condition of the
engine. The exhaust deposits here are an
indication of the engine's state of tune. If the
oioe is black and sootv. the enaine is in need
&a tune-up, includlng'i thorough fuel system
Inspection and adjustment.
1 F~rmlyapply the handbrake, then jack up
the front of the veh~cieand suooort it securelv
on axle stands (see " ~ a c k and i ~ veh,cle
suppofl). Remove the front roadwheeis.
2 For a aulck check, the th~cknessof frlctlon
mater,al rima ning on each brake pad can be
measured through tne aperture n tne canper
body. If any pad's frn'on mater a1 is worn to
the specified thickness or iess, ail four pads
must be renewed as a set. (Pad wear warning
contacts are fltted to the ~nboerdpads, but
this should not be used as an excuse for
omlnlng a wsual check.)
3 For a comprehensive check, the brake pads
shouid be removed and cieaned. Th~swiil
allow the ooeration of the calloer to be
checked, an; the orane osc itself'to be fully
examined for condton on both sdes. Referto
Chapter 9 for further information
1 Chock the front wheels, then jack up the
rear of the vehicle and support it on axie
stands (see "Jeck~ngand vehicle support").
Remove the rear roadwheels.
2 For a auick check. the thickness of friction
matenal &main.ng on eacn brake pad can oe
measLreo through rhe apendre in the ca lper
bodv. If anv oad's friction material is worn to
must ;be renewed as a set.
3 For a comprehensive check, the brake pads
shouid be removed and cleaned. This wiil
allow the operation of the caliper to be
checked, and the brake disc itself to be fully
examined far condition on both sides. Refer to
Chapter 9 for further information.
I I
16.2 Headlight beam adjustment screws
1 Vertical adjustment screw
2 Horizontaladjustment screw
1 Once the car has been washed and all tar
soots and other sulfate blemishes have been
cieaned off, carefully check all paintwork,
looking closely for chips or scratches. Pay
oarticular attention to vulnerable areas such
i s the front panels (oonnet and spoiler), and
around the wneel arcnes. Any damage to the
paintwork must be rectified as soon as
possible to comply with the terms of the
manufacturer's anti-corrosion warranties;
check with a Renault dealer for details.
2 If a chip or light scratch is found which is
recent and stiii free from rust, it can be
touched-up using the appropriate touch-up
stick which can be obtained from Renault
dealen. &1y more serious damage, or rusted
stone ch'ps, can oe repa'rea as described in
Chapter 1I,but if damage or corrosion is so
severe that'a oanel must be renewed. seek
professional advice as soon as possible.
3 Always check that the door and ventilation
ooenina
, - .
drain hdes and oioes are comoletelv
clear, so that water can drain out.
.
4 The wax-based underbody protective
coating should be inspected annually,
preferably just prior to Winter, when the
underbody should be washed down as
thoroughly as possible without disturbing the
protective coating (see Chapter 11. Section 2,
regarding the use of steam cleaners). Any
damase to the coatina shouid be reoaired
bslnga s~1rab.ewax-based sealer. If any of
the booy panes are d stdrbed for repair or
renewal, do not forget to replace the coating
and to Inject wax into door panels, sills and
box sections, to maintam the level of
protection provided by the vehicle
manufacturer.
-
1 Accurate checkina and adiustment of the
heaalight oeams :s only possible using optical
beam setting equipment, and this work shouid
therefore be carried out bv a Renauit dealer or
a garage w'tn the ~ l e c e s s b
facilities.
2 In an emergency, the headlight beams can
be adjusted by tuming .the screws shown (see
illustration).
Front suspension and steering
1 Raise the front of the car and securely
support it on axle stands (see "Jacking and
vehicle support").
 rery 6000 miles IA-IQ
2 Vlsually inspect the balljoint dust covers
and the steerino oear rubber oaiters for solits.
chafingor deteiorahon (seeillustrat~on).' ~ n y
wear of these components will cause loss of
lubricant, together with dirt and water entry,
resulting in rapid deterioration of the bailjoints
or steering gear.
3 On cars with wwer steerino. check the fluid
hoses for chafing or deterioration, and the
Pipe and hose unions for fluid leakage. Also
check for slgns of fiuld leakage under
pressure from the steering gear rubber
gaiters, which would indicate failed fluid seals
wflhin the steering gear.
4 Grasp the roadwheel at the 12 o'clock and gear rubber gaiter
6 o'clock positions, and try to rock it (see
illustroaOn), Very sllght fme play may be felt, around the shock absorber bodv. or from the
rubber galter around the rod. Shobld
but if the movement is aooreciable. further
any fluid oe noticed, the shock absorber is
investigation is neceasa&'to determine the
defective internallv. and should be renewed.
source. Continue rocking the wneei wh:le an
Note: Shock absirbers should always be
assistant deoresses the brake oedal. If the renewed in pairs on the same axle.
movement 1s now eliminated or'significantly
11 The efficiency of the shock aosorber may
reciuced, is likely that the hub bearings are
be checked by bouncing the vehicle at each
at faun. If the tree Mav k still evident w~ththe
corner. Generally speaking, the booy will
brake pedal depr&&, then there is wear in return to its normal position and stop after
thesuspension joints or mountulgs. belna depressed. If it rises and returns on a
5 NOWa m o the roadwheel at the ~3o'clock reb&no; the snocn absorber is prooably
and 3 o'clcik POSitiOns, and try to rock it as suspect. Also examine the shock absorber
Wore. Any movement felt now may agaln be upper and lower mountings for any signs of 1 Where applicable, remove the wheel trims,
Cawed by weer in the hub bearings, or in the wear. and slacken the roadwneel bolts slightly.
W k rod balllolnts. If a balljolnt is worn, the 2 Tighten the bolts to the specifled torque.
Vlsual movement will be obvious. If the Inner uslcg =torque wrencn.
joint ls~ausoect,it can be felt bv olacino a
hand over the stewing gear rubbe; gaiter and
gnpping the track rod. If the wheel is now
mcked, movement will be felt at the inner ioant
it wear has taken olace. 1 With the vehtcle ralsed and securelv
6 Uslng a large icrewdriyer n Rat bar, check sdpported on stands (see 'Jacking an2
tor wear in ihasuswnslon mounting bushes bv veh~clesupport"), turn the steering onro full
leveflno between the relevant &soension lock then slowlv mate the madwheel. lnsoect
compoient and its attachment potni. Some the cond~tioni f the outer constant veidcity
lllQVsmentis to be exF%oted, as the mountinos (CV) loint rubber gaiters while squeezing the
We made of rubber. but excessive wear shouid gaiters to open out the folds (see illustration).
be obvious. Also check the condition of any check for slans of crllckino. sol~ts or
Wa!a tubbar bushes,looking for splits, cracks deterioration oithe r~oberwhiih m i y allow
61Contaminationof the rubber. the grease to escape and lead to water and oper&ng.$p~q&w~:~nu~~i'~gpm!~e.sjg~
% With the Far %ding on Its whesls, have an grit entry cnto the jo~nt.Also check tne security @lass ,@o -tpagt,@ .!h@: filt&dn.ier unit :@e@
kR t??ianttfurm the Seming wheel back and
,; :h Lh.ut:eh 'elgOTb.of a turn each way.
?4BeX3 sM@d@ vm:tittle, if any, lost
~
and conoition of the retaining clips. Repeat
these checks on the inner CV joints. If any
damage or deterioration is found, the gaiters
6 !- . - if?@;,&tjn~~ireaamofbvbmes
i s ~ $ k m ~ c i ~ y level
w t is ibw, and
p m w n % iadmeshould be sought. Do not
b??kwp-th~'sW&ing wheel and should oe renewedas described In Chapter 8.
he&> W W is m t p e case, closely 2 At the same ttme check the general
.
.!-'joipS.and mouniings previously
byt in additionoheck for wear of
ng ~lolunnunivemijoint apd the,

'&~.pW@t.hslront wheels, then jack up the

P
~

01 the car and support it on axle stands

*.bckIng end vehide suppon'l.
,Working as described above for the front
3
@Spenslon, check the rear hub beanngs, the
bospenslon bushes and the shock aosorber
*@ma
&e&.-
for wear.
check
<
-
18.1 ~ h e c ~ n g t cbnditloh
he
driirwhaft out* constant velocity
-
Wme
joint
. ICV)
. ..
' YO Check for aliy signs of fluid leakage rubber gaiter glass (2) with the system i n operation
1A.20 - 6000 miles
Every
a- Check the tenslon and condition of the air
~ ~~ ~
under the car is clear of dirt and debris, and 5 During the Winter period, it Is advlsabie to
conditioning compressor drivebelt. Refer to unblock it if necessary. S milariy, check that run tne air conditioning system 0~CaSi0nally
the auxiliary drivebelt checking proceodre in the condenser ffns are clear, and if necessary (for 10 mlnutes or so once a monrh) n order to
Section 6 of this Chaoter for datalls. remove dirt and debris Lsng a sofr brush or a ensue conect functioning of the compressor
4 Check that the evaporator water drain tube water Jetfrom a garden has;. and distribution of the oil within the system.

Every 12 000 miles (20 000 km)

-

C - r n engine
1 Release the sprlng clips and removethe wing
nut from me mr cleaner cover (see Illustration).
E'tywe ennglnes
2 peho.$s ~h*:f9~~is~rews
horn the top bf the
cover, and reI@.$e~!he spring clip.$ Iseit

212 Air cleaner-cover removal

4 Screws
E-type engine
6 Spring clip
-
illustration).
F3P engines
models
-
BppnoakePair
cleaner new Qe ba-
-' W,l nrr;pIBaner cover
.ne m o v a l
tyi)8 e*, - 5 Screw
3 Remove the five' s&$%~~ i ' o ~ a t i u n d t h e
edge of the a r cleaner cover (see ilustration).
e uzrm$nut Y Sp#ng clip Release the vacdum hose from the cllps on the

~ ~.
218. Unwxewwthe.two air cleaner sewn 'from under the vehicle (see lllustratlons).
-
$~$~~~m&iia@dnaW 6overameW
~l#~~r.
FOP englne wtm.Fpancak$"nlrfiIter. Note
.
weuum .hose;c~li~padtooovgr; .
-
securing screws (awowed) FsP<erngb.
witheir cleaner behind front.wing,p~v,eJ,

cleaner behind front wing panel

 Every 12 000 m.iles 1A.21
F7P (16-valve) engine
- .. I
7 Release the seven spnng dips and remove
tne three screws from the air cleaner housing
(sea Illustration)
All models
8 L i off the aa cleaner cover, or separate the
parts of the housing, as appi~cable.
9 Remove the element from inside the air
cleaner body [see Illustrations).
10 Clean the ~ n s ~ dofethe air cleaner body,
be~nocareful not to oet dlrt Into the Intake
ductr~lt a new finer element.
11 Reht the cover, or reassemble the housing
and secure wlth the screws or wlng nut and housing -FIP (+B-vahre) engine
spring clips.
12 On F3P engine models wlth the air cleaner
behind the left-hand front wlng panel, refit the
elernenvtrav assemblv as follows.
aJ &?endihe two s&tlons of tne tray.
b) $I& the upper secbon of the tray (wth the
element in dace) Info the ancleaner CaSlna.
C) Push the lower rapsmd secuon of the tray
into position, then S B C U ~with lhs cllp.
d Wi9t ihe air cleaner cover, then lower the
mhlcfe to the ground.

21.9b .. .
F3P engine with mircleawr
behimd fmnt wing panel.. .
PI& ...an* F7p~(lbvalve)mane

Renew the spark plugs as described in
Sestlm &of this Chapter.
13 HTW,dkmWtorbap
end rotvr m chsok
Warning; Voltages produced by
an eleetronlc ignition system are
conslderablv higher than those
p m d u w d by conventional systems.
Eatreme cam must be taken when worklng
on the system with the ignition switched
on. Persew wlth surgically-implanted
wldlac pacOrnsKsr davioes should keep
rveN d e a r of the ignition cimits,
components and test equipment.
1 The spark plug HT leaas should be checmd
whenever new spark plugs are inslacledin the
engine.
2 Ensure that the leads are numbered before
removlng them, to avoid confusion when
reflmng (see Illustrations). Pull one HT lead
from its plug by grlpp~ngthe end fitting, not
the lead, otherwise the lead connection may
be fractured.
3 Check Inside the end fltting for signs of
corrosion. which wlll look l ~ k ea white crustv
powaer. scrape odt such deposlts uslng a
small screwdriver. Pusn the end fitting oac6
onto the spark plug, ensunng that R r a tight
fit on the plug. If not, remove the lead agaln
l -
end us8 pllers to carefully crlmp the metal
connector inside the end flttlng untll it flts
5ecuety on the end of the spa* plug.
4 Uslng a oiean rag, wlpe the entire length of
the lead to remove any built-up dlrt and
grease. Once the lead 1s clean, cherA for
burns, cracks and other damage. Do not bend
.
the lead excesslvelv or .oull the lead lencith-
- burned or loose contats. Shnilariy Inspect
wise - the conductor insioe mignt break.
5 Disconnect tne other end of the lead horn
the distrib~torcap. Again, p~ oniy on the end
fltting. Cneck for conosion an0 a t~ghtfit in the
same manner as the spark plug end. ~f an
ohmmeter 1s available, check the continuttyof
the HT lead bv connecting the meter between
the spark piug ena of-the eao and the
segment tnsioe the distrloLtor cap. (Resistive
leads are commonly fined, giving an
ohmmeter reading of several nundred or
tho~sandohms per lead.) Refir the lead
securely on comolel~on.
6 Check the remalnlng HT leads one at a
time, in the same way.
7 If new HT leads are required, pumhase a
I
m.Za HT lead connection diagram
C-lype engine only
set for your specific vehicle and englne.
8 Remove the distributor cap. wipeit clean
and carefully inspect itinsidmd out for slgns
of cracks, carbon tracks (hacKing)snd Warn,
the rotor arm. Renew these components if any
defects are fmnd (see Chapter 58 or 5C). It .s
common practice to renew the cap and rotor
a m wheneyer new HTJeads are fitted. When
fittlng a new cap, remove the H l leads from
the old cap one at a t~me,and fit them to the
new cao In the B x B s t m e Iocafipn - do not
simultaneously remove all the leads from the
old cap, or fvrlng-order confusion mayaccur.
9 Even wdh the igniLon system in first-class
conddion, some engines may slill occasionally
experience poor starting, attr outable to oamp
ignition components; a spray sealing coal to
exclude rQalsturefrom the ignition system wlll
help to st@ a car when only a very poor spark
occurs.
.
23- HT lead connectiop diagram -
all other engines
 ? Listen for a m @DBuaLnoim f r m the
engfne, clutch a6d 1riifi&8@h,~
8 Make sure that the. ~glqe.runssmoothly
wnen idlina, and that ther8iPno hesltatlon
when ad%tqti"K., ~ .
9 Che~k that @hef@!p$ll@bh, the c l w h
actiw is ,smmtti , p d g~OgresesVe, that ihe
drive l ~ t a w n ~ , ~ m pLdiif:'%'pqdd ~ ~ g @ 14 Check that there k
travel la not 'k&$$5i@i ~l$a.l.@tenfor$ny
nol.,w&n thsi ~r&@h&~rs~d@&
lo Chedb ,&hi% a/l ' p t B,W,Me ?&q&ed wrrwtly, wifhout excesalye m y m m t
smopl!ii, ,gltfi$g ogtce, gI?d ifitlbl, @B gear Isver, and that it holds the vehidastag
lm a&i$n 8 not-abnormaiiy vague or on a slope.
"not@hV. 16 Test the operation of the
11 On autotMtllctransmissten mod&, make
sure.,t&t &I gearchenges occur smoothly,
wi@$at@naWling, and wlthout anincrease h
an@Ns:+wd Detween ch@giesO . heck tnift
@@'ftr& g@%&$~fig#&dan ~. & ,s$l,*.q,$Q
*-.
@%d&@fi&::w.:~f
; ~

egv .pr@iem ais @R$

key&~wi$,&d to s Renauk deder.
12 sten en fofa kieiql~~c cllcking soLnd from
the fbnt d ~ ~ v e h l c l e . . at
ks vehiile is driven
Jlowlv in a'hrale wah the'steefirm on full-lock
691:d60t €fi&&iii~%in 66th d$ed~ons.If a
@ ~ ~ R i ~ pheiird,~ ~ thisf p lndic~tes
B ~ ~ wear h a
drlvegha%~&m(cieeChapter 8).

#- ~ _---
I
3 .---
'
i
6 2-.-.--
....
. -0--0 ~.-.-
-
.s
(58 000 km) .
direct f m m the outsloe
~ ~~~ -.-. of.. the enaine
26 A
ri cleaner air te
I compartment (cold a.r), and the omer from a
~ dthe exhaust manifold (warm aid. A
~ h r 0 on
.UI&mip'ule t8iemmtat entrok-iflap l r i l ~ e
,h;cr:aW.Cl'eaner:ittlet,either dlrectly.or undeijke
influenoe dfiavacuum capsule. When the
ambient air temswmtofe is belo* Kre'
IpMatBrmiwd ~evei,the flap directd warm dr
fr0hthe eXhauat manifold shroud. AS %ha
temPerarure of the lncomino lambleM) Mr
rises, me Rap opens to admm-&itlev air b m
OUZSidetWekeoap wnfl1,eventuaIly It Isfuilyopm,
Wifi~,
ori which the fuel Inleetion i m 3 The temprature con0roi sysbw Qt8ad.W
for manges in air temperature.) each type of engine i s sho\Nn .in Zhe
2 m e r has two sources QT ar, one accompinying Illustrations laesiltuatretlona)~
- , ;
4 l e t r g l ne
~m~ pt . . .. ..
4 To tast the smtem m o x e . ~ e a ~ & e a k l w
b o q as desc&ed in. the:rgte~qpk'&6
Chapter 4. d~t8Eb.the temp8c&lie.@@mhL
mit, and immerse .it . ln-.&S&w&e~

. . .
FiWaw&.e

A Coldalrlnlet D 76 ~ w r e [ f o r
B Hot-airinlet i ~ha~irorjiat vacu&~psule:In tha a@4wner Inlet shuts
C Comrnlffap off the cold air'hrleta@mperetures beow - 3 Rirlntake cover
 w D&I ekthwnosatievawurn valve
l~.**&cm
"'-
.. ',.$, Ppm~rilet
manifold
1.;
+c!g&@tIe
. @<rneiw~ic
.D strip
~di-ema@d sptem, but place the unitin
,&@wma1:Wlow
. temperature operation
wlgsfrgtlpn); Warm the unit gently @or
:w.Bb a, hairdryer) to check .high
t e ~ n q p & operat@:
&Tp-t@_ ZpwE$eratih oftiietherm&t&ic
.*j a a ' ~ i $ & t I a e i hfiom .thwniipibld
@&e?wslue. (Connect:a len* of MaSmC
..ty~!@hen:b,?tw~WveIw~and~.s~~k!thmqh, L&iI and me homo m&an/c +IC&
t@&se, o r ~ ~ r J l y v r t ~ u mB~haMwAlp
~sl~g advised' io takefhe ciy to a Renhult derUei M
# i
&$ebilst-rS,t ,'y@ue,:tsmpe~gWw~~eIbw have the w&?k'&e&out. On ail ivpes' of
, ~ ~ ~ ~ l l ~ ~ . & i . ~ a w m ~ 8 h 9 v J l d ~ n ~ W ~ automtic trsnsmlssion, take ~ g r e a ci& d i o
-.:>A .-. +.'*..'.., 1 ..r. , .-->,Xi; InbodLcedirt hto Hiet?&i&sslon.
1 ~h&aljQmatlb hahsmission fluid ihouid
n
i 13b
' pL3a
- ~ .-' -
fio&,
-~
"whm,&fbb
-*~-
2 Position tha car over an inspection pit, on
cal ramis, &lackit u P h t make sure that n
is level.
dangerous and .l(o&frrq,liquid, and the9 Place a s u i t a b l e ~ l h w b h e a t hhidraln
-@lug6n thb tran&iSd6hk@&pCu~W
preo~ut@ns@ccp~&d.when handling.li theddin ~~ila'dndW lll6'~ td&rr(*

t 26.1 Typical in-line fuel fi

clamp
 check that the operating levers on the rear
brake trailing she* return to thelr correct
positions, wim their stoppeas in contact with
iheedge o f the @iiilin$&jve$.
V Wtth the aid'df&.Wlsfent, tighten the
1 Chock fhe front wheels! ahen jack up tne adjuster nut on @@IkWt@@iever operating
rear of the vehica and support it on axle md so that the lever &@ph :rear brake
stands ( s e ~%wingand &j@@wrpportn). assembty starts to move.as,@ehandbrake is
Remavefbe
. - - ~~rear roadwheds.~
~ ~
moved between thefirsf and Sewnd notch
2 For a gvck c w , !be thlckhess of friction lolick) of its ratchet mechantsin. This is the
mateMl%imaini!$%n.eT~bnake wid can oe case when the stop-pegs a& still in contact
m e w M th&i the ap&% nthe caliper wlth the shoes when the hanabrake is on the
body. If any wd%'fiict$'JIni ai is worn to first notch of the ratchet, but no lonaer
the smified thickness o r l s' a l i four pads contact the shoes when the nandbrake ison
mustbe renewed as a set. the second notch. Once the adjustment is
3 For a comprehensive check, the brake pads conect, hold the adjuster nut and seoureiy
should be removed and cleaned. This will tiohten %heloclulut. ~-~ ~~ Where
- - necessaiv,. refit
- .~~
the-
allow the operatloo of the oalioer to be c a ~ c o c n v m heat shield retalnlng nuts.
.. cheeked, ana the brake osc it& to be fully 9 Reffnhe brake drums aa dbsolibedin Chap
.$2:&&a&@~.the wi,ring hamess. ~ , u n i ! g examinedior andition onbbth stdes. Referto ter 9,then lowerthev6hicie to the around.
Chapter 9 for furth&~~lilennation 10 With the vehicle standing ~ " i t sw W s ,
d&s the automatic transmission knd
repeatedly dedress the footbrake to adiusl
the shoe-&d&m-~l.earancQ~ W i @ step<&-
ing the pedal, havd,idnassistaetlisten to the
rear d r u m t~ahgolc 4juster.srmf
mechanism t@.furm~l@b&; If 4ht.s sm ,a
clicMng sound 'Wl'l'1-lWghwdinipn *e
'

1m e hwatsmke ~ h o u l dbe capable of adjuster strut as the pararil Is m-..

holdlna the o a e d vehicle m t l o n ~ ~ w
even
. on
steep8io&, when applied with 'moderate
force The mech&@ ,$hould be flrm and 11 Checn that the handbrake c f i elide ~
~ uunscrew
, (butdonot Dositlve in feel, no Uhce of stiffness or freely by pulling on their hontmds: sndchesk
.q.wflngthe.rear w i n e iponginess from the cables, and shoula that the operating levers on 4herear bake
ggnde@@y. U n y m and release imlnediateiy the handbrake .ever is calioels move sm&hk.
bolt, and swivel the link released. if the'mechanism is faurn/ in anv of
*fi@s'e' 'f&pe&$;. !i* m* t.*e''
theautomati0 twnsmission as far as ? m W ~ ~ ' f d l l bk&ieGa ~ $ . ~od&%&h
FbC. rear drwh+*b~s,.Yf: ?hi4 hanHbmke !s ' ~ 5 1
.iWWlt the pan hnm the bottom ofthe
mcw~Si-Si~ m k s b ~ o TOWM@ tis 9dfi6
tM@~Mion,:,md r h o v e the gasket. the r~rr'Me~SeIf-a&sZ mb&&&m. IGUP
,igJ$~bslt$he filter and its seal (see lunctlou. This willleadtirthe'brak~peda%
,b-eM) eiw .' l @l
Illu~n)). .as the shoe Nnlhpsw w .
l&:Clw fhe,$xnand the sediment magnet UZider no circYmS&tii*es should me'h@~@
hYyn/ne.the ban g,asket and the dran and ca$leh be tighfsned X n an ht@tB@t R,
@&rlg*p plugs, and renew them if
.cornensam b'xcesive b* I%&/ trav~l,'
ndi%&y. T 2 chock the front wheels and release the
14 Fn,the..n@w fliter together with its@&:and handbrake. Jack up the rear of the vepi*ed
tiahten the bolts. support it on axle stands (see "Jack,ng and
15 Flt the pan together with a new gasket, vehicle support7. On models with a catalylic
converter, Lndo the heat sMe~drekdghg hut@)
and lower the rear of the heat stiiyl'd tdgain
access to the handbrake cable adjuster'ndt
9. S acken me locknut, then tul9 sleckep.me
&!ee.adjuster nut (seelustra&on). -. ,

6r sirgt;& freeto t@C& 1ti bath

Jf b b.@rn,,;$h!+bW6ah06 and
'mwa;t be:Mmoved and overhauled as

t : $ i H . l nSdim 1abt:~a)xter9.
'%d1~k.~9@i/W @ff fkf#~~#fifW h M bV
,h,p~siur Wtp+M the c%rn&eter &+he
bRI@3hoas.iss1iMWr~uced.
7 Check that tne handorake cables slide Gth new Rhld, and continue pdmpmg Lntil
freely by pulling on their front ends. Also only the new Ruid r e m h in the reservoir and
 new fluidcenbe seen emerging from'the bleed

Warn&: Wait unfllfha engine is expawion tankand slowly unscrew the cap. tha tags together wifhpliers.
Cold, befa* sefiing *Is om- Wait until all pressure has escaped, then 4 Move the &ntalnerbeneath the cylinder
ceduea, @ D b n o k w ~ M e e r eto remove the cap. block drain plug, On the C1ty~eengine, the

II
 1A.26 Every 2 years ,

@Aa Coolant drain plug (6)on the rear of
1 -
lho eyllndar blook E-type engine
&%in plug is located on the crankshaft pulley
into the wntainer.
d Flush the system if necessary as described
In the following paragraphs, then refit the
..&$4 plug and secure the bottom hose. Use a
nauyih.~?clip if necessaly. Refill the system
r&&cribed later in this Section.
mr
n flushing
7 With time, the cooling system may
Pratruallv lose its efficiencv if the radiator
matrix becomes choKed w~ h; rLst and scale
deposits. If thfs is the'case, the system must
be flushed as fo lows. First drain the coolant
as already described.
8 Loosen the clip and disconnect the top hose
fmm the radiator. Insert a garden hose in the
radiator top hose connection stub, and allow expansion tank untll the coolant i s at the
the water to circulate through the radiator until maximum level.
it runs clear from the bottom outlet. 16 Start the engine and run It at 1500 rpm (ie
9 To flush the engine and the remainder of a fast Idle s p w for approximately 4 minutes.
the system, disconnect the top hose at the Keep the expansion tank topped-up to the
water pump on the C-type engine, or remove max4mumlevel during this period.
the thermostat as described in Chapter 3 on 17 Refit the pressure cap to the expansion
the other engines. insert the garden hose, and tank, and run the enoine at 1500 rpm for
allow the water to circulate through the engine approximately 10 minites untll the electrlc
until it runs clear from the bottom hose. cooling fan cuts in. During this pNiod, the
10 In severe cases of contamination, the coolant will circ~latearound the engine and
radiator shouid be reverse-flushed.To do this, any remaining alr will be purged to the
first remove it from the car, as described in expansion tank.
Chapter 3, invert it and insert a hose in the 18 Switch off the engrne and allow it to cwl.
bottom outlet. Continue flushina until clear then check the coolant levei as described
water runs from the too hose outlit earlier and top-up if necessaly.
11 if, after a reasonable perlod, the water still
does not run clear, the radrator should be AnWreeze mixtwe
flushed with a good proprietary cleaning 19 The antmeeze shouid always be renewed
system. at the SDecifled intervals. This is necessaw
12 Regular renewal of the antifreeze mixture not only'to marntain the antiiwze
as s~ecified should Drevent severe but also to prevent corrosion which would
contamination of tne system; Note that as the otherwise occur as the corrosion Inhibitors
raoiator is made of alLmlnium, it 1s important become progressively less effective.
not to use Caustic soda or alkaline compounds 20 Always use an ethylene-glycol based
to clean t . See Chapter 3 for more details. antifreeze wh~cnis suitable for use in mixed-
metal cooling systems. The proportion of -
Filling antifreeze and levels of protection afforded
13 Refit the cyllnder block dram plug, are indicated in the Specifications
radiator bottom hose and anv other hoses 21 Before adding antifreeze, the cooling
removed if the system has just been llusned. system should be completely drained,
14 Open the coolant bleed screws. On tne C- preferably flushed, and all hoses checked for
type engine, there are three bleed screws - condition and security.
one each on the heater supply and return 22 After filling with the correct watery
hoses, and one in the top hose next to the antifreeze mixture, a label should be attached
thermostat. On the other engines, there is only to the radiator or exnansion tank statino the
one, situated on one side of the radiator type and concerntion of antifreeze u&"&
towards the top (see illustration). the date installed. Any subsequent topping-up
16 Pour the appropriate mixture of water and should be made with the same tvoe and
antifreeze into the expansion tank, and close concentration of antifrwze.
..
each bleed screw in turn as soon as a 23 Do not use engine antifreeze in the screen
continuous flow of bubble-free coolant can be washer sy-*, %it will cay- damage to the
seen flowing from it. Continue to fill the vehicle @ntwork.

. .,,.j, 1 <;
. ,
~.

..
,
::8 , .- < .. .
. .
.,
, h i 4
.--. .A
- . .
36Ab Coolant drain plug (mowed) on the 36.14 Open the bleed screw (arrowed) o r
' . .

'
-
gcylintir block F-type englnes
' ~ n B ~ ~ W m n o vfore clarity)
d
the radiator when refilling the cooling
system
.:*-, ,.
 Chapter I Part B:
Routine maintenance and servicing .
"Phase 3" models (models from May 1996)
Contents
Air filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Handbrakeadjustment check ..............................26
Automatic transmission fluid and filter renewal ................. 24 Headlight beam alignment check ........................... 14
Automatic transmission fluid level check ..................... 4 .and air conditioning
Heating .system
. ...................
check 18
Auxiliary drivebelt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hinge and lock lubrication .................................30
Bodywork and underbody condition check . . . . . . . . . . . . . . . . . . . . 13 ..................
HT lead. distributor cap and rotor arm cheek 21
Brake fluid renewal ...................................... 27 Intensive maintenance .................................... 2
Clutchoperationcheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Manual gearbox oil level check ............................. 31
Coolant renewal ......................................... 33 Rearbrakepadanddisccheck ............................. 12
Driveshaflgaitercheck ...................................16 Rear brake shoe and drum check........................... 25
Engine oil and filter renewal ................................ 3 Roadtest .............................................. 22
Exhaustgasemissionscheck .............................. 8 Seatbeltcheck .........................................29
Exhaustsystemcheck .................................... 10 Sparkplugcheck ........................................ 7
Fluid leak check ......................................... 5 Spark plug renewal ......................................20
Front brake pad and d!sc check . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Steering and suspension component check ................... 15
Front wneel alignment cneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . Timing belt renewal .....................................- 3 2
Fuel filter renewal ........................................ 23 Wheel bolt tightness check ................. 17
General infonnatlon ...................................... 1

] Degrees of difficulty
 1B.2 Servicing specifications - "Phase 3"

i
Note: Refer to "Englne identification" on page REF-4 for details of engine identification.
Lubricants and fluids
Refer to "Weekly checks*
Capacities
Engine oil
Excluding oil filter:
D-type engine ........ ............... 4.0 litres
1171 cc E-typeengines ..... .................... 3.5 litres
1390 cc E-type engines ..... .................... 3.5 lit re^
F3P engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 iitres
R P (16-valve) engine:
Engineswith steel sump ................................. 3.5 iitres
Engines with aluminium sump ............................ 4.2 litres
Including oil filter:
Ail engines except F7P (16-valve) ............................ 0.5 litre
F7P (16-valve) engine ..................................... 0.2 litre
Differencebetween "MAX" and 'MIN" dipstick marks:
D-type engine ........................................... 2.0 litres
E-type engines ....................;..................... 1.5 liires
F3P engines ............................................. 2.0 iitres
F7P (16-valve) engine:
Engines fitted with blue marked dipstick .................... 1.1 litres ., .
,, .
All other engines ....................................... 0.6 litre . .
Coollng system
.D-typeengine
- .............................................. 5.0 litres -;
.@,wff
engines ............................................. 6.2 iitres ..
>F@engities ;-............................................. 6.4iltres
r w g - v a l v e ) engine ..........................................7.0 litres
Wl@tnk
................................. 43 litres
MI m@lsexcept "16-valve*
"1:6-valve"m.odeis ........... - ............................. 50 iitres
Manual geaaox
Four-speed:
. . ',Ffl
,?
>.
. .
;.:.:
JBO .................................. ............. 3.25 litres
.
,,.,,g., ....... 2.75 iitres
jsl,....................................
Fivewspeed:
;<.
JE3zgdJB3 ................................ :............. 9.4litres
J85 ..............................................
~. .. .. : ; 2.8 litres .

Automatle transmissfon
- .... .. -.
_ _.?. .:
Main s m o n : , ..
. 22, . 9.'-:.%?
Totd:aapacity ...........................................
5.7 litres :: . * .- -....
Drahhr*ld
.<. retlll ........................................... 3.5 iitres .* . 2. .
;.
.
Fir@l#fi#~.ssdan ...........................................
1.O iitre .
. .
.
. I I

R o w w @ ~ . d s t e e r i n rewrvoir
g
:.
.,~. . .I_
4..

M$~,$$.@t~nt~tiicalpump.. ..............................
1.1 litres ' . . . ~.
~odel$ with eleario.pump ................................... 0.7 litte . . . ..
. .
~
-

~- .\
v,

, . Zl'.
1
.- . I
 Servicing specifications - "Phase 3" m.3

Engine
Oil filter type:
D-type engine ......i ......,......:.........: .................. Champion F124 ..
E-type engines
F3P engines
........:. ....................................
...
>

..................................................
Champion F103 . . .*"
Champion F103 ..... -'r;E+
" "
' .
F7P (16-valve) engines .. >........................... .!....... Champion F120 .
; ..
.'. .4. ?
.'. ::
Cooling system
~ntifreez*mrxture:
.............................................
Protection to -23°C
Protection to -40'C ; .
................ ..., ,: .. *, ........... :.+

Fuel system . .. . . . .I
Air cleaner element type: .-A,-
.....C .... . '

............................... I,,; ......, . .......... Cham~iontvDe not a v d

+
D-type engine
E-type engines ..................... ,..,, , , , : ~ + . ~ ? r ..:i,~......
~
F3P engines ........., ..........,.i.. .:....,,..-...
. -,... ...........
............. .......................................
,
.
F7P (16-valve) engine
,
Fuel filter element type:
...... ... . . . ;-........ ;....~.........
All except D-type engines
....................;. ...,. ...... ...... ....#.
2. i,; i,;.i 5.:
D-type engines ....
., .
..i i.
Idle speed ........................<,., ........,-:,. ;r,. ............. Not adjustable ,
-.

....*~,........
:Idle mixture (CO content) ~~

. :... ...... %* .*,. . .'.,-.

. . . . . :;.
.$
; ~
.$ .:s. *..... 0.5 % maximum @d
, .:,7'?
jgnition system
Firing order ...............................................
.. ... ....,
Location of No 1 cylinder ..... <.. ,....; ......... .......
.$.... Flywheel end
Ignition timing ..................; .':. ... .. . ....%
2. . ~ . i
, :i 2 .; . ... .:.
:.~. Not adjustable ( @ m y - c q l r o U e d )
Spark piugs:
Type:
D-type engine .....................................,. ... Champion RC9YCC
E-type engines .......................................... Champion RC9YCC
F3P engines .......................... .................. Champion RN9YCC .
..........
~

1764 cc (WP) engine ................... ..,.;a. 2 . ; Champion RC7BMC . -

Electrode gap ............................................. 0.80 t 0.05 mm . . ,.., .
8

Braking'system . . . .... . ,.. . -.

Friction lining minimum thickness: 4..
.*. ..
&,t; . -
Front brake pad (including bactdng plate) !

Rear brake pad (including backing plate) ..............

Rear brake shoe (including shoe)
+j....!2:.a.:

,,.... ,. ........
....,.......................... &.,...
..., 6.0 mm
511 mm
2.5,mm
.. '.,I .
. .<<...
Wiper blades fi
Windscreen ............................; ... ,. ,.,; ,,;.. ... ..: ....
Tailgate .................................................. 4Y :.,:I.
Torque wrench settings Nrn I
Engine sump drain plug ................. ................ . 15 to 25 . . .
; 2 .. ~,... ;i.
s p a piugs:
Taper seat plugs ......... ...........................................
: 15 to 20 .- I
Plugs with sealing washer .....................:.............
,v:17:. 24 to 30
.....,...............................
Automatic transmission gauze filter
Automatic transmission sump pan .................................
Roadwheelbolts ...........................................
5
~. 10 ...
90 66
i
.,
_ .1 i
 The maintenance intervals In this manual
are provlded with the ass~mptionthat yo^,
Whhe dmlef; WMl ha carrying out the work.
Thwm are the minlmum maintenance #ntervals
feeommended by ds for vehiies dr:ven dally.
IPpSM.1.<%@3#tokeep y@Urvehicle Ini Peak
,&#Win a$ XtI trines, yQ$ figy ~ i i 'to h
, ,
perform some of these procedures more
often. We encourage freqdent maintenance,
because it enhances the efficlencv.
performance and'reale value of your venide.
Ifthe vehicle IS driven in dusty areas, used
to tqw e%Jr&er, 'or@rivenfrequently at slow
saeeds (idling in traffic) 6r on short jomeys,
more frequent maintenance intervals are
recommended.
When the vehicle is new. it shauld be
,
serviced by a factory-authorised oealer
service department, in order to preserve the
factoy warranty
1 Suspension stmt upper
rnrnrni@
2 Jaek location
3 W e fluldrsse~;yolr~ ..
4 Air cleaner:cover ..
5 msenscr
w ~ I y
B <apn~efeflOok
7
8
,.-.- " " , '. 2
9 .Minm&&swa'tch
10 Mme
qmpter - :
fa '&&g W.',,
lg @t@?nqg&iue&wind .
13 C g o l f @ c ~ o t q ~ . .,
14 POywBe.@&~&fluid ..:
.@3s@volr
16 ~ l w ; l l e ~ l d i p ~: %k
Mf Altenwior
H
EB
.Pow:mwpwmp
W n e - o i lBIlar cap
...>
.

'ol%@imIB@ @nition)
m0duIct

I Wb&an:h.spIas_h shield
2 Svmp.dmin.plu@
3 Beke dim
leas Maintenance - component location

Underbannet view of F3P (17g4 ccl multi-ooint fuel iniection engine model
VINplate
Suspensionstrut upper
mounting
Jack location
MAPsensor
Idle speed control wve
Coolant wansbn tank
Washerfluid w o i r
fbcafb3l
Ignitton coil
Automatic @h#miSgion
oornputer
I Relay box

Battery negattve tennhal '

Cbofing fan maor
DisMutor cap
Power steerfng fluid '
resewair
. Engine 011 level dipsfl& '
Rlternatw
Engine oil filler cap
I I

Fuel fi/ter
&el injecttion type)
Heat shield
Foe1 fwh
h%ndb.wkeWES
&-st pipe
Tofs'ionLxv
T W n g em
Exhaust rear silencer
Brake presswe-reguklh,
load-sen9tive valve
Rear crossmember
Anti-roll bar
Fuel filler pipe
Brake caliper
Shockabso&er
M S wheel sensor w/d&
connectm

1 This Chapter is designed to help the home
mechanic maintain hisiher vehicle fa? safety,
economy, lang life and peak performance.
2 m e Chapter contains a master
maintenance sohedule, followed by Sections
dealing specifically wjfh each task in the
schedule. Visual checks, adjustments,
component renewal and other helpful items
are included. Refer to the accompanying
illustrations of the engine compartment and
the underside of the vehicle for the locations
of the various components.
3 Servicing your vehicle in accordance with
the mileageltime maintenance schedule and
the follow-ng Sectsons w~llprov de a planneo
maintenance programme, wh cn s h o ~ l dresLt
in a long and reltable service l~fe.Th.s is a
comprehensive plan, so malnta~nlngsome
items but not others at the specified service
~ntervals,will not producethe same results.
4 As you sarvlce your vehlcle, you will
discover that many of the procedures can -
and should -be grouped together, because of
the particular procedure being performed, or
because of the proximity of two otherwlse-
unrelated components to one another. For
example, d the vehlcle is ra~sedfor any
reason, the exhaust can be inspected at the
Same tlme as the suspension and steerlng
components.
Evew 1'0000 miles (16 000 km) or 6 months
from poss~bleskin lrrltants and other harmful
centamlnants In used englne olis, it is
Maintenance ~rocedures18.7
and tools required. If a problem 1s
encountered, seek advlce from a parts
specialist, or a dealer servied department.
1 If, from the time the veh~cie1s new, the
routlne maintenance schedule is followed
closely, and frequent checks are made of fluld
levels and high-wear items, as suggested
throughout this manual, the engine will be
.-
keDt In relatlvelv oood runnino condltlon. and
the need for aoa t onal word v". be minimsea.
2 11 is possib e that there w~ilDe times when
the eng ne is running poor Y due ro the lac6 of
regular maihtenmce.~hisiseven more likely
if a used vehicle, which has not received
regular and frequent maintenance checks, is
purchased. In such cases, additional work
may need to be carried out, outside of the
regular maintenance intervals.
3 If engine wear is suspected, a compression
test (refer to Chapter 2A. 2B, 2C and 2D as
applicable) will provide valuable information
regarding the overall performance of the main
internal components. Such a test can be used
as a basis to decide on the extent of the work
to be carried out. If, for example, a
axle stands (see "Jack~ng and veh~cle releases fmm the threads, move it away sharply
support"). Wh~chevermethod is chosen, make so the stream of 011issuing from the sump runs
sure that the car remains as level as possible, into the contamer, not up your sleeve!
to enable the oli to drain fully.
2 Removethe oli filler cap from the valve cover.
then positlon a sudable contalner beneath the
sump. Clean the dra~nplug and the area around
3.1 Tools and materials necessaryfor the
engine oil change and filter renewal
extensive overnaL worn is caned o ~first.
i
4 The fo.lowlng senes of operar.ons are those
most othen required to improve the perfor-
mange ofr generally 'poor-running engine:
P F i m q oparatfons
a) Clean, Insped and test the baltery (refer
to "Weakly checks").
b) C h e k all the eng~ne-relatedfluids (refer
to%m Checks").
cJ Check the mridltion and tensron of the
auxiliary drivebelt (Section 6).
dl Renew the spa& plugs (Section 7).
eJ Check the condition of the air f l k , and
renew if necessarv
~~~~~~
.--~~
,lSsction 191
~
f ) Renew the fuel filter (Section 23).
g, ChecK the condrbon of a!l h m s , ma
check for fluia leaks 19ection5).
5 if t h r above ~ ~ e r a t i a ;noi:p.rove
l ~ . ~ ~ fully
effective, carry out the foilowjne $ $ h @ r r r y
operations:
opewons
All Items listed under "Primary operations'.
plus the following:
a) Check the charging system (refer ta
Chapter5P).
b) Check the ignition system (refer to
Chapter 5C).
c) Check the fuel system (refer to the
relevantPartofChapter4).
.
3.2a Engine sump drain plug IeoeUon (1)
all except F7P (ISvahre] englnes
-
 18.8 Every 10 000 miles
3.2b Ennins sump drain plug location ( I ) - u m e w the sump>Mnplug
- n P [lkvahre)sngine
3 Allow 'some time for the ald oll to drain,
noking that it may be necessary to reposition
the c m i n e r as the d l flow stows to a trickle.
4 Afler all the ail has drained, wipe off the
drbin plug with a clean rag and renew its
sealing washer. Clean the area around the
draln plug owning, then refit and tl~htenthe
plug to'the specifid torque setting.
5 Move the container into position under the
oil filter, located on the front of the cylinder
Mock on all except D-type engines, or at the
w.timIng belt end comer of the englne on D-
type engines.
6 On the F7P (16-valve) engine there 1s only
llrnited room between the subframe and the
sump, and it js very difficult to tealeach up to the
oil Blter. However, it is possible to gain'access
' thrwgh this space, and it is not necessary to
remove any body or engine companents.
Note that the 011 fllter on F7P (16-valve)
engin- Is mounted on an ofl woler.
7 Using an oil filter removal tool, slacken the
filter hitially (on the F7?/1 &valve mglne, tty to
unscrew the filter by hand first). Loosely wrap
m e mgs<aroundthe oil f i b , then unscrew R
mqd immediately position it with its open and
uppermost to prevent further spillage of oil.
bmove the oll filter from the engine wmpartm-
ent and emp& fhs oil into the container.
8 U%,a clean rag to mmwe all oil, dirt: and
sludge from the filter seating area on the
4.5 Automatic bansmlssion fluid filler W e
(D)and vent
3.2~~&i~'ttieqm&l Mitiplqg key to
engine. Check the old fher to make sum that
the rubber sealing ring hasn't stuck to the
engine. If it has, d l l y remove It.
9 AppIy a light coating of clean oil to the
sealing ring on the new Alter, than screw k into
position on the engine (see iliustration).
Tighten the filter Rmlly by hand only - do not
use any tools, Wipe clean the exterior of the
oil filter.
10 Remove the old oil and all tools from
under the mr,then Ff applicable) lower thecar
to the ground.
11 Fill the enginB with the speclfied quantity
and grade of oil, as described in "Weekly
checks". Poyr the oil in slowly, otherwise it
may overflow from the top of the valvs cover.
Check that the oil level is up to the maximum
mark on the dipstick, then refit and tighten the
oil filler cap.
12 Start the engine and run it far a fevv
mlnutes, checking that there are no leaks
around Iheail filter seal and the sump drain
plug. Note that wken the engine Is first
etaited, there will be a delay of a few m r r d s
before the oil pressure warnlng light gaes aut
while the new filter fills with oil. Do nd race
tlie engine while the warning IlgMis on.
13 Switch off the engine and wait a few
minutes for the all to ssettle in the sumo mce-
--.r -
more. With the new oil circulated and the filter
now cornpl&ely full, recheck the l e v ~on l the
I Final drive
4.8 Automatic transmissionfinal drive oil
level plug (Cl
L
3.d NPbW
a Mgh- - --- ,-. .- !n oil To
Zhet&@liigring before fming the new oil
filter
d'pdti&and add more oil if n m s a r y .
14 biii;&ed ttve wed engine dl safely with
M+r$cq to 'Ger~pdrepair p m d u m n ' - i n
thcs:Ref&e'Won oF9Ms manual.
: fluid l e ~c&$M*
N ~ t e The l p r
ow u r
n 'w
the aufgmatic fransmisslon is pweul
~ i n @ i ~ 8 . f @and 3
, the home m h a n i q w o i :
be well advised ta t a k the car to. a '~&&$jlf
d&Ier to have ttte work c . out, a$.@
test equlpnient is newssaw ta wrj. @,.J.J
check. However, the followin@prom&@ ! s
given for those who m y f i @ v qc5pss
~ @,jQ,k
equipment Note Mat the final dtfw ~7,bkp!?
not .cfi~ckedas a routine d n t m task ~ #
A is smkd for life.
Main ' ~ m i s ' i o d . L
IFirst add 0.5 litre dihespecifierd>flPIJdt p h
Wmsmlssion by femovlp t b xenf from,*
l ~ ofp thr!filler t u b and ii@ng a dean fun@
with she-mesh filter. RaW theven%
Position the car on a ramp; or JEIckitIrp.,@
support on axle stands (see "Ja~king'mrJ
3..Cbnne$t the RemuR XW5 t& m@f"qIb
diagnostic socket, and enter *dO'P fben
n u m b "04". 'm,
With themlector lever in
run the engine at idle s p b d until the
temperature reaches 60°C.
4 With the engine still running, unscrew the
topping-up plug on the transmisalon: Allow
the excess fluld to run out into a callbrata
wnhlnw for 20 seconds, then ref~tthe pl.ug.
The amount oT fluid should be more than 0.1
Hre; If It is not, the fluid level in the
transmission is i n c o r n .
6 If fluid is to be added, pour 1 litre of the
specified fluid thmugh the filIer tub@after
removing the w n t (seeiHustmtion).AIIoV the
transmission to cool down. then repeat the
checking procedure again as described In the
previous paragraphs.
6 This Is not a routine operatbn, but It may be
considered necessary if there is reason to
 -Every 10 000 m i l s j,~r
that the oll level Is inoorre+
If Mwe has b m an oit leak.
the oar on ramps, or j e k H u
'&,+la stands (see ' J a ~ k i t ? ~

e$naj*drive ~ e v d
$ua-lk&@d
ht-hand driveshafi on the rl ht-
of g+ jransmis- iii

the ~ev&$the oil IS u

plug hole. Ifnot, Inject
$orrect grad@into the hole until it ~ e r f l o w ~ n ~ *
10 Wlpa clean the level plug,-then reflt 'and
tlghten it.
-q1 Lower the cat to the ground. hoses, c&*e$ Ilnes* and a e
r damage. Pay
paiti~ularatteniron to the vant plpbs and
ham, which oftan loop up around ,the flller
I A ksak in #e cooffng system wilt
s h w up as whi#e- w rwf-whWr
-iis on the a m m k r g the bak '1
neck and can become blocked ar crimped.
Follow the lines to the front of the vehicle,
carefully inppectingthem all the way. Renew notlna that it ma$ @ h e e m r y to dlill out the
1 damaged sections as neeBssm. Similarly, sacurhg bets &I c.&n models.
,k$t$uatly Inspect the engine joint faces, whllsf the yehide is raised, take the 3 Check the driveb@ltfa)'FT ~'radks,splitting,
p@teand a d s far any signs of water or prl opp~rtunltyt o insgect,all ynilderhpdy brake kaylng or damage, whirst rotamng the
gab Pay panicular attention to the areas fluid pipei'and h&&, '
h u n d t!w valve cover, cylinder head, oil f i k v 7 From M i f n tfi$"~ic$nb '&k$%rtinent,
crankshafk clocllwise using p yitable spanner
applied to the crankshaft pulley bolt, so that
:&hd sump jolnt races. Bear in mlnd that, o w a'f?~ckth~6&curity of all fuel, vmuurn and the enllre length of each belt is -mined {see
a period of time, some very slight seepage brake how atta&h~wltaand pips unions, and Illustration). Check also for signs of glazing
hrn these areas Is to be expected - what you inspect a i l _ b q f ~ kln,k, r chafing and (shiny patches) and for separation of h e belt
@e really looking for is any indication of a d e t # 6 0 k W e : plies. Renew the belt if worn or damaged, with
krious leak. Should a leak be found, renew 8 Chmk-the odrriiiioh of the power steering reference to the appropriate paragraphs later

I
Ehegffendlng gaskei or oil seal by referringto fluid , p l w a n d ~ h o wand, where,applicable,
Chapters In thls manual.
Also check the security and condition of+ll & h&&.
-*the engine-related pipes and hoses, and,@l
+ydraulic and braking system pipes and
,hoses (we Illustration). Ensure that all cable
th# autorn&iv ka@,rnlon fluid ~oolerpipes
. .n----
in this &tion.
D-type engine
alternator drivebelt
Removal
-
4 Remove the power steering p
. ..I
~
**c
&s or securing clips are In place, and h goad as described later in thls Section.
~ondilon.Glips which are broken or missing 5 Slacken the alternator mounting bo%s,'d&
can lead to chafing of the hoses, pipes or move the alternator until the belt can be
ylrlng, which could cause more serious Note: Disconnect the battery negative lead slipped from the pulleys (see 1Ilustr;itbn).
,. groblems in the future. befom w $@e sKQ@ a rQW , . . >. -. ' , .:
3 Carefully check the radiator hoses and E,*', .-a- -
&eater hoses along their entire length . Renew
,any hose which Is cracked, swollen or
Idete~rated.Cracks will show up better if the 1 The type and n u ~ b eof r a s i & drive be^
hme is equeezed. Pay close attention to the fitted varies depending on model. To W k tR$
hose cllps that secure the hoses to the condition of the drivebelt(s), p r o d as frjlbws, $ i ~ ~ i n ' g ' g $mounting
and rfi'liZght~, h~ and
,cooling system components. Hose clips can 2 Apply the handbrake tRW jack up the fmf@ tms16:iw'v&hb&
(6Inchand puncture hoses, multing in cooling of the vehicle and s@pokt it an axle &and$ ? T~nsi~##kdrlvBbBlf as described in the
;system leaks. If the crimped-type hose clips (see "Jacking and vehicle supporl'~,Removg;
used, it may be a g o d idea to replace
standard worm-drive cllps.
aH the cooling system 'components
1 ( ~ O S B Sjoint
~ faces, etc) for l e a k (see Haynes
Hipt). Where any problem are found on
system components, renew t h component or
&sk& with reference to Chapter 3.
5 Wih the vehicle raised, inspect the fuel
tank and flllar neck $r punctures, u a c b and
bother damage. The conneciian between the
: ,filler neck and tank is especially critical (see
Ulwhtiod. Sometimes a rubber filler neck or
. I c ~ n n e c t i nhose
~ will leak due to loose
; ,retaining clamps or deteriorated rubber. I I
6 Carefully chwk all rubber hoses and metal 5.5 Pay particular attentlw to the m t i i o n
I
I fuel lines leading away from the fuel tank. of the rubber hosa (amwed)wfrkh 6,3 Checking for drivebeltwwr -
W ~ & , ~ flpgm g r connections, deteriorated connects the fuel filler neck to the tank multi-ribbsd type s j w n
E-type engines
Removal
- Tensioning
power steering pump dilv~belf 48 Correct tensionlng of the drivebelt w?ll
( p d e t s withut air c o ~ ~ n ~ hensure
g j that it has- a long life. Bpyarg,
33 Worklng at the top o f the piimp: loosen
We upper pump mounting nut (whkh c h m s
he pump to the adjusrer strut) whllst
;counterholding the bolt, and loasen dm&
adjuster strut lmlulut and adjuster nut.
34 Working at the bottom of the pump,,
loosen the lower pump mwnting nut, again
wuntethofding the tmR,
tension in the drlvebelt,
from the pulleys.
"'
35 Back off the adjuster nut to relieve the
. slip the.dl;iriy&,
, men
p
Refitting
SB Fit the belt aroun& the pull$ys. en&%&
hat the W t Is of the correct type if it is,b,elnQ
rsnewd. Take up the slack in the belt b-y
tQhtening the qdjuster nut.
37 Tenslon the drivhelt as describd in Rhe
fellowing.mra~raphs.
Tensinnkg
88 ,:Correct tensionlng of the drivebelt will
.Q~LIT~ that R has a long life. Beware,
%%wever, oi avertighbning, as this can cause
wear in the pump.
M-sivs
39 The belt should be tensioned so that there
Is MWew 3.2 and 3.5 mm of free movment,
under firm thumb pressure at the mid-pointof
the W t run between the pulleys.
40 with the mounting nuts just holding the
pump firm, m d the adjuster locknut loosened,
turn the adjuster nut untll the correct tension
is achieved, then tighten the adjuster nut,
locknut and pump rnountlng nuts.
41 When,a new belt has been fltted, it will
p r o e l y stretch sJlghtly when then engine is
run. After fitting a new belt, run the engine
until the cooling fan cuts in, then stop the
engine anU re-check the b l t tenslon.
42 With the engine warm, the belt dejection
should b between 5.2 and 6.7 mm, using the
methd described in paragraph 39.
E-type engines -
air cmditJonfng compressor
drivebelt (models without power munterholdinp the bolt. Loosen the a 4 ~ &
steering) ,e9k7*r8 .n . strut locknut and adjuster ntlt. Also loosen tEe
~~~0~~~~~~~~~ + 7 --;
43 Worki ng cbmpartrnent, loosen the upper alternator mountrhg tkit,
L o w ~ t h etup belt tensionar pulley tira~ket again counierholdlng the bolt {see
skiiring bolts.
the adjuster strut locknut and tho 57 Back off the adjuster nut to relieve the
nut, then back olf'the adjugar nut to tendon in the drivebit, then slip th@'driWebelt
rehue the tension In the drivebelt.
45 Sllp the drivebelt from thep-@$y~
,.
c,;
. L -
RPfitting F- am
46 Fit the belt around the puilg&j ensuring
that the belt Is of tho correct type If% la being
renewed. Take up the slack In the belt by
tightenlng the,adjuster nut.
47 Tendon the drivebelt as described in the
following #amgraph&
excessive wear in the compressor.
--A
49 At tho time of writing. no information
prm -y?g@ ressure at the mld-point ~f t'e
belt (un getween the crankshaft Phd
komp'esbr pulYys. Consult a Renault dealw
:for recxlrnrnendatlonsif in doubt.
-
however, of overlightening, as this can musk
available for Ule recomrnmded belt TenS@)T,
but a reasanable approxlmatlon would 6&
,approximately 4 mm of free movement, q@e?
9 With the tensloner pulley bracket securing
:bolts
I<
@S
EvkryaEO OM) miles r i p 1 1
just holding the bracket flrm, turn the
6.50 ~ooseningthe alternator upper
-
mounting nut F3P engine models without
power &&rlng or air condWclning
gdjuster nut until the correct tension is
chieved, then tighten the adjuster nut, TensSwing s*3,.,.- -:. rrj-
7 ocknut and pulley hack@ securing bolts. MI ProCwd a k " ~ & W dli3'mrffmpW2
B -
&-typo en ines to 56, if not-alreadydone. rc
kir mndi oning compressor/ 61 Corr,ect tsnslonlng of the drlvebelt wiIl
power xtteePing pump ddmbelf ensure that it ,ha# a long. lkfs. Beware
however, of overIightenlng,.as this can cause
',%IOn rhbdels fitted with both power steering excessive wear in the m a t o r qdlw wate
$nd air conaitioning, the procedure for belt
pump.
removal, refitting and tenslonlng is as 62 The belt should be tenslors@,so t h a t t h e
described previously for models with air is:Mween 2,.5and 3.5 rnm of kee movement,
conditioning. Consult a Renault dealer for under firm thumb pressure at the mid-point d
datalls of the belt tension recommendation. the belt run between the crankshaft and
F3P engines - alternator pulleys (sm illustration).
03 With the mounting nuts just holding the
modek without power sfeering
alternator firm, turn the adjuster nut until the
or air condjtioning correct tension is achieved, then tighten th4
Removal adjuster nut, the locknut, the bolt securing the
52 Remove the right-hand headlight, as adjuster strut to the 6ngi@, ,pd JQywi
wL
described In Chapter 12, Section 9. rnountlng nuts and bottk "
64 When a new belt has been fitted, i t w$l
53 For Improved access, apply the
probably Stretch slightly when then engins is
handbrake, then jack up the front of the car
run. After fitting a new helt, run the engina
and support securely on axle stands (see
untll the cooling fan cuts in, then &ap the
s jack in^ h d VdIi~kSUpp~d~.
54 Remove the right-hand roadwheel, then
remave tKe anglne splash shield from the
subfrarne to Improve access. Where
applicable, undlp the brake pad wear sensor
wiring from the splash shield, taking care not
to strain the wiring.
55 Working at the bottom of the alternator,
loosen the lower mounting nut (which w u r e s
the alternator to the adjuster strut) whl) t
bolt securing the adjuster ststrut to the anglne.
56 Working at the top of the alternator,
illustration).
from the pulleys, taking note of its routing.
Refitting
58 Flt the belt around the pulleys, ensuring
that the belt Is d the comci type ifit is baing
renewed. fake up the slack In the belt by - --
6.02 Amiliary drhrebslt tension checking
tightening the adjuster nut. Ensure that the
belt is routed as noted before removal.
-
point (F3) FSP englne models without
power steering or air conditioning
59 Tension the drivebelt as described in the
following paragraphs. F3 = PR to 3.5 m f l iqld/3. &W
 la.^:, Hew I 0 000 miles
Refitting

route-d round the pu~te$g$@~&d before

moml.

.
7Z Tension the,ddypb&@&d$Wfi
following m ~ r a p h 8 : '+r c r c .
Tensioning 94 +P', -
R
i the

n P ~ O D S ~d
and 68, if rrot almbdyd~
74 Correct tensioning k
~ & h ' %spph~
'$*&$Zbe~€ Mil
ensure that it has a long IIh. Beware,
BI

however, of overtightef;lng, sts thy? can cause d m c r i b e d $ p ~ , p p b d Q + ) .$ ,- - ~ i

excessive wear In the dW"m'ator and/or 41 Refit be h w d h h t ' with
Chaptw 6- $e, 9.
~~ - .- -
C I pumps. ;rw*%Fr
'6.75 Auxiliary drivebelt tensioii'b~&kin~ 15 The belt should be tensioned so that there
-
9 n t (Fa F3P engine models with p o w is betwfien 3.5 and 4.5 mmaf free movement,
F7P (I@-mIva)engine ;Y
M n g and w i t h u t air conditiohing under firm thumb pressureat thqmirl-point 'of Removal ;*.; : -- L-IL

Wa@rpumppdley D P o w e r s M n g the k t wn betwean the alternator and power 92 Remove t(;e &hf~hand h e a d l & S z
Ctanksha'ftpulley pump pulley steering pump pulleys (see illustration). dsscriWi0 C h m f 12, W i p n 9. '-L
Mmator pulley F Tensioner pulley 76 Turn the t~blsionerpulley clockwise using 83 on r n h . W& with a o h s i c d h l d ~ n i s a ~
= 3.5 to 4 3 mrn cold15.5 to 7.0 mm warm a spanner on 'the Rats provided until the unscrew the twd seeuil?g bolt$; W O V e t@
cormct tension is achieved, Lock the shield from the fuel tank-ro-&ijri6~ei*h@~~
f$6 With the englne warm, the belt deflection tensioner pulley in position by tightening the then dismnfiwt the hB$q fram the qCtIstsrr t
4hsuld be betwem 3.5 and 4.5 mm, using the Allen bolt whilst counterholding the pulley. 94 Slacken the screw &urlng tha viri@
ilsfii&hod descfibed In paragraph 62. 77 Run the engine for approximately 5 bracket to the inner front;wi~~d.piv0.t- '
:b On completian. refit the engine splash minutes, and recheck the drivebelt tension as bracket rearwards to irnpnYe awes& tt6 8

?
4hlrld and h e ~ r o a d w b lLower

$q~ engimr -
*ode/$ with power steering, ,
. the car to the described in paragraph 75. belt f e n ~ i ~ @ , o u ! W , b a l ~ 1 ~ ~ ~ I
:@rbrjnd,and refit the headlight as dmcribed in 78 With the eng\ine warm, the belt defiection 95 SlacIt&J?@'balt
qhapter 12, Mia? B. should be between 5.5 and 9.0 mrn, using the tensioner $IlW,-Uslng-,a 7.mm Allw
method described in paragraph 75.
79 On completion, refit the engine splash
(due to the limited>access,if a bit is J~9@.$,il
P
In jffi% tenV@~@f.f.R
_
or '

ahieldand the roadwheel. Lower the car to the

prkd wiEhout alr conditionlmg, ,, ground, and refftMe headlight as described in
f f a .U
Removal Chapter 12, Section 9.
3 7 P L m & s described in p a n g r a d FbP.,eng~ngs
@ 54, , . I I -,I lil'h&~s wit@
-
I . - .air copditioning
3
stands pee
"JacIdng and vehIcle.~ppFtq.
@ slacken the bolt in the centre of the
iensioner pulley, using a 7 rnm Allen key or bi. ' R e m a 1 !: J ., ,' 98 ~ k & v e the right-hand front raisdwhe
-W Using an open-ended spanner on the flats 80 Remove fhe r$$fi!-hand headlight Bs then re!.Base the securing clip and t w ~ v te
~$rovid@d, turn the tensloner pulley clockwise described In Chapter72, Section 9. engihe splash shield from the subfrarne (see
,to relieve the tension in the drivebelt. 8'f Blacken We bolt in the centn of .the
.
Illbwfion). Note theft the brake pad wmr
,FO Carefully release the drivebelt from the tensioner pulley, uslng a 7 mm Allen key or bit sendor wiring must be unclipped from the
ull+ys, noting its routing, and withdraw the (seeillulration). splash shield before it em be mmoVed. T a b
care not to strain the wiring.
82 Using an open-ended spanner on the flats 99 Working under the wheel m h , un,du fHe
provided, turn the Zensioner pulley clockwise two securing screws and remow the timing
to relieve the tension in the drivebek. belt lower cover to expose Qbscrankshaft
83 Carefully release the dhvebelt from the pulley (seeillustration).
pulleys, noting Its routing, and withdraw the
belt.
Refitting
84 Fit the belt around the pulleys, snsurlng
that the beit ISof the correct type H il is being
renewed. Make sure that the belt is corr&ly
routed round the pull@, as noted herors
removal.
86 Tension the drivebelt as dsscri&&&.,&
1. 1
following p a r a g r ~ , b .
6-81 Slackeniq the auxiliary drlverw Tenslonlrrg
:,.a:.
-
tendoner pulley bolt F8P engine m o d e
with Jr wndttioning " . Pwceed.gs ..a8~yi'ipedIn paragraphs 80
and &Ibif not already dane.
h m- 7 4 . - 6.M Unscrewing thq wir,inp BracFekto;
I Tenslonerpulley , 87 C o r ~ m l@nsioning
t> of the drivebelt wili
'9 Tensimggpulley boff
- ''
' '
gnsure that it has a long lib. Beware, iner,$mm,*ining p a W & -F - c
$ Altemabr lower mounting bolt however, oT ovettlghfening, as this can cause W? ( 1 6 - V d ~ BhgW
~) 7 1.- -4
 Every 10.0001rm:iled; l p ~

k g n d B , g Remollng &&'tlrPrlhQ+eIl lower'm$er

s . ~ l . ~ ~ & ~ ~ @ &lash , Q ~ ' P~(eZl s a s i ~ g - t h i h ~ d r the
i~~lir
- sbidd -T7@?.l@@Iib]
elrgine - . W ~ ' ( l % h a i dengine
) W W I I @ O F ~ WF;m,Q&valjle)
~~,- engb
1.P;O Wo&lng h @ ' t h e headlight apatture, 1QgTurn the tensioner pulley clockwise using
& Y ~ U Id ~l& the driuebelt tram the a>spqnwon the flat? pravlded until the
no~g I$ routing, and withdraw the wrlcy~ tension Is actiteva, b e k the
rilllst&bn). tenaldner pghy in position by tightening the
mmw Nlgn bolt whilst coynterholding tha pulley
-wll;!@t .fjla bJ$apund the pulleys, ,ensQfng
$@,,:el,@& i~ 3 t t ~ i . c b r typb<
q ~ ~fit is.~ n g
m+fed,.'M%e suya ?hat*& heit is awry
pgq;@ynd !he puk*, as noiBd bfore
remoyal.
:@& ;$en$@~,~b
.ddveblt as describd in the
WI~:parabjraphs.
@tiGoning
TWLprod& ,m'&&bed In paragraphs 82 leati iq9eP $ti!*Fie,;&$ "@f~&,&*&$ . . ,tl&i
tW$'R%GtYrWydohe, uncllp the HT'&~&-U~Y~,
q@&im~t~tensbnifi~ OT >medmeblt &ill 4 Q6 $ ~ d 4 ~ ~ r n , , F7P
t h e (Id-v&].
&sure that It has a long llfe. Beware, r m o v o the endne $o.ver, whl& ie
hmeve~,bf owrlight~~ing, as ?his can '-use secured,bytw.6 e h (a* 121~i&tbh].
&east~b wear in the alternator and/or
P U ~ P ~ .
'IDS The belt should be tensioned so that
thwe is beween t.5 and 2.5 mm of tree
m W m n t , under flrrh thumb pressure-at the
miepolnt of the b l t run betwean tb p w a r
&teesing pump or'ldier pulley [as applicable)
amd thprdtevnator-pulley(s~lllustwtion).

A W6te~
@kt&
~ l @ !
B CrnnksAaft
4
Q Powersteering
pump or idler
P U ~ ~ Y
- -
8.108 6 o u d d & r i O ~ ~ ~ ~pulley
i - r
- 7.4 ~ern&atHi$
;
m$I@,B6 W k md oily, then it is likely th#
m'mgln~~lsdmwm, as W as the mlmm

I
1 T h G 1 w n the* & n d specifid by
I srndhly and'msilythrough itsn'fulltravel, and
hemi n thdr corred order, Where applicable,
refit the HT lead cover or the engine t ~ GpQ V ~ L
M9.w: A tachometer md an exhaust gas
@I@F wCIi be required to carry out this
pcomdum accurately.
l"pCQ content is elwtranicdy controlled
on dl mdds with a catalytic conv&w (see
relpvmt Part of Chapter 4 for details). Thls
means that no CO adjustment Is possible.
Hp~ever,the sphaust gas emlssi~nscan be
&~ecke~,using an exhaust gas analyser to
ensure that- the engine management system
and tb, catalytic converter are operating
WmAly.
P.B@fo&-checkirq the exhaust gas missions,
ensure that the spark plugs a* In gpod
condition and correctly - gapped.
- .. Make sure
that the engine is at operating temperature,
that all electrical mrhoorients&e switched off
Every 10 0.00mil&
prgbhrn wi~iWsh~~&h?anag&%tay@B
br'fhe cabtytie convert$r; R&e,r.tci th6 rBlaW~t
Part of dh'apter 4 for f m r details.
h a * . CM~h"iWlM.hmctlonsai,rrect1yY with
k
botjl Ih~gsarboxend and hdde the cat, for
signs of wear artd fraying.
i Wdh the e n p e cold (at Isast an hour after
Me vehicle has been driven), check the
complete e~haustsystem from the engine to
the end of the tllpipe- Ideally, the ingpection
should be carried out with the vehicle on a
hoist to permR unrestricted access, but if e
holst Ip not available* ralse and support the
vehbla safe1y on gxle stands (see "Jacking
and Wide support").
2 Cheok the exhaust pipes and connections
far evidence of leaks, severe corrosion and
damage. Make sure that all bracksts and
mountlrrgs are in qood condlfion and tight,
Leakage at any of the jolrrts or In other
of the system will usually show up as a black
sooty staIn In the vicinity of the leak.
- -
.--..- - and
9 .Rattles - - ..-. nniaas
.- other -
- .- -- can. nftnn
.- - .. be
--
traced to the exhaust system, especially the
bra~kd? ~ nirruntings. Try' to mova be
aha
pipesand silqmers. If the"cernpopeM6,c@
Gome into 'sontact with th@ hay or
suspendon petrts, sewre the system with*^
rnarrtlqs or If possibleJsqgrate tlw joifis
and t d s t the ptpes as necessary ta prpvide
addidboa] clearance.
4 Run the engine at idling sped. Have an
assistant place a cloth or rag over the rear end
of,thn axhaust pips, and llsten for any escape
@Lfhau&laasrls that would indicate a leak.
5.Q~.wrnplstion,lower the car to the ground.
0 T k inside oT the 'exhaust tailpipe can' be an
lndlcatiun of the running condttion of the
engine. The exhaust ddpoosits here are an
1.~15
e ~ #roadvlrhePds.
x s p p ~ & $ ~ ~ m ~ ufwrd ~s
2 Far a qulW,chwl~the thickness of friction
materlal remainina on each brake md can be
the ber;lflds$&k&I&:
; p'~
at1 four pads
-*%%:>.-.". .
this shauld 'nd '6e @edrl@' an w ~ u s ; for
ornittin. s visual ~ n ~ . d .
formined for.mnditlon on both sidm.eefqr6
Chapter 9 for further information,
rear of the vehicle and support U sn axle
a a n d s (see "Jaclclng and vehicle support").
Remove the rear roadwhesls.
2 For a quick ch@ck,the thickness Q friction
material re aining on each.brake pad can
be
7
measured t rough the @pertun in the calfper
body. If any pad's ft'ictlon material Is<wornto
the specified thlcknqs or less, all faur pads
must be ~ n & e d a ~ a - s s t t .
I
3 For a cmpre~gnsla/8sh~h. the'brake pads
should b8'r'emaued arrd eleaned: This wllf
a ~ k w'we ~wta~n at the 'caliper to toe
&&&;',&d %e IyaEedistr itself to be fully
& I ~ fpl.qndi~ on buth sides. Refer t~
Ghaptpr$ for Wrther information.
1 Once the car hae been mlkd @@,&
spars and other surface bferigsheiib e b&n
cleaned off, careTully check rU ;painwork,
IooWrig clasely tar chi@ 'pr s6.r8&he& 2%
particular attentian ta~vulrle-@hlewmqgh
as the fant panda monh6t Wl apofia$
mc archas. h y d.d.wtlb
palntwork must b$ Hptiffgd & -:,<as
possible to comply wifh.tKb\Tems.a .the
manufactUrer's anti-eb$rWBh Wdfhs;
check with a R a u H dealerklctietails.
ii 03 y & a # p ~ w rstewing, check theauid
hcse8 for ~hglflwor deterroratbn, and fhe
p f ~ + d ,b i q yhrank fsf"flwi&@.-~lW
d m k for s~ans of fluid. led&&&un%&
prewure frs$ the stmdmg g& ~ ~ 6 1
QMers. whtch WM~J indie& fd&i.fliiid/'ls

-- - - a:]
 3h6..~~the fwo alr cleaner corer
(-,wings w w (arrowed) - F3P.mgine
with air cfeanw behind front win^ panel
19.7 Three screws securing the air cleaner
-
housing F7P (16-valve) engine
-
F3P engine
models with air cleaner behind
le#-hand front wing panel
4 Apply the handbrake, then jack up the front
of the vehicle and support securely on axle
stands (see "Jacking aid vehicle support").
6 Worklw under the front left-hand corner of
the engine compartment, unscrew the two
secur4ng screws, and lower the air cleaner
cover (see illustration).
8 Twist the securing clip through 90°, then
pull the air cleaner tray down and wRhdraw it
from under the vehicle ( s eillustrations).
F7P (1 6-vaIve] engine
7 Release the seven spring clips and remove
the three screws from the alr cleaner housing
I" (see illustration).
Ig.9~ ...and F7P (16-valve) engine
I 0 . b Twist t b smrlng dip ...
.,...~..,rw..+..asir~~wm~~
-
-
down F3P engine with atr deaner behind
Wont wing pan'el
-
19.9a Removing the air cleaner element
F3P engine with '[pancake" air filter ...
19.9b . ..
F3P engine with air cleaner
behind front wing panel . .. I
AII models
8 Lift off the air cleaner cover, or separate the
parts of the housing, as applicable.
1 The spark plug HT leads should be checked
whenever new spark plugs are instatled in the
. ... . .
engme.
2 Ensure that the leads are numbered before
1
9 Remove the element from inside the air
them, to avoid confusion
cleaner body (see illustrations).
refitting (see illustration). Pull one HT lead
10 Clean the inside of the air cleaner body,
from its plug by gripping the end fitting, not
being careful not to get dirt into the intake
the lead, otherwise the lead connectionmay
duct. Fit a new filter element.
be fractured.
11 Refit the cover, or reassemble the housing
Check inside the end fitting for signs of
and secure with the screws or wing nut and
corrosion, which will look Ilke a white crusty
spring clips.
powder. Scrape out such deposits using a
I
shall
-. .. - . . .. . . .. . Push
... screwdriver. ... the
. . . . fittina
. . end back
.x - -
I
onto the spark plug, ensuring that It is a tight
fit on the plug. If not, remove the lead again
and use pliers to carefully crimp the metal
cannector inside the end fitting until it fits
securely on the end of the spark ~ l u a .
Renew the spark plugs as described in
*ion 7.
4 using a clean rag, wipe the &ire-length of
the lead to remove any built-up dirt and
Warning: Voltages produced by
A
pwduwd
an electronic p i t i o n system are
considerably higher than those
by nnvuntlnal eystems.
E x t m e care must be &ken when working
on the system with the ignition switched
on. Persons with surgically-implan fed
cardiac pacemaker devices should keep
well dear of the ignition circuits, 21.2 HT lead connection diagram
all engines
-
componentsand test equipment.
 grease. Once the lead Is clean, check for
gums, cracks md other damage. Do not bend
lead excessively or pull the lead length-
wise - the conductor lnslde might break sure that all gearchanges occur
5 Disconnect the other end of the lead from
the distrjbutpr cap ar &I, as apgllmble. Again,

8 Check the remaining HT leads on+ &%a,

Renew these compwents if any &feels am

the old cap one at a time, and lit them to t b engine, clutdl and wnsmissim. ritm~f4~&h'~iukP the vaewurn, t h ~ nsCEVt WIB
new cap in the m#ct same location - do not &.Make sw&hat&e engine runs smoothly snglw. As th&rigiW&Ws, there should h a
slmultaneousiy remove all the leads from tb& w 1dlh-Q gnd thathere Is no.h&dtbn nd4t)geabIe 'Qive* in 4he brake bpdal aB
old cap, a fidng-order confusion m y occur w# aml.la6n vacuum builds up. Allow Wendfie ?o run for
9 Even with the ignition system in first-class $&he@$tm +&,gg~pplS@ble, the olut& st lea& IWd rnbutea, m l thm swltsh it.&: tf
condition, same engines may still occasionally amoh IQ &b& an&.pmgresslve, that the the hake perld is now dmressed again,
e%wienca.prxrrstarting, attributable to damp dn'ye i p t , an9 that the ppdd shoutd be psslbls to d&mt a hlss from the
ignition components; a spray sealing coat to t r q J ~+ts
l n6l&~&shle. Also ti8ten for any s w o as Me pedal is dqwaw~pl.M h ~ a h u t
exdude moisture from the ignWon system will nolspyhmif+@~. pvgl is dqpssed. but m fim ap"plltxiWdr@%'~' tUi4hdr hisskg
h d ~ t ~ & w ~ bmn aniy
r a vew poor spark 10 Gf-ie& &t 41:gears can be engag& s ~ o tu~ b he p d i and SRQWC&
O ~ G U WI L , .. -- w M -~ ,.D&@, t b t the ~WlslEtevably'bdW. . * " ' -

L k 33
*' "' ' +,
-' 1..
/
- 'J *.:I'd

1' .
!'. .
- . . c-
J -I*

the fuel pump toward8:the engine).

the hose dips and the'fililter Beeuring cla

d - 3 3 @b@$~$~e
hbse ol~.tppand check t h U

is pointing in the direction offuel flow (from

r. :3.- c ..

The fuel filter is lacated under the car, just

ty&.t$lse and s u ~ w tthe
t

w on ih'e tank sida sf the

J?sXnDarWthe Tom screw ,fmnl the filter 23.3a Fjttfng a new fuel filter. Arrow on +.b..Tightmi"g the fuel #It&securing
, :-ring clamp, and stacken the hose cllp~.If filter shows direction qtw~l.$&y, ,r ,: clamp d a k .
 7 Llslng a trolley jack and .blo~kof wood, rear drum b@W, if .the L a n m is mot
rais~the auto ma ti^ .tr#smiMi~n f&r:enough fun~fiwn,@T@wyw:is
g 1ntX@kf&d@@@d,
to tm bfik and rerhoV@Qha battery mourttlng/ the r.%ar.$fa&W % & j & j 3 m mjunbt ~
trar;rsmiss$onmgunting,hm#ketb fumtion.mis wfl~~I~~~
8 Remove the front I&-hand roadwheel, and becoming e x h es+h-@t% M v d r .
nmove the plastic cover in order to galn - U no C ~ T C W ~ W M
amess to the tfansmlssion pan rhaunting,
bob
9 Wddw Uder the W, U I I B C W . (hUt do mt
remove) tihe mar boR murlng tb~rearengine
mounbtng IlhR tolhs underbQdy. Unscrew and
remove the front balk and swivel the link whlcle support"). Undo thw %&it BW$I
downwads5. rebinidg nut($] and lower the~mhr&tHeW
10 Raise the automattetransmissinn --tar as shield to gain inm~ to the -,hr&sj,@ls
possible. adjuster nut.
11 Unbolt the pan from the hottarn of the 8 Slacken the locknut, then fully,$acbn tk
transmissbn, and amou4,the gasket. ~ b @ u w e r rnut (smlusbatlori)l
12 Unbolt the filter and it5 seal (-4
Illum1ii). k&Wt mar dwm
I S W a n the pan and the se@mmt:magnef, 4 R,- :b&th tear b m b Wnria
&ernin& the pan gasket and the drain land tiwdBW.in&Impter 9.
tapping-up plugs, and renew them if
~ W ~ ~ .
74 Fitthe new Rlter together with ltg seal, and
.@W$
W e that spec~W Ranauft test a h t e n thbolts. deadib&hWai~n.*I~:8'~~~
15 ,Rt the pan tagdher with a new gaskak,
*,,is ,n-$-y to d w c k thii f l ~ d 6 ff is d l , b m k w f i & t W d j j w h d ~ b y
W -ten We huh.
flB l % & - . r e d h gp r d u r e is a.r@vmlof fjve at sbx 3 l d h # b % h & ~ + ~ & @ M r e
rembval, but finally refifl f tie M s t r d s i o n W h b W e &Ws iB d$htll f & d ~ k I v
duld as described in Saction 4. 7 EM&k f h l the hatldbWk& &We
freely hy pulling om Xh$Tr h.@MMEIS,A&
c'heak th&tWe a p e m lkvers on TEre W Y
Whp:aUt@xt&LFe~ansmission
. fluid should bra& +wlngl >shoesmum to ~ B t aotreoi r
m3&kl&&.b@@ when wid. p~itlons,mPMr $ t ~ p m ~mo&d l n Mth
8-PdhPi me mr mer am Inspection :pit, on thejddn'' Bf We'Mlhaahbe W.
mqtmpa, or j~ekit up. hut make wre that .it
W@el:
3 P@&?vsuiMbl~conbilker Iqsmth thesdmin 1 dha* thg front wheels, then jack up the mi .mthat ma laver DW- mk-rb&
m p u n m m h W pf the zieh'icle arrd support it an a l e
qlys%n the ~ s m i s ~ o n o s upan, assembb st:m#.rttmbWasthe ~hmtlmkwis
WrdW.plua+an@allsw the fluidqo d ~ a l n ~ ( m?tgmd$ :$we *dadcin~and vehicle suppaw). moued baW~smQhe ftw and g e m d meR
Illu~n), RefhWetherearroacbhwls.
9 'Fir a qcriek check, the thickness gf H&on [GIIG~) of Its ratchet mechanism. This Ts the
4 Remove the bai4et-y as des~ribed In case when $he hp-pegs are still in w n h t
EhapterW. material remdning on each brake pad can be
'with the shoes when -the handbrake Is on the
5 Disconnect the wiring harness mounting measured through the aperture in the mliper first noFh of the ,ra;tc.h&, but no fangar
Blip3 from thth8 automatic transmission and body. If any pad's fritztlon material is w r n to CGflWfh g ~ ~ d ~ ~ ,41C$ @ ;ham~~&qp:&
@b
the specified thickness or lee, qlJtour-
%py mounting. the sgmnd riawh.:~mcethsadj&fi&Kkb
fI ,Qaaah the power-asslsted steering hose rnu&be.mmewed as a set. corm&, 4mId $hb-ad_lw,n@and s w w l y
3 For a mrnprehensiuecheck, t b . b r a k p d s
nibpndng fmm the bt&y mounting.
8houl8 Be removed and cleanea. Thl$ Will tigmen thw bdkrn@, :mj rthg .
s $ w
allaw Zhe aperahn of ths mliper .to be GOFWBPM tshHd-mjnllg. mu%.
checked, and the brake disc i b l f ta be-Ywlly 9 R&t the brake dfWm as desoeiw In
e x m i n d fgr condltlon on botbsides. lA&r to Chapter 9, then lawe'r tM rehide~kbVh~a
a

(4haptar-8 for further Lnformation. ground.

1 The . l ' t & t W e s W I d 'be &&&& 8

holdingthe p a b d vrhideatetiq,pr&@$
sbs~t. @ o w , when a ~ n I i e @ ~ 4 ~ i A ~ @
fiorcse. T~~.,IW~EWIIS~'JWI~ +e fmn.amd
W i v e i n c W l , ~ ~mi h.Irraw dl; stiffness ar

~ I mematie
P tremisgiwlis~
retainingbolts (1)
10 With h e v&lcle standtna on it8 wheels.

5 w k;Iiet-tp~~ q ~ w i ~ t * f i p r n ~ - i p ,
c w k W for l ~ k & b . ~ ~ ) v ? d a t i f i?he
fid
r&mt&b type, pull the $&It all the .yay3au2 drivashft oll sa&,%d &pail& I
sp$qxwy~(s,.f@ ~@r&@.th~,webbi~. d LOW ttk M V ~ I ~ W ~ W ~ B * ~'..* C'
 Maintenanlceprocedures
10.22

Every 2,years, regardless of mileage

N- Renadt do not specify renewal i n t m I s
for h mdant, brrf it is advisable to drain and
mfi(!theqsbm evey two years to ensure fhat
ttie wrnssfon inhibiting prapeMes of the
e-t are maintained.
Dnl'ihlng
drain plug and secure'the'battorn hme. Use a
new hhos dip if necessary. REPRl the system
as described later in this Section.
System flushing
7 With time, the cooling system may
gradually lose its efficiency If the radiajor
matrix becomes choked with rust and scale
deposits. If this Is the case, the system must
be flushed as follows. First drain the coolant
as atready described.
15 Pour the appropriate mixture of water and
antifreeze into the expansion tank, and close
each bleed screw 'In turn as soon as a
continuous flow of bubble-free coolant cm be
seen flowing from it. Continue to 6H'the
expansion tank until the coolant Is at the
maximum level.
I 6 Start the engine and run it at 1500 rpm Qe
afast idle s m for apprqxirnately 4 mlnqes.
Keep the expansion tank topped-up to 'the
maxlmum level during this perid.

*@-;,
8 Loosen the clip and disconnect the top I?Reflt the pressure cap to the exparishn

a Waml~g:Wait until the engine is

&I$' he$~restarting this pro-
,*-#=Do not aIlow.antiwexcr to
. -< - e your
~ ~ 6wHh t skin, or with the
pa nf& surteces of the vebide. Rinse off
* , l ie -m tu of -.
1 If fhd er&ipe 1s cold, unscrew and remove
m~ pcessura cap from tha expnslon tank. If It
@nW#&sjbk to wait untH the engine is coldr
& : P J m a aultable container beneath the
bp$tqm .hose connection to the radiator or
water pump.
&@men the clip, then disconnect the
bo$bm-hes&and allaw the coolant to drain
intg,the c~mtalner.The hose clips fitted as
qiigirral equipment .are releas4 by sqoesdng
the tags- togemer with pliers.
4 mete appl~mble, move the container
@mmlf~ the .qlinder blmk drain plug [there Is
not cylinder block drain plug on the D-type
englne]. The drain plug is located on the rear
dght?hand Jde of the cylinder block (see
Uluslrations).
5 Unscrew the plug, and drain the coolant
into the container.
IFlush the:system If necessary as described
jn the following paragraphs, then refit the
. 14 Open the coolant bleed screw,situated should be mad6 @ti me same typ6 h d
hose from the radiator. lnseflAagarden hose in
the radiator fop hose connection stub, and
allow the water to circulate through the
radiator until It runs clear Tram the bottom
outlet.
tank, and run the engine at 1500 rpm for
approximately 10 minute& until 'the 'elBtrlc
coojing fan cuts in. During this period, the
coolapt will circulate around 'the eqginbvatyd
any rehlalnlng air will be purge4 to ' t k
9 To fluslithe engine and the remainder of the
system, remove the thermostat as describd
ercpansiw tint+
18 $witch off fhe engine end allow it to cool,
than chd& ' h e coolant level as des,crlved
in Chapter 3. hsert the garden hose, and allow
the water to circlilata through the engine undl eartler and t o p - u p . ~ f + ~ , c e s ~ ~ .
it tuns dear from the bottom hose.
$0 In severe cases of contamination, the
Ank'freezec mIMwm
radiatqr *puld bs mm~~~-Rushed. To do this, 19 The anthe& should,,el,w?ys be renewed
fimi remove It from the car, as described in at the specifiwd ini&$a'1~: phk Is' necessaQ
Ch>apter3, inve* It and insert a hose in the not only to maintain thgr.Wik&e prop,efib$
but also f o prevenl -ddrib'i$tw &$h' w00ld
bottom outlet. Continue flushing until dear
water runs from the top hose outlet. otherwise omur as the carrosim inhjbitars
become progressivelyIqmLef%@g.
I1 If, after a reasonable period, the water still
does not run clear, the radiator should be 2q Always use an 6thylen~-ilycol baed
adfreeze which is suhabl~fbr uw in mi?+-
flushed with a good propriekary cleaning
srstem- m t a l cooling systems, The proportion of
12 Regular renewal of the antifreeze mixture antifreeze and leve!s of protection afforded
as .spmified should prevent severe contam- ape indicated in the SpXkalions.
[ n a b of ?hesystem. Note that as the radiator 21 Befofe addiRZ( a~tlfrGeze,the ,c&rhlnQ
is made of ahmlnium, it Is important not to sysfem should b~ cornpl&ely draln!d,
use kauslic soda or alkaline compounds to preferably-flushed, and dl kmes checked for
clean it. Sea Chapter 3 for more details. condition and s e c u ~ .
22 After' flllhg with the correor w a t d
n~ting antifreeze mixture, a label should be machd
13 Reflt the cyllnder block drain plug, to the radiator g r expansion tank stating the
radiator bottom hose and any other hoses .type and concentration of.antif~eqeusd,and
thedate In$talle,d. +,ysq$sequenY t a p e u p
removed if the system has just been flushed.
on one side of the radiator towards the tog cone~~on-p$ptifpeeze..
(see fllustratlon). On D-type e n g j y , also 25 do not u W ,in thescreen
open the bled screw in the herater at the washed sy#tem, ~ ' j fki l l causedamegp ta the
rear of the engine compartment: vehicle paintwork.

95.4a Coolant drain plug (B) on the rear of

-
the cylinder block E-type engine
33 I 5 Ifi gu#; l e i bn ma
m i -!W cyfl..,b,'blwk -:F-lype engines
(ehgihe ~ & M i b t 'for
I darlty) -
ihe.mdigtar when refilling the w l l n g
 .
..
- ~ l f 7 l * : I~ , I i . l i v t
'I, 3
\* +

'.-,
.. .. j.41 .
-
Gl4
-p 2
-- .

' 31F?
, < I.. .:
1; '*
' ?k
~4

Chapte,r2 P,artA: .,.... ,. "11. 7

11 08 cc [C-typ-e)e,ng'inein-car re
,. ------
L:,. - . , .

M& +,& %,j,gi&f#m@j+[~n" m:paWREF4Br details #&gine identification.

Four-cylinder, in-ling overhead valva

C1 E
 Torque
..& wrencb W p g s ,.;'b~m - IMft
gOcker shal7 ..... .;. ... . ; . , i . , 5 r , : .,; >... $5,toZO 11 to 15
... i~.:-:'

t
i;;iui. ;
: ::.yi.: :-..ii-

!,.. ....,,:, , ,.,..,,. .......... ,...... ,

;i

shaft sprocket, .:,,,. ......

;,I
, -
22
..
I

ksfia* s ~ r ~ k @ @ ~ l $ y *
Bolt 40 mm IQ~Q,?;,+~??, ,- ... ..., ...I...-......,.-....i, 59
. ,. .
.
,,
.! t;L?r9
Bolt&mmlong: ........2.;..b,;;,~,.b~:~.r.~.-~.~i.-~+~~.cy",v.p,f;,:+c~ ;liQ
,@lg-end)caps ...., .................... .:.
.*,

8.1 .- T-
. .
.
;.. ....'55 lb 65
neetins . ,. *.*.-. ..:.. P C ' ,
Majn bearing capo .......................... ;..-.....
- - ; . _I..r ' , A
i.i 41 to 48 -:d .-
Flywheel (use new bolts and thread locking cornporn4 ..............UI
Cylinder: hwd bolts:
,. ........... ....,... ..!.... .... q 37
L,-da
4Pf048-ga,Fh
-- $Jnr
co el'!,..,.... :;;.- $5bL65
Stage 2 *... ;....; ..... ........,......*....... .................
..?.. ......I r r t ;
. , , -
: .Run engine fc&.minutas, then 40~ p cool fpr Z!l4
n .'
; ;
,
$ 6 3 I 3 ,
., , .- , @ boll I -,t i- '
! , , F
4
-55?0"06 al''tb48
Stage 4 re.-f:. .--
...,.........................
..............; - ........ .....
,.--.4.-r,..,*rr .."#
Loosen and:tighten.remainlirg bolts4n turn to Stage 3 satking
.A
---- *

Engine description w'i:hdh&shaft is chain-driven @&='-he

1 General information .,. 3 The
englne is of four-cylinder, in-tine,
mkshaft, and operates the rocker arms @
p,ushmds. The inlet and exhaust values a r ~
I :overhead valve type, mounted transversely in

the front of the car (see U l u s t m t h ) .

:4 The cast-iron cylinder block Is of the
each closed by a single valYe sfifinp, an8
operate In guides pressed into the cylindsr
I
m'ls Part of Chapter 2 Is devoted to i n c a i renewable wet llner type. The crankshaft is head. The valves am actuated directly by thp
palr procedures for the 1108 cc (c-typ~j ,supported within the cyllnder block on five Pocker arm4
ulna Similar infomatlon covm-ing the other 7 A semi-closed crankcase ventllatlon sysbrh
shell-type main bearings. Thrustwashers am
.enginetypes can be found in Parts B, C and D
&'this Chapter. MI procedures concerning
fitted at the centre main bearing, to control
Is m p l W . and c@lIrq&:gm,Wyedmm
&om the rocker cover v b a hose % the alr.
1
e@ine removal and refitting, and engi~e cranksh& endfloat,
blgck/cyllnder head overhaut for all engin@''15 The connecting rods are attached to the 8 Lubrication is provlded
can be fwnd in Part E of this Chapter: crankshaft by horiztsntally-spla shdl-type blg-
P Most of the aperations Included in this P@ :end bearings, and to the pistons by
are based on the sssump$on Mat the englne Is interference-fit gudgeon pins. The aluminium externally-mounted full-fl
t i l l installed in the car. Therefore, if thk infor- alloy pistons are of the slipper type, and are engine oil gallery, and then to the crankshat
W o n is h i n g used during a complete engirm f i e d wlth three piston rings, comprising two camshaft and rocker shaft b,earings (SB.
overhad, wfth the engine already removed, compression rings and 5 scraper-type 91 Illustration). A pressure , relief valve _l
b ma"y of the steps included bwill not apply. oonlrol ring. - -.-- Incorporated>in theoil purrrp;? '. -j-1:'
- 1

1.3 C-type (1108 cc) engim I.8 Lubrication circuit for the C-type (11[)8 cc) ~ g h e
description and int~pmtation %
$
 2A.4 1I 08 cc (C-type) epg ine in-car rapgir procedyws

rsl T m the engine ih a ebckw~spldjrectiqti

Until No 3 exh@st9qdvglewmple$dy we@,
&en adIW ihe valve c l e a m w on N,o&inl@ I
,wd-No 2 d a u & velves,,(see tllustratiod,
Continue to adjust the vglve clearanoes in the '!
230Jlc9jww , . , ,. ,-- . ,.,
.+. . r
a m Exhaust valve p a u d valve Inlet,mlQ
"fuflyonm toadfie rnatli4 ;,,
lE 31 A€
n f

*'3EA Yf4Lv41 . -"-'&& ' - '0 I

q F l? $1 c*, . YE Vl
4 E
>2E'.I ."' 1I ' IqE "
.#.:I

-9 Adjusting a valve clearance I 0 Remduaethe socket or spanner fmm the

crankshafl pulley bdt.
-$Wsconnect the crankcase ventlla@onhose 11 Before rewing the valve cover, check that
mrn the valve cover. the spring c l i p are correctly e n m e d with the
4 UWCWWthe nuts, and r~rnovethe valve grooves Ett each end of the ro~ker shaft.
wwand$asket. $2 Refit the spark plugs as described in
5 Remove the spark plugs, with referen- to Chapter 1A or 1B.
GhapFr 1A or 15 if necessary, In order to 13 W i t the valve W W , a new W k e t
q k e h ~ n i n the g engine easier. where necmary, and tighten the nuts. :
I;Dfew.>the valve positions on a piece of 14 Reconnect the crankshaft ventilatiotRm
pappr, numbetlng them 1 to 4 inlet and and refit the cable-holdlng bluck.
qMpst_according to their cylinders, from the 15 Reflt the air cleaner with reference to
f l l l p e l (left-hand) end of the engine (ie I I, Ghapter 4A. -- - pultq retajnmg h h - ttrjs-bk Is-vefl tight.
IE, 21, 2E, 3E, 31, 4E, 41). As the valve
desranca are adjusted, c m s them off.
7 Uslng a socket or spanner on the
orrlnkshaft pulley bolt, turn the engine in a
e)ockwisedirection until No 1 exhaust valve is : @
.o
rn
)iu
lsl l i
crankshaft pulley hub
2 Re- the sump described in w o n 7.
3 Rejer to Section 3 and turn the crmksh&to
brlng Mo 1 piston to TDC, an the firing m ka.
4 Lock fhg starter ring gear to prevent the
engine turning, by using a Wide-bladed
screwdjiver I n $ e ~ &between the ring ,gear
teeth and the crankcase. Altmatfvdy, snmge
4th gear and have an assistant depress the
footbrake p~dal.WIfh 'the engine lo&!@, uw
asocket or s p a n w t & u n w w t h e cmbhafl
5 With the bait rem&,llft off the pullsy and
dthdraw the pulley hub. If fh8 hub Is tight,
sing two scmwdrim, or
mrefulJylev61t
use a i w d b
RPee-legged puller (see

empletely open (ie the valve spring is
qqpletely compressed).
8 Ifir&rtafmler blade of the correct thickness
(seeSpecifications)htween the No 3 cyllndar
i n k valve stem and,the end of the rockeram.
It shauld k a firm allding fit. If adjustment is
rye~essary,loosen thp locknut on the rocker
arm using a ring spanner, and turn t h e
adjusfment screw with a screwdriver untH the
fit Is correct. Ti&ten the locknut and recheck
the adjustment, then repeat the adjustment
procedure on No 4 cytinder exhaust valve.
Mate that the clearances for the Inlet end
M a u s t valves are different.
8 Un-screw t h e h @ w d bolts securing the
timlnq cover kb the cyllndsr block. Carefully
aW,*nd a new timing cover gasket nr C t F prjm the ~ m i n gcover off, "sing a serewdrlver
&/60 mix0
paste (or a suitable alternatim - to it. Remove the g&& (where fw.
d p ik* w~IIbe rwu~mdan ~ m d ~ g ' . . I 7 ~ h s s w sthq compo$entg of the timing
,.:f?h0val 9 chain tansionar, n o 9 g that OA p4 two t
may be fitted. The @echanical tensioner yv
Is
-71 Slacken the alternator mountings and )dehtified byjylts tensi&ing spring and
adjustment arm bolt, push the alternator In mbuntlfig b ~ ne .automatic hydy!ic
towards the engine, and slip the drivebelt off tensidne$is idatifled by ifs piston plunger
the fiulleys. Unscrew the bolt securing the d,, twomounting bdb (see f l l h t i o m ) .
alternator adjustment arm to the water pump, 8 T, m,,e rbe mechanical-typ~~nsioner,
"and swing the alternator clear of the m w penmk ~echnlolmsuse a spwlal tubular tool
[see Illustrations6.7a and 6.7b). wMch locates over the tensiona and spring,
.

lipper and swng end together,'and

he' aslembly from the cyllnder
.+..-: 1r -- . r .

5 Washer
6 SpHng 9 Washer
7 Sllpperam I0 Retain~ngbdf
 1 108 cc (C-type) engine in-car repair procedures 2/46
- -- - -
C,.

h 1 0 ' Rernwinq the timing chain m d

->
I, -BPr=ir?b liming dDver oil seal
4 If a hydraulic tdnsiongr b fitted, lock thi! suppSied with a 2 mm thick safety ~ a d i b *
plungprpy.tyittg laeklng wirearound the M y .
Onse'kw tfie hbuhting bolts, and withdraw
the tensionsr from the block. Extra~tthe
inserted between the pad and the temiong
body to preverlt the assembly flying apart.
17 Renew the oil seal in the timtng cover &
5.20 cowctalignment of crahkshaft a
camshaft sprocket Yifiming marks a
-filt&r'from the hole in thewinder block. driving out the old "sing a suitable drift, block and over the slipper arm- Refn the
I D Bend back.the locktab, than unscrew and Install the new seal using a large socket or retaining bolt and tigMam It swurely with an
remove the camshaft sprockel e l n l n g bolt. block of wood (see illustration). Allen key.
R ~ D t Yh washer.
~ Withdraw the camshaTt 24 If a hydraulic-type tensianer i& fifld, first
s p m M and chain from the camshaft, then RtitfiffIng insert,-thegauze filter In the ~ylinderblock
release the chaln from the crankshaft $8 Refit the Woodruff key to the crankshaft (S* illustrafion). Remove the 3W-r
sprocket (seeillustration). Use two screw- slot, and then tap the cranlcshafl sprocket into (If fitting a new tensloner) and locate the
drfvem or a puller to remove the sprocket from posiiion. Ensue that the timing mark on the tensioner on the cylinder block. Insert and
the crankshaft. sprocket is on the side facing away from the tighten the boBsts.Push the slipper fully
4 1 With the sprockets and chain removed, englne. inwards, then release it. The piston should
&eek that the Wodruff key in the nose ofthe 19 Turn the crankshaft ifnecessary until the spring out automati~ally under spring
erankshafl is a tight fit in Its slot. If not, timing notch on the flywheel is in line with the Pressurn.
TDC mark on the timing scale. 25 Oil the chain, sprockets and tensioner.
Wmove it now, and store it safely to avoid the
risk of It dropping out and getting last. 20 Tgmpordly place the camshaft sprocket Ensure that the mating faces of the timing
in position. Turn the camshaft so that the cover and cyllnder block are clean and dry,
Inspection timing marks on the sprocket fats are with all h c e s of old sealant ~'WTIOV~. A net4
allgned m shown (sae inustration). Remove oil seal must be in place in the timing wver.
12 Examine the timing chain. Chain wear can
26 If ihere are no locating dowels far the
k judged by holding the chain horizontally the camshaft s p k e t .
and observing how far it sags. R e n w the 21 Flt the tlmlng chain to €he camshaft tlmlng cover, a gmket n~ustbeflfied. Lo*
chain without question if it has covered sprocket, position the sprmket in its the gasket on the cylindw bloak, retdning it
approximate fitted pasition, and ~ w a i eth8 with a smwr of g-. Fit the timing cover.
upwcurds of 30 000 miles (50 000 km), or if It
bbeen noisy in operation. chain bven. the e>Mn&hafi,spro~;kef. Pasftion and finger-tighten the nuts and bolts. Oil the
13 h i n e all the teeth on the wmshaft and the camshaft sprocket on ths>camshaft,and PulleY hub, and WmPQrarHY fit It on the ePrd df
p k s h d t sprwkets. If t h s e are 'hooked' in check that the marks are a l l aligned when the crankhaft so that the tlming mvel is
appearance,,r w w the sprockets. It is goad there is an equal abount ,oY =a .l& an both positioned Wrreetky, theh tighten'the,r;bver
nuts and bolter,
practice to renew the s p r o c h and chain as sides of the chain.
22 Refif the camshaft,spmcket t$tdniag)-bst l o A w Ndowels are fmd, apply a
a set,,sines the old components will have using a new locktab, and Ziihten 6 t h b a t to bsadWFeW of CfiF 4/60m1x0 Pasta (or a sUmbl8
worn togher.
the spvified t o r q ~ ~ ' & m e ~ l p z k tt&a b altwgtiuej>tp.the-timingcover joint fw (see
14 If a mechanical-type chain tensioner Is
fitted, examine the chain contact pad. Renew 23 retain the bolt. -
If a ~hanIml'~fens1oner
i l l & &position'&; mvei over the
Is fittbd, p l w - I t dpwels:md.Wfher two studs. Reflt the nuts and
the tsnsioner assembly if the pad is h~avlly in the reiainlng,abol+rs,then progressively tighten
in position and Iwate the spring
scored, or if there is any suspicion ihat the ?em in a, diagonal sequence.
ping-has h-me weak. I
If a hydraulle-type chaln tensioner is
Med, dismantle it by rele&ng the slipper
pleton with a 3 mm Anen key. Examine the
816f&,&ring, sleeve and tensiowr'bndy bore
@i@wof scoring, and renew $ wiUent Also .
@%&hthd fbhsioner if the chain contact pad Is
@dly scored.
4 ~ :P. ' i h ~hydraulic tensioner is serviceable,
I@i9rl~te.the components and reassemble,
,wcBltlfe .sleeVe in the slipber piston first 'by
tprnhg it clo~kwisewith an Allen key, then
slide thk Bsembly into the tensioner body.
AVOMpressing the slipper now, or the sleeve
wlll be released anrl the whole assembly will 524 Location (F) of gauze RRer in the
fly apart. New hydraulic tensioners are cyllnder block for the hydraulic tensioner
=Gum.
15 Where applicable, recorned t&'# pump) or the drlvegm&ndl
Sir&* W a$ level 9er~~mth-eiimH$$j pump]!' ' - -. ;
tfp sump. qgrtqm%ntes and l--lly
16 R& the 'fiywlrml mv@y pI&@c %a g* Xor qny skgns @f&'ring d~
bellhmin$,Mf~e&~' &pump if thmconditionsam
I 7 Fill She erngjne with 0% H h :
,c@fqpWr~w4& ,
.1@1WR I ~ ' e n d l n e a and:qghwen
d
twbbw . . . :;.
 2A*..l.Q 1108 cc ( C - t y @ P ' g @ ~ & m Y ~ p a procedures
- - - --
Remk [iTywhed end) oil seal
Remove the. flywheel as descrlbed In
-ion 10.
* Prjse out the old olf seal using a small
%~rewdriu~r. terklng care not to damage the
p-08 d the crankshaft. Alternatively, the oll
6eal can be removed by drilling two small
$ 0 1 . ~diagonally opposite each other and
fnserthg self-tapping screws In them. A pair
, ~ grips
f can then be used to pull out the oil
k d ,by pulling on each side in turn.
5 Inspect the seal rubbing surface on the
@rankshaft. If it Is grooved or rough in the area
where the old seal was fitted, the new seal
~RQUJCIbe fitted approximately 2 rnrn less
amp, so that it rubs on an unworn part of the
$rankhaft surface.
%; Wlpe clean the pll seal seating, then dip
Ithe.new seal in fresh englne all and locate it
;over the crankshaft ftwith its closed side
@cing outwards. Maks*surethat the ail seal
,;lip is not damaged as i t is located on the
*rankhaft.
b ,Using a metal tube, drive the oil seal
$$guately into the bore. A bfwk of wood cut to
$ass over the.end of the crankshaft may be
Refit the flyyheel refq,a~~$,&Se&-
.&
- -
ir
--
8 Apply a few drops of locking fluid to the
threads of the new bolts. Fit the bolts, and
flghtan ttpm ih a dlagonal sequence to the
specifled torque.
9 R d t the clutch w " i t h ' ~ ~ to
b Mapter'6.
e
10 Refit the gearbox as described ri$-2
3 Mark the ~~WSSBJ in relation to the crank- \ .-
shaft.
4 The flywheel must now be held stationary then jack
-%hup e front
while the bolts arc loosened. Locate a long of the car and support it on axle stands (see
bolt In one of the bnsmlssion mounting bolt "Jackingand vehicle support").
holes, and either ,insert a wide-bladed screw- 2 Visually inspect the rubber pads on the
driver in the W e r ring gear, or use a pleee of emin&-x mountings for signs of cracking
bent metal bar engaged with the ring g a r , and deteriwatim (see Illusbwlon). Careful usa
5 Unscrew the mounting bolts and wlfhdraw of a Iwer M I help to determine the condition of
the flywheel from the crankshart. Be careful the mbber p9ds. If there is ex- movement
-
n d t o drop It It Is heavy. Obtaln new hafts for in the mounting, or If the rubber has de-
teriorated, the rnwnting should brenewed.
use when Mtting.
Front right-hand engine mwntlng
I Examine the nywheel for scaring d t h e dutch Removal plflP
face, and for wear or chlpping of the ring gear 3 Unscrew the nut and m o v e the plate fdm
teeth. IC'the clutch fam is scored, the 8 y w I - d
under the front subframe.
may be machined until flat, but renewal is 4 Using a hoist, raise the rlght-hand side',of
prefepable. If the ring gear is worn or damaged,
the engine by 50 to 75 mr$ "'- . .r .,.a :
It may be possible to renw It separately, but 5 Unscrew the nuts a ~ ~ @ m & ' # i i ~
this job is best left to a Renault dealer or
anglneerlng woks. The temperature to whiCh'
from the bracket. "*" ' .
+ + ~ : x
the new rlrtg gear must be h~ated for tnstallatlon
is critical and, If nol done accuratelv, - . the
haFdp= of ths $ll@,,d*ed. - -- - -
Rbmi~ ' -
1
Fit the new mounting using a reversal of W.
moval procedure.
7 Clean the flywheel and
then kcate the flywheel on the IeW-hand ;BfigIne/
maldng sure that any previously-made F r b o x mounting
'kernoval r;.s,.
) Using a socket through the hole in the
subframe, unscrew the lower mountlng nut.
9 Take the weight of the gearbox wlth h,
trolley jack then unscrew the upper nut and
withdraw the mounting from the engine
compartment. if necessary, the mounting
bracket can be unbolt4 from the gearbox.
Refitting
the removal
Rear mounting
12 Unscrew and remove lhe thmugh-bott.
13 Unbolt the mounting from the s u h
and H necessary unbolt the braeket from t
cylinder block.
*.
Refitting
14 Fit the new mounttng.uslng a reversal d
the removal procedure.
: Contents
r~rns- Mremoval, I n w o n and refitting :.;,,.s .:.,. z.:. 4,;;..10 ;,, General information .; ...
, k s h a f k front oil seal - renewal ...........................9 Oil pump -dismantling,
&ompression test - description and interp-tim ; 2 ............. Oil pump - removal and
8nnkshM oil seals - renewal ......... .-.:. .'. ..............15 Sump and oil plck-up plpe - &OH arid refttlM ;1.
. -
A2 ...........
- ........
&...

%rankshaft pulley - removal and refitting ..................... 5

............
Tlmlng bit removal, Inspection, mMting and adjustmeot 7
- ....................... Timing b R covers - removal and mfittictg , r,:.A ,

.
,@linder head removal and rellttlng
-
t Engindgwhx mountings Inspection, removal and r m l n g ...
.I1
-17
E w i m oil and Rlter renewal. ................ .&a G h a p t ~1A or 1B
Thing belt tensioner and sprockets remod, inspectiand
reAtting .............................
9~ M - r
- . L .9
6

3 \.F..~*
1;.

Englne oll level check .................. ; ;.See "W&y ehecb" Top dead centre (TDC) for No 1 plston - l o ~ a t i n w , A 3
~+(tia%: .
) :.-
w h e s l - ramoval. Inspection and refifXing ...... .i..rr is..16 Valve clearances - adjustment a.,+,. :,i+ ,~.~,.,,,
&,4
'cknl#L.~?&: ..
Degrees of difficulty
,I - T-4- - * 'f ,

rG.u-p.5
Bpecifications , . -'a , .- ..
. L . m .I
Bdfk R e k to 'Engtne'fdentificetion"on page R E F 4 for details of englne idetrfifIcatEom
,-

-
-
:Emera1
Typb i: i ..........................
* .- .......... ..... .;, -....t .
i

........................................... :......
.
;

. . .
;

. .
2..

.
Four-cylinder, ln-llne, overhead camshaft
D7F
'-Ib
. - - - - - -
-1

' ", 23 * CV' -*,&.&

. . , ..,. ,, +
;-a #ww-<-r', ' :>--
-Aka;: '=I.-
A4- . -i .*
m c l l b # H ~tr- ~
;
" p
. . .;* ...
f

,< C. 'I . .

... P

..... . ...... :q
.........
.. . ., .
; > . - * . = *
,!<,!.#r$>>,~~~~~:*
, , . ; . ?, p,,.

-
.
)I

I.......... *., ...............

.I&.. ..*4,. ,!. ..Dl.,... a&
,
2 . 1.7.
37 -J .&-.

--
, . .'q*
h:+TbL-
.
: 8 -L

bl, ?
:. -2

. -,. I

I
4 4
1 R y pdisqft~~pp
W )b a e ' M W i p o i h t
~nithewkdkrthat*& piston rWhestas.th6

the e h d d .thamrnpmion stroke, and warn sp$as&t @ nyg&fm_mds-gg&t&

- &IPW woke; hewever, for nsawmk ref-
at U ~ a ~ df the on me of tfie tee&
the puqase-dNrnlrrg the engine,(*,,retern
.to the p m ~ m OT MU 3 *ton the mq
w m p m s ~ l ~strnka
r ~ hlo 1 piston Is -
tIwbl md oftw mlnh
 t

- &PBq@
v&Iw $bump@6pohs imtW and ,sxki@
V&e&>~b.' ' , - .<
q;Tum thq~opgji%'InWct&Mlsedlrwltm
) a i lthe eWWaaSLlV@ W&bm@
adWtmWt

exhaust mhteawmmtho exhaust !manifold

Jda. As the valve cjeapanaeo w adjueed,
s Turn ~~~~0 .PrImq~Io+phn-b
m,2w
l-
L ~ ~ i ~ n 8 5 ~ , a l W W
p@siffOn..'mw
W#!w~fCr:ih &$I*
mwlaff untll the firsf %0t(t!3~
W W G ~

Wing .bdj mmr, &r the ~ 1 1 ~ 4OQVBG,

8 as
a~@tWle!(ir- ~tempoq!breflt-the
dvwwsrhiawhfln'@~(~e411~k
9~ b ~ ~ ~ ~ I r S d ~ ~ ~
{ ~ B p d f i m t ! a n $betwen
) the Plo 3 @lloder
+d-1~@r.$@y9*m and the and of*mro&a
"Fn. shoM. :he a. t i p srqg., tit, H
@ ~ > m s m p~1wm%d
~ , ~ -"writ
$<. ~ ~ ~ ~ ~ ~-+& ~&- d + @ f & ~ ~ ~
&?&r $g,mFpj~ . . ~ wi i$.15
f i
#i@dtIif& un%l the t 4s ddrr& (w
'

+lUasWWqm)i HoId:W& adJustmer&W w ,

*he
@Wsrnl, $the ' . l o a W .arid ~ d ~ h a &
&di~r~dpmWw?&dJirailnmprm~um
 the lowe? engln?,, mounting bracke~u~ger
tlnflnq belt covek8s d&bed In Secttcrn 17.

@WC
, m s v e the rigl'ii-hand front road

- andap&#le-flv5:-
5, t*.*~Ma hhJd * m y in k*

-;@$ pu@iy bolt an4 recover Me

@&$@; P&nYpv& the nulley f r m the
. mnfai3hsipt(wIluidmh~).

,, .-
?@,anaw&.ipm,&&5&t& .
RmaoprgI
1m n - the mgatlve I&.
$&,ffitFptrmlng Mt ov the ombMm bolt, Ulen t m >the eranlWmft cl&se gkc'en f he -&A iipmnk&-@a~&g.
t~l@haftspr-5 f
an etrpmd tfie wg&t thm,uptr two bnplebrwolutlons, and &&
2
@,,@"dr@qp.veR, d b ~ b k h W$&d$> $0;
@,y&&&V7"113~1Mg W the beltfromt run Is that the tlm?ng IllarkS, am &Ull dl@W(&H $i&ht h samsfmft frum ;ra@t& er@l
w kd.slackis OR the tews~onww ~ t SWWI 31.M W ~ M~ ttensam . c ~ b v. tre
tan - - - 7 - . . T . .from
- - -+abrtt~htd - - st&i '
- . , - . w&'IB?~I$'&~
-.>
d 'ttrtj.-b&t, #MI ftt th$-$dt a h & be i a ~ ~ l b a ~ $ * ~ , u 8 i ~ 6lhe
h i o n e r pulley. W h w app~aQb, IImus90 tqol ak'@ +I& B~-&&G*
7 - .
1 r n ~ ~.~ ~ l ra&h
igtb strin
- -
nut$ ~d
lone loria. the athnr &en\
Y-.----.=,
w@,
- 7 -
9--
-..- snd.mr&& ,:j' T r
7,VrCI.

One nut mtl bnR shotlld form

-
MUm(W Wpon r n g h q n ~ @It, : with 17 EbfJt the two *&IG outer amins belt he pivot pf a%() tml mf w 4 M n qI
fke tfmlng marks an -.the ar s h e gind aom, w- n- n af thct'dP oP:t&foki~
c a y & a f t % P r ~ eDo not %kf g t
f bikt 18 Sefflt the lower ' mghe mqirntldg
a - a n.-d
...---
-A

angage wjth a e spm~..-.

- --
-,T -- -
--.,.-- fitm
? k ~ t'ImnkW ,
,
ahstply dMng rdiRtfrsg, and ensure ThaE.th4' bmcWirnlng be& rwer, and thw unmr -,....--
-- .. --,-" - B.B.
illu*+r=tien -- -~rt&rnat~lvetv. - - -&
if *e -- 1
b@W<ql,Wm31y clentraUy h the ,engine m u n h bradE4 with Me& to GO& and roc@ shaft rue rerfro3ddu, t ~ $
dam$h'W &n be hBM' ilatisriaty ' u ~ a w
&fable spmrmr on t h flab ~ @vp@,ayi'fx!@
ttnhIR$ &R knd bT the msh&,bnothlw '
h the to m e w&e m cg t&BX 1

InspsMon
'
4 #e spmckst moxoumfy, and m ~ ~ i t
ii&+&wa.dgrsQFw q j , Qr g ~
w@'@,&ohdes In ~tfha
G $ ~ Qp~i i 3~
temio& qtk$ &$
~ $urn t ~ et e n s i m r as
w I

6: R M t WR ~ b t'tdn$?lritq
, thibthle lugwt
n w 6ni11th'e bat rup between @p
W?pW* wnWfdt~ P W I- ~apmc141t
b'fwFsTW t h ~ u g h45* under mderate -
with the thumb and f . ~ h & r ~ , o n ' f h emmnwil
k@Tu!I h h e n the'm h r pump pulley wd 4 Remove the tlming b'a# as d e w b d In ~ ~ * , ~ ~ p m ~ L ~ ~

In p~sitlohusing the
&&pr b ~ fa h me

b ~oranksh,aftpull&
d&crlWfn~~n#,

WfWng
' .r-+ ~
- m%he,S-Dr---.--
& b- - - -ma&&. --..-.<-

~ U r h lgh t i ~ bn'4td
1 ~ 1i$MeI@t
~ &i$ia,
thediwft ~ ~ g h g e ~ spmcket
T h e bolt wlth the &-out In the md of the~rankshaff.
Wte fhai the s$o~ket h n g e shoutit be
Inmhqw tR^eTEX:Wt!4 on tha
abuld b-danad with the wrre8pondlng
?K@ at O f P b h m of the ail pump.Tlah&
(&*mU&adon),
IZ Refit a@.,r:@@~ntfre tlmlng b l t m
,&~'w+wW~ 'f,
@B%!!Bw* I B ~ 2 NO&@** .orthe s@, then pTf8B
ai4 the~WC' SU &Ma&$ a sh~lllwwd&er,
A~~ Wln cam nato darndge the sum of the
~
fa. U-
Lgas described In paragmph+l. esms$,&Wtw&tlve~,
t g mi recww the nrnwed by drillim~
tho m ~ ~ # I t nut
thaall s d a n be
smdLtw!eq (BqonNy
wbtier, then with$aw the tendow pAul1q opposite each & w a n d Insertingself-bpplng
f!mq j q u d bn the wwar Rump. &m -in them-A pairsf-grlps~m.t&hUi
@w@lOOh used b pull out the OH E+ by pllling(0nmeh
side-In ,tftmi
t6 a.WWPI Wmi?ner pulley, but do nd u$e 3~lfispett.~tb-8mI ~iubblngsurfacs on the
s t ~ yW%=gwW-m t may mtpa MI& m
whichl tIf ,I&~sl@mv&~o'r k the,m
~dllgh,
Mwl-SM the mates fr&y# whet&itW,~ld -ssEit $& fiW::it16. m W seal
WI*. o w i m d r s g r o
n w
r,~ ~p k : ~ q e e ohouki 'b5Rttedslightly &e deeply, w th%
th&WmbIy I f mere Is any doubt ghauf -its. rubs on .an unwom'mt d.*e surfam
,gjf thwe are,W Y - ~ ~ $ Q W S ~ ~ ~ B
WM dam-. - ?JP&$=&*~%$'Q~ meah: a e i -W ap W
o o s t over
~
Remihg' 3-Y..
8

28 @ #e pulley to the stud on

Wppr &I% W t h s! drre&flonon
$%&
H w C vlitfs on tfp g u e face d
@n fit WrW&tdrBhd !ha nut3
Itt$l%Whanut at this stage,
i,PhhW# ends.&.&WW 7- ii~wfigMI -W

I-r pwmp~pullsy gragypk $p'P'mA,&i~i~wtk@, ,A

bhkk d wood a t io m%&~bv5r3he enad the
t@%e water pu pqll!ny1s htntergrd with the camshaft may t~ d i n a t a d .
MI ~brnfi,;l% ca'iidot be ierm'vb. 6 Ftdtzke cmsh&wiacket as deacrlbed In
TrnW.
 kaW fmnt oll seal, with RepamrPg le E
Wt the. w k b r &at a~mrnbly pnd
10 cLi,lb.nh h% h e h g w
- mes-ir~
the then ins* the bbk and
th<eremqaftl'qrw;fie^ 9rhCt!mMmpe-.-.
z~y~b~w
tm
,w thehead,
11 R d t (If mrustplare we original
ioyllt~dkrhead asAd836rlbaplIn

thbstplate hherlrrg , r & W , mwre that tt is

fffted the c o r n way mhd, as n W . bfm,
~ & i . t h MwPl tl&Cn tbhb.
If W u r e thjs ,encUI08t' zm dewlb&1In
paragraph 1,and rr&wsure W 8 Os oithtn
bra Ilmih givdn In the Qmifimttans.
-9 a n M Fan only &due fbwear of
k@?@w th&thrus@lataorthe cam&&.
aiid
the cam$haft bearing su@ctxl,
lobis foi w w rldbas and scokina. 33 Fit a aew"mm~h~$Pfto~t 011 seal w M mYww 1

~Mmnm,2e'Sed .gl. 3 &plyBehanEfbrak @?jack up thafmot

lr R,Mt camshaft $pn:ket, r n a M ~ofthe
~ whhle and support securely on axla
that the 4%t~ r n g w ~Hh'ththamt-out in the && (&&
I$ *&~&TR$
$ &hd h#@di:
em& of the ' M a a H . Holtf tha &ch'SHaR Rmwb$fmhntright-hand mdwi-14.
&Warrary usin$ the W h o d employed on a D&$~WW"bath$w n-iead.
@ Tb lm&e aceguss, m & wthe Mnet as
d&@w
4 aP$3hhtk&
iir wlk@&ll.
~ o l f n i =,dewitred
$ ~ ~ in
m q t e r TA w t B.
S'RMTW t b timing bett as deadbed ih

jgld$mrmeWF ewht-m
fheT4mbwpump... . .
 fl.t.f@,,.&tdfr&mtit8*arm+atthe
tamlibion end of the v,alw cwer

- - - -- - ----

I
-a
P
d m q e tbe.gfpbtf a w . 'Id1d4B I m m U the-llplryt Cwm
17 Cqeflly tih the ~ylindrrr,head from the t W e h m m I caniMerso1endd wlve
b h k [me ILk#rtratlont. Rmwer the cylin&r adhesive 8w mg paper, seal the water,-pi1 Checb that the two IwatIng davhls are In

1
hmdgdek;and discard It. and bdl holes in the wfinhr bl&
18 ,U WIrN, the mndmft mn be m m d crankcase, TO prevent ca&n entering the
ri&xh&ied in Smtion 10, md the wiindw @P bWwn ti^ &cans and bwes, smear a
b e d can be WrtmtIed a~ &mibd.in Part E
dthk Chapter.
htis gferase:In gap,, After ctmnh~each
plan, use 4gmall W g h to femm,all traces
of grease arcl wbm fmm the gap, limn wipe
hWng my,thds mta(~derwith a &NI claRh. Clem
Pt all the pistm.ln We.same wgy.
lTm,rn@hg&.of We eyllnder head and 20 ~ ~ surfwes,of th&@lnder
B theCmatliiQ
~ ~ l w btcWcmnkcase
iw must be perfectly bIW~ranbaw and the qlinder head for
clean Wrrr refitting he hmd. Use a hard niuks, dm~,swat&wahd other darnage. If
p&h or w~d soraper to remove all taw of slight, they may b$~ g n carefulty d wlth 9
gasket and carbon. Also dean ths piston file, but iP exmmlvq, rnachinlng may be .the
4,'
vwnp.. Take partinlar care, as the mtt an& abmalhexo.ramawa1.
dumlo.ium.Wyisdarrm@.easily. Also, mke 21 If WW-9. d,the EylltlfitX h ~ ga$(~t
d w Apsryy,;a;I&Mhl ~ f ~ m $ mtaethen
$$w.thatthe carbon Is not allowed to enter 8- la s u $ p a W , us9.a stWgw-&gekq
I the ,dl and water passages - thls is check It for distanton. B~fm tp Part.E af mls
@lylarl y important for the lub r l d o n G h W If nwmary,
I m, ilB car- muld block.the dl sup& 22 wipe dean t& rnatlqg surfaces-of the
b any ~f the englrrq mmppnents. Using cylinder head and.eylirlder blockbrankcme.
position at each end of ths cyllnder
blmWcrankcase surface.
25 Check that No I piston Is M I mltiond @
TDC wlfh the cambafl and w&&aft s@&d
made cxrrrecfly aligned (mW on 3).l3q
rotate the ~mSfi@ft h d crankshaft untll the
tfmlng hlt has been Mtfed.
24 Flt the n.ew ~yIIndqrhead gasket to the
qtlndar bjock, ensurtng that it locates
corr,gctIy wer the d~,weh,wlth the TOPu
marking vlsible on the Inlet manifold side of
hw i n e we ~uWPP~:
24s Lsww the cjfllddy h a d ihfo padxion,
locating It on the
t h r ~ i ~ h ~ ~ I ~ ~ r
t t l e , y m of the b i t Mds.
29 Weftill .fitihe-new wllnder b a d b
oa
and ~ & k In,nby h.nd aniy, udY Rngr-
v@hi.
~ m n
> mWW wah w hosg:pps.
t e inanitokl
t as described in 6 -Ji'q
eve ,&'the
h o l l m d Ring Wle to the HWng
k&r daht-hand wrner.bf1tha
*@&
arihp osW-UP
the>&'

-'a

it p&u
minfp.fh~~~mp
13'bwa4t~esrm and w1fhd.m.w it f - ~ m
$ b i g &iie-*t4iW&
fi'W 1-
ea3N~&k,~lb$.

ix
.I-
1wbfM.Jhe p p J &
@tt81& b , p & u * ~ i i ushg ~ ~ r iWhir4
the dl. !ck;=ktp
,p.- @PpI2pd
"aa~I$dv~ eL%&

14 k1-dart'twi%&la'ht

15 W e a
'
:w&hw w if d9.W

plpe$l&pmlml atthis w e . -
'*
,

if Paskim,the: sump undar the cylnder

Into psI'tron,
-,, .-. In

.
10-fi
~UD
j .

bt m

p k e t m th? 4mp, nqlllls

that the flat edMm ofm8'aasket should k e

lii~lmt#cij'~7d&~by:b~t-m pkibtrp

bl~&~fi&t,w l w h apapptlcable, rnanQul& h.

&9 % ~ .
I
sump,

.'
dwi

M Ias
k

.vx
thg dt-

@yb**iek:
I.

18 afbf4h@hurnp te cyiiriddt blah

niflpu~atr~git, over We an pfek-~~p pi@
~we'p~*si$p~~re), m~~lng t~ t&.ge$w
gm$+ In $mItbn4 and hl$M the-
F&&?bveyWh%nm.e.tj&k If, a deriarl'
s*enwt~*9pMatbm.
t%RW* M b w - d , Mi* €ippirw%;
mmne-d erwr wMw$lw,
twd a '

faG e a b x b e l W ! n g e~w't?l@b ~ ' ~ ~ ) @ @ f $ ~ b ~ap ~ ~ - t r p12.M Fit a new O-ring to the oil
sewfftgb& It) @@wedwith -1nB and inverted)
~ap~eud Mck-uP
 $0 Reflt It)? crankshaft slprpcket, rnnsMng
that the Iw,on the spwket w e wHh the
oarresp&pgL C @ W ~ in t& end af the
GrmMbftt
j3 ,Re.cogn~&,thebw 411 pressure warnlng
+

IlghlMpb Jrlw plug.

IS Wit4he sumpw &&bed n tiib Inarm.
In Q ~ o 12,
,. 7 - " -
~ @ ~ O Vthe
B thlng beti as described 'in t B Place thwtrolly pck and blo'ch of WDRU 3 ~nspectWIBseal rubbhg- s
S&tion 7.
2T@mpm~ly fd[t the rlgH-ha$ bww
under t b sump to toppopart the angtwr;Mn m,w6 .Hit b
-& (WMIIIQb t W & l m i ~ @QVH $at r
k
d C r r q m meIWw W , m d Wst Wh~tg The old -1 Wm
20 Unbolt thafight-bd l o w .sng!ne wt-&euld be fftagd1Jig~ly.lw dq$b, w t w ~
qlMr he&, and tighten the 8e~uringbob. i~*rn.rrgrrg*@P w W p r u~ b man~ unworn~ wrt pf the s u t l m .
8 *hnnWa hoist and lifting facbk to the
*fitf'y#yeon thb rigtFC-bnd lower ,ehgiqe
hum bsn d&b& In W o n 7. 4 Wipe gem the oil seal s W n g ; h &tile
npw,& III fpash w f n b 015 and laGater R w e f
~~~~~~~~~ &vk, atid &athe
hol&'to )@.take the weight afthe engine,
the crankshaft with Rs closed sMe facing
wtwards. Make sure that the QIIseal ng Is not
4.WpkEmt] un@r the vehicle, withdraw the
Wey jack andl block of.wood from under the
sm, then m o v e the sump wlth reference
f a W m 12. &
No spare pad6 are available br tl~esj!pump, & f m krpovql&.the old sfAal (m d w
'q:#@nnm%~ MOng plug tiam the low all are provided .H t h m i*widenoe of a
and no weerr llrnlt ~ W c a l i o n a g v 91%e
p$+@m $mhg IigH d*. far the Internd ofmpmmts. H wear or damage emr@m-j#?Jw Pf ofa* Q@m Q@
B::)rr'&w r ~ l m r i m spf&Kd'irotnttie b wpeated,8 new pump m b J y - 8 h a u l dbb we &jd df 4 t S &- Jnay b.used
w afrnsm&h&
'E U n L WWig w i n ! &bo%,, and Wlthdmw
#$.oil pump mm wfr frqrtt of tha ~ylbfl&
%WW!W~l.
j ~ the rrdn otl pallwy
@ " R ' W t h & M n from
iqIhWW,
tM amkshaft @onfoil 4.irom Ih
en@ ail s m
FPmtrnrn'I~~hL
'*mias 1 RBMQv@ththe t&nR8Mfl spract, &
XI Gpnmnm reming by thoroughly dewrib@ In .SajEon 3.
dwins &e d n g f a ~ &
c#the oil pump add

b h w ~ ~ . tii the
~ slp Y
e c i d totiue.
 M ~erigagerdwith
use 4 pk+ W ~ E .rriet@
he dn$j~ ~ R t $ h i j i r Wa.wiWle
y, t&I rn

5 AJn?ww the rr(ollWng b o b andl w w d m

%tie 1
- tfrprh .ae &rahkshafb [me
tntnwm+ ta~mmilnmt"biifap::'n -:'ItL
hd$? '
Isp-n 1

6 ExemlhC k e -#I for emrihg of ih8

&m@n

I
Q1IltcH 'an&* WW'WthFpphg:oT fhe 1 +@pIyW WW4H&nja@k'bptii%ffant
clutah Taw t ear&, R df tRrerpavr-'and,a~ppmt it s w w l y bn axla
? $ g , ~ ? ~ p t h'IFthe
,
may bK p$dbfe- fb have, the BVwMaI
ewi&mim &&/& *m
rn&fdrid, but renewal Is ptqfmble. If ha ring D V t s a & l ~fhspa*t'%a pubbw pads 5n the
geai-ii worn'or d w a e d , It m& be m l e ~ k & ~ ~ ~ ~ ~.4$r~ elma& sf n t
-@y ~t&Wm@,Me-
M I ~ ~ t-
~ I 8 1a$ddMa~&ion, u s&me
e d er
m b b w p a & . ' F ~ b ~ ~ ~ r n e n
W*mmriB::@ i E 4 M w h ~~,
~ \ a C P u , ~ ~ ~ ~ t ~ )&"the ~ ~ s f ha mountfry)shwld km maw&
t a rhdt nhwill
&a=.

I
Rempvat

pr&ysly-rnadw rn& are &nd..$?b

the flwhsel boM holes are 6 f f e . & f e
f l ~gndpnb &,fWd In ~a@&!ibq. 4
8 Apply a% W p a d [oeWn@ flLdblrtithe $
~n$$ji.s: M
ru&&r, h n
.gr,wm %w
id withdim me
t h r e &'-thy new ,flMqg.~b@&., !;F&.tCe WF, ?hen u n p q w the t w p l t s
b o b , and tWht8n Msnf in Q ' 'dtmoml sakurltig the bm&el to the towar
sequmce to &e spdfied to~guein'thg'iwa mw&pg bmpgtIrn4 b@ p ~ ~ Md $ b
stages given'ln the Speclfltatlons. F W ~ ~ t h Gs l W h
t2he bhkkat ~ ~ m ~ ~ r r s
 1 149 cc p-type) engine in-car repair pmcad.uw BBmAf10

h-amesa-*$.@w=.. .
wi
ri~t R @ & ~ Y l o w en$im~
r
,$'&ltdng Jsarev~ald~r6gwai butegm rnmn~mg-bnwkeWmhg beh
the plastic W n g &It wyr'&m P - 9 :
&.ssch~jiig n&ana boits to the spsc~fied
torque, 'Md bH mptetion, check mgna if
WMW . , , . ... - - 2

.
- 2

13 Canefqlly mWel b dip wmi&+h~W

Rmml +
&%W adjust 'them
pijsftIon of the &glM

ve
~ t r n ~ ~ ~ ~ ~ 8h Rsmow
. the right-hand upp& engins
'

ym&d-
'>'

b w n emh side mguntlw bracket as d-md PW!PFJ&In uncllp the h o ~ sfm@ ,- ;#&
,a f + h
fh7s w o n , -:
@w~w,ma '- m;nl 02 #:
9 Un~lItlp,W .cK9$~4M q W liw~fm the t4 lrnwew h * u k km s @ & e * l ~
sRB[r& a metal plate, 'orfader blada <& front d f 'fie rwwer ~ g i n * rnountipg engin@m n g bwk*!?g
the _ojl<ndsr head, the^ &@il&& t l
MW%4Wkrm# throughthe t w dots in)#& bmchMl~ngbelt-W-(swIlrQdmfbni, belt wvw ~W&e.,wl,wrt!
,@~~Mg~~pyhth't~f tlrmket. The clwranw on 30 VwnnW %@, fdollrrwhg yitiw bmkMlrnlng
Bm $ldw 8hwjd be We samg, le, the cani'wtois, #Pn m o v i the wlrlng. m e & hose,-and wlthdraw the brackeU~ng,b&
m*tR-w
met@$Ilth1teP rubber ahald $B c l w 9~ rmy +?gm!~, VOY bp~b@
hd~'4&@4lw nseunting Wk~t.. timing belt 'cover, noting +a mu>lngof me
T;F>- ,8bMtW@twa &ng uj.rfm>p tpp Cm I ~W
9 l wsY. 15 Rmlnrr Is a reversal of Fem6Mb ,but
the mfr?le_mentlimiter plate to t b h~d y , and 4
'jad&st-$hposl£jan of the Hrniter uM 3 b bj D(S rnPuM.
&bm iei,.rmtrdliaed ,within tb rnou@-ng
~~ ?Idhrn the m,oymsiit lhItw
Wdq bb m w @ e t i o n .
 has W R ~ e m d : ~ ~ ~ r A - mtbSs
r l ~ t n
sedork - .

tubber Is imbi~mlhi&'$Be
mwrrtlng p m Mhlch la &It& ",me
2
RemaRll
$7 wRe4pvg'the rlght-hand upper %nglne
m h € W gb W b &BB- pmbtously ln 2~ ww ~ w ~tp w lmng~eand
9
% $6 I~h-hnbenllne I R h g bca&bt,
.-&i
18 UrimqtHs four $muring bcil%,~nortm .MI$@€ 9&&tp~ lust M e th? wbhl of the
mIIW?,#'the both also secure the e n g p m r i r ~ n-06 a
t l w ,:off the m o ~ ~ e r p H&emov.6
~ ~ - f l ~ h .thwt'llR t 'ma battery as d%erlbed in
Uhlkw, and withdraw the m a ~ n f ' h g *ta. 24 W&qye tm, wl jnJ&tlon computer as
r t ; l b r n W w t ammbb.
-0
ehw
de6dW in dc-
26 ~ d i i p qWYwring hwnwses, s@ly4
4~ ~ i r r s ~ w a ~d f & h o \m
; " a l , butlaave h w , &, frnm fha m e m n g b * W
kfbp~w hbmf
~ W@W~~m&iit mur(tina
how, until th6 upper englho 'rn&uitl@ n Unbolt ttte battery nrountlng sIdep1ate
&#&& %as m n W i W es dm- ham the 'and m 63B R 1-
<p@&w&
* .. hthis Saction. lh&Wunsj.
2 g ' ~ y ~ 1&k v the W t i m OT #$.
rnoudn~braqbt/battery mounting on m.
&&&I enable the bmcketlmountirQ W ,b6
r& h L artgtM p ~ j o n .
28 Urn- the Md 'nuts ,Wyth@we
mounting bmeWb&yy ip~ntMgdb:Wa
gearbax rnau&nb *rWfi@dI'&, &&-~r
~ P Rwwrlng
S t+t&wtteru . m a w
tathe body, and -&€h&w rll6kd&&MW
--- mounting (a- IkqrMollS).
' R a m m~!a
a w.rd OF ~ W I hut , dcr a 'Witt~ng
18:a mue&ii df t t m r b l~~~u t ~ l RW-WM
f IS a 13- Bf - ~ ~ , ~ p m ? y a
thsmmrn&limtter~urthg l M e s the m@unltw b w k W & ~prc~&ur~+lbutlghtepth~~wmrlngn~mand
~
, P ~ ~ J O WbWw b t ~ I W U W ~ o~ ~QX ~~ ~~ ~ ~ M ~ Q I Qhb U m & ukty,
 Chapter 2 Part C:
1171 cc and 1390 cc (E-type)
engine in-car repair procedures
-
-

-
Camshaft removal, Inspection and refitting ..................8 ..........
FtywheeVdiimptate- ternoval, lnspctlon and rewlng .I3
Camshaft oil seal - renewal ................................ 7 General information ...................................... 1
Compression test - description and Interpretation .............. 2 Oil pump and spmkeis - removal, lnspectfonand ~ ~ .......
n I tg
............................
Crankshafl all seat@)- renewal . I 2 Sump - removal and reflttlng.............................. -10
- ...............
Cyllnder head removal, inspectIan and M l n g .................
9 Tlming bekt - removal, inspmtlon and refitting 5
Englne/trensrnIsslon mountings - inspdlon, renewal and l m l n g tld sprockets and tansioner - removal, Inspectlnn and
adjustment ........................................... 14 rdittlng .............................................. 6
- -
Engine 011 and filter renewal .............. .See Chapter t A or 1B Top Dead Centre (TDC) for No 1 piston locating .............. 3
Engine oll lev& check ..................... .See WaeWy c k k s w Valve clearances - adjustment .............................. 4

Degrees of difficulty

Ii' ~pecifications
Note: Mfw to " ~ n ~ i identifihn"
ne on page REF-4 Tor d&i/s of englne Identification. I

Type ....................................................Four-cyljnder, In-line, ovemead camshaft

II
Dmignatton
Rling order
...............................................E7F or R J
...............................................1-3-4-2 (No I cyllnder at flywhee~driveplateend)
Dlrectlon of wsnksllaft rotation ...............................
Clodkwlse v h e d from pulley end
1

\ E7F englne E7J englne

Bore .................................................... 75.8mm '' z5.8.mm
Stroke .................................................... 64.9 mm 77.0 mm
'11 ,

Gapaeity .................................................. 1371 cc 1390 ec

Ewnpresslon ratlo......................................... 9.26 :-1 9.5 : 1
I MWrnurn power output (typical) .............................. 43 43 (60 bhp) at 6OOO.rpm -58 kW (80 bhp) at 5750 rpm
Maximum torque (typical) .................................... 85 Nm (63lbf ft) at 3500 rpm 107 Mrn (79 lbf fifi)at

Inlet.....................................................0.10 mrn
BWst ..................................................OP5mm
Lubrication system , .I, . . .-
.Bysem.pressure: . . .,- ..

i
I
0
Atldle .................................................1.0bar
At 4400 rpm
' 11pump type
............................................
..................................... .....
Oll .pump dwances:
, ,:
T.-
3,Obars
Two-gear
. A db.. , ,,

%m-ta-body (mlnlmum) .................................. 0.110 mm

-1
Gear-to-body (maximum) .................................. 0.249 mrn
Gear endfloat (minlrnurn) ................................... 0.020rnm
Gear endfloat (maxlrnurn) .................................. 0.086 mm
2 0 2 1171 cc and 1390 cc (E-type) engine in-car repair procedures
Ynaertan
become:
 in-carmpatr pmcedw:
11?6 cc and 1390 a~(E-&p@mgine SS
#

5,.i3 Timing marks (TOW- on the

cranM&$pfmk& a d M . o l l t & l ,m
4
I
I
should h@,p9~1itiw sq thafJt.w!I 1 - i ~
the ,da@ahaflspmckit In alignment wItH i$e - !

1
6.40 TWgg belt and W n $ mar@

..
2C.6 I f 'isl CE and 3agOa~tE-typ~

31 Reflt tha pla&lg~cavwhrslda the rlght-

t y d w h d mh
Wj'R&% the F138.$Wwl and lower tWmr to
qnd..
a . a #%,fhtbgonnavuiul w-
W'td.
34 BkimmI~"*& p s i - w twd, the0
the mg.%tlv4lead.

b b m & ~ m + . ~ ~ *
uslilg h , - ~ i ~ @ ~ rule
& b h l

32 If tm adIustmmt is Eneiormt, the

tensianer hub will Raw to itfe r&p@18m+H-
ThetqwbrwunWFWb m d . - u m b ,
&nce If if were tij h:i30~e.Iom,
i5ansH&tlf@
dnglne dIwrm wputtt result,
89 Tempat&fy &fit fhaehltrWlaft pulw ~4
q bolt. Using a &dm We pulley M,#m .
the &~gins'IhthroughWa m m W e tevolubm
In t+ n m a l $ i i ; t M && the timlng,
b ~ lrenslon
t and ma!@ sure that Yhe tlmlng
rn* are still tn allgmmt. Remsva the mqshaf:
PUM. 4' A p$@ hay be h W W to m v e the
24 Hfl the timing Mt COW% tlgkrsn d~ smWs(see TodVp3.
bbw. 6' Whet& appliwhk, m w the WIjruffhey
to tFe nos6 d >from'Via &jot h the martkahaft tm IWw
25 R& the srmk~haff'~phjtay
-ths &I&@, !#@hSWW
the bolt b the.sp%Medhtque, h ~ l d h $ ' b
arbnkmaft ~ t @ l ~ a rMing
y
*-
'in Pi*.b.olt. f BhkV e w , th. key is incmonre6 m t b
'the mellyd b !dtp5ra1 thq nut artd wrthdraw the:

-
d~&dln@&phIl. mslpnp~ @om*the s&d on thab front mva
28 Wit md te@m ~e~altwnator drjvabeh [it'& il-.
wlth mkmnce bb&&ter IA4r I 8.
W, *;an$ mmthql o w -&in
its p w w s ~ c qpw&rs,
j ad figMen,Aa
,mto@W@i,$d$W-
Bd3the~lCfiIt~g
&VW hCW-tpthe QM-
hand end of @e.qlihdmhead, and tQI3ten tli'B
,sits. . adiiiaa normdly I& the ~koi the enghe.
a Fleflt the mineu p m maunfino-bfmkd: 8 8pln the tenslowbi, hand, and check # fQr
my.qughnaswr t i g h t k . Do nOt attemNXo
dean It with solvent, $s.thls m y enter the
hferim
ing adj&tmiinttmwIth to&@&an 14).
Tighten the bolts and nut .to tb+pmWed
t6iW RWI* tbp W wjack M !w+t-
30 where applkdtjlw,r6fkffie plrssttr; W r t o
$6,t4p M th8 win$mounthq brae& and
@M -w*
 ~ginein-car repair pmcedures 207

g a new amahaft 011-seal 8.- Two of the rockemhaft sewdng

L o b (~~

s~endcm+%Jl-.takingw
not to 'datRad* Wngsst1l4aw W e
rn*&@. ; - I v --
I R e ~ a v p the camshaft sprocket as InapeMon
>mwMe&m,a Remowal 8 Bamine thd ~GWBhaftR%gmL
$ u W ~ ~
;&hiare *ti6a i d position ot the. old iol~-1. 1 Remow* qfimdar haad .as d e p W In cam lcrbeo and fQdp&p~ ~ ~
1VsIfiq ~ t h , . ~ h . t fph
f e Wlql8, @law it an the wwk@rldh, q#p1imbW rn m fidgw % i$&nm.
i.
&3h&,the qrd"h&& 2 w m l y u w m the bptt Rold fhe ~ & ~ ~ ~ r n s h a f t ~- ~ &
~ ~ ~ p tFre d We nag In the cyl[r;laterhead. tacker rhm@ rs$lni% pl@th.kfm-$&r am apmn7.
d&mar,aU f t k nll an tha auter p M e b r head, -ahd withdraw the shrift. Not$ that the I,l%aMlne i h canditlbn ,of the b&1&
$!U 9f the new bti Wl. w e we s& bffs,@$Wqt,@ Na$ld bf&MMfor sutT$ces both an the c m 8 :gin@ ~ mnn+ha
:S~MC@ n the ~yllnderhead. d v e theseal gosftron ~ f & erMaal. Nunibers~ 2 ' 4~ dayllndw head, If the h d W n g slafaeeS ate
@k d!l k p , wing a metal N b whkh has an b o b hay? sOJ,W *an&, whewas 'the other wOtn-W'8Wely, the cyllnder head will nead
~ a l b i a m e t e sb'htly
r ,lessthan that of the bolts have fiallakr shanks. ~helr'688dsare rd wre-ed,
krqio Qtq Cyllndw p a d Illustmon). qplpuqd ag s b n bee illustrations). .
M h k s-Mthat the oil seal (I8€he correCt wav S' Hold Me camsiaft st'a~anaryusfq a
~p.agn,eran ~.eBsBp&bl . l @
provlded on the 70 Lubdwte .the bearing 8 u & w h the
&WMff, th& b ~ lahd
t withdraw and'*
qli~ddW MM )@urn&, ttkn
the spmka (seehltlsmiei. ins& 4h~~eamhaffM tbe head.

M ~ . W w l W W : c a m 8 ~ dwrrn
~ aat
. dlal gauge
2 0 8 11'11 cc and 1,390 ec (E-ttype)engine in-carrepair pm~edures

3 s~ p
4 ~ WhIM a ~ & ~ w ~ ~ ~
&&pb e t Wm&$ 1'
*rC lbliit b@ween 5% Wff~lKWk
gasket (wd xyllnder hiuc'k .d m w &e
:&wvT$mbiw ttresamshaff~urlrtg b ~ ~ w ~ ~ ~ d s W t b h #ma
ti$eb$lih"i $
boA 7 Dimnne& tfie+am&Wr mbfe, wlth To do Zhis, pull the dirlbutor end of the
$5 Refit Uue ro& shaft and mt$nlhg.pfBxeI retmca to Chapter 4s.Ppsitlpn the die to g!inkr head forward sa as to, swim1 it
thn,$nt& the hoh?n tf18iron'gind pC6itiahs o m stder W n d frre siqgls b.dt,+till fi*& fin maw
wjsti~@+tw In[& q d mat@
+a;,# msrntiqtds tk@ h W IfWTo ip Priginat p&1.0n; If thii
vR~31:d:h",z'R,Md~ied m a$n be r - O V Aai fhfh s Q Q ~QtH-
. fi3ced-p Is not Wlqwad*, here .is a
swb-lg* die.Rfi&$ the Vart~upfuai YaqUurn and
matant hoses and ,slWioal feeds from the th@r b
@&$Iw OT thg Wh@@
@bm.w kinq
IM$B mavmand
q d1s@r4dr wing
throw0 NdY W from We Injet W i f ~ l CWPd~ r M&g&#$
t~
@M @ \h&~rgdlllq~
&whyh ik BBy d tR \tiie
sdlt.
6 h a p t 4@,
~ Ba preparad for fuel s p l l l ~ ,
A!-&Qim7g &e.$;ithi#16t 4WnpipB. I ~~<G%,'.~*-~O~@$WWB
9 b.~Mthe iltw and dh@onraectthe wk~tE;~B€&%>I- @p do&I 6lr the b
nt
%nmb$& rl@Vh?d PXITW' &-the bhck' fa&
4@yMntmkpwh=fmh mqP*:
~ ) # w h & d Web. iB that t ~ Q
h 9 W M in^ not
'bmar ~ ~ r ~ ~ P r w r , t e rotated
h~ t awith t @e cylin-der >head m o v e d ,
Wskrd. o h M s e the c&rder limwill.@ dlspl&.
1$JxGnnect both battew [ a s(d,yqys F) ~ w ~ h m ? 6 s ~ . t hW iet k ~ ~ h o t q m t h s c r a n k s h & ( a ( l ~
MOnnect fhd negative W flM. w h cow* ckan €ha pgton crowns), clamp the Irhm
2 Dmtn the cooling system, irr@jdikg the 10 Msc~nnsqtthe Hf'teads from the sp& u~inq;~@@lf. and w ~ s orh make
~ ~up some
arng~~,brqa& pmwa b . : m 1~ plugs, $nd pull them cwefutly from the W
.q
lg@d m , t b lead holder on the valve cover. Unbolt and
I R T h e b t ~ . , d m i,pwg,I~,
n
m m 6Wi' wt.Of flat Mk,hdd
tbtightlhgtld War f&e mg$?b&dAO~h b&th m v a -holder.

g cyiinaermm~rnkt
q ~ o r r f n *e 'IW-W~WM 1
g
- do- 9.16 Clamps (arrows holding the
-( cylinder liners in place
1 e~gr'ne
1-171 cc and 7 3W.m,@-f~y;p9, in-cw repair pm&utm 2GW

blmk Clean the pfstbn crowns In ths same

r e n p a j n i q , ~ ~ ~p
g @ the main Hahtanlng
pr(ieiduCkrh ~ e e H l ~ l m ~ ~
,27 H n q w y dwe, refit lhe roc++ shaft
a d i&th,g $la&. Inserf We bits In their
sriglnal, p@sbr)s, and tighten them
ppogr$&ivk
W !If Bp,be apwW torque-
cy m r ,hwd'has h e n .ovelhauIed,
n lt3 ~ o r ~ l ~ l i i b & h Wthe
figvalw d m -
at this *, to p r W any pasalbltlty d the
Mves touehim the plstirrls &*ti h e timing
TS & ~ k yp~?p:k'ai~ti
j wu for ntclb~,dm belt Is bekq fittededt
Turn the cranwaff so that
-ch& and &hef dam a lf-djgh they f t p L@no Wbns at W.Us&& socket m
qmq~.@@!l~ 9 w da a file, may ba
b repairmare seriaua damage by
the cam-&afi spro~htto turn 'the camsfiaft
'@IdC hw the *>? Note: 4 engine liffing holst wl/f be m q u W
@'IningIbul @la b a wmtallst jab. ~ dthe t fhetmostat with mfwence to duflng thls procedure. A new sump gasket w161
1Q Lf w&ags of the cyllnder head is Chaprerp
N@$pqb€it user strprrghi;edge m G h a k Jtf& W i t the fiming b ~ l twlth refereme to
lI&rli@; $hew the protrusion of .the -on 5.
~$@tbl: Ijnpm $El@ead tfiesa Items om b~ 97 If-nbt a k d y done, adjost the vatre
-a$suc#at& wlth the 'hesd gasket blowing. clearances as ckwbed h Serctbn 4.
@I&!> t ~ l ' P & .E W~MSChspter for further
W%HBn.
20 C@r-out dl the bolt hdes in the block
dng-dblw'cfe&er, OPa rm and screwdfiw
leadsinihehdder; '

S6 Rednfi&t the mkshaft vdl@ion-and

eaolant hos.~.
3s Mtt the H d & h y l mahifold$, or
reconndtha vwlQus +ces4p them, wit$
referenke to C#t@ir 4B. R~dohheciffik
ehaustdwrmpfpe.
37 Reconnect the accelerator cable, afid
adjust It wlth refBreneeto Chapter&.
m Reeonne@ all 'wlres 7n t@lrcWWt
oosltions.

bqlnn5G acthis GhaptStP. The first thre; . .bob.

2C.10 1171 cc and 1'390cc (E-ty~~ eengine
) in-car repair procedures

@&a Unscrew the securing bolb'. . .

mouritfhg Iln& Unscrew and m o u e the f r ~ n t ef?g!ne rnbunting upper b W e f and nut,
bolt, and whl the Ilnk dowriw8rds. tig*lk thie nut to the switid Xbrque.
B Remove the exhaust d~whpipe with Remayetlve halt:
mfmnceto Chaprer4E. i i R a t h a f ie-bar and c a v l mamtjlv tb
.g' U n 6 m the bolts W r h g the ,?ngine-m- the geatbox Mhougdn86ng and e@ne bto&
aewbax t & h r and cover &amblrif W the 18 Refit'the exhaust downplpe and tighten
~ s bdlhou.slng
~ xand eng!ne b&k, and QI@bqlt. R& to Chapter 48 If rieww$.
bWW & fRXTl h & J ~ D f f l l i S h l @ O ~ ) . qfi R&t the enalne rear rnowtlna l ~ n kmd
10 VVmgqw#q b o ~ r s ~ rthe i neqmp.to
~
h e c#&&bf&, kwtl&&% tw@WW . W-
- :>

rn*3Ktf N@m#.
2f &$~.~~&tdem&d~n C W ~ I .
!%@Me RWC" wqer t~me 1rmW of'the
w h d arch.
d . t f i i poditJon pf the fight-hand e@lne 5p ; 1 W h * l cmnd lower thg, W to
tih-mj4gbp@ tj-m"Win rblHah W Pb'?h"e the ground,
auty yqurrYtng nut, tlM uri+rew Wnuf. 24 ~efB1:themgjna w i i ail,awithWeno8 Po
A W h q h b i ito tba @ n e H W h q & ~ ~ $ o Chapter 1A or 1B.
Racsnne tha battery posltlw lead, then
$e n&w lead
06 dd& hand, &Nw
and Wlifidrn~ *
$?,gmfQW
f*
> .

&if44b
.I&Wbi kVj WGM of gasw f r m *Ks
s$dw:duk qltl s n p , and wipe t h i dry.
~
W W.W netw.Qmptan thsqump; malcltig 1 R p y e the tlmlnq Mt end the m k d m f t
&jlh# Tk'k b-ttp poshttll3fied on ihk sprackd wph reference to ~ w m n5s &d 6.
iwV@i-seGtfm(*lRusti;atlaflL 2 F@-Iw t@"rrnpas d q In @&tion 10.
15 &W thk g~tiiDto the cvllndw black. and 9 Remove the Woodruff kev . m n f W
t+rn .gl_pt tn ffie :e&$q~aff iG
9,
.iit~-n):
4 Un.bhdtrbp fmt mver from the,:qIin*r
block (see Ilustratlori).
 1171 w: qnd 1390.eo ktype):engine in-car repair p r o w d u ~2Clll

11.9 011 pump mounting bolts ( a m o d f4.11 Checking the cleafanee behv68n'the
dl pump gears and body
1
e ~ by w
wu
nt
lgthe d ~ r n c bee- hfimng Mere the DIU ~ J ; s @ it,, it . ~be
saver Jdnt'-. If my 16 Wlpe %leanthe 011 pimp and crankcase
twd d Umi the new ail seal
~ r ~ u ha&
I
~qw,toremw$wn mw ,S
-
f l , F W @ m s f : @17e *m w k ttwis lowing eowe~sare
w~qjnawi& *pndePms ma th t ~ ~ :
pasitlo" ~ a11 ~
the ,
Isf valve md and p m p on thdm tnsee two momtttnq
<$wGm AP.RdWe f?@ end stop* &tb.TQm 9bdhaw&y.
@b Mma~ethrs smng and plston, r e t fhe wma
sN6 ~ ~ ~ y c )pdb
Wuddionl. I& Engage lhL oil p m p @rocket wiiR The
19 Examine dw valve ~ i * @ n@ seat &?in, then d n g a g ~thg chain with the
drW&'$p~&&, and loUS?a the
qpr6cket dn tfie oil putrip huh.
a ~rqn-rn'hd&,then in& $he sprocket
wta s[ghk~h;W& ~ h l l eholding
Mth rny"~.
21 ad &al I" ?kid mnt cover should be
r&nswed whenever the cover 1s removed.
Mote the fi* pwltlvn of the otd seal, then i
mn*uta swwVea
and M~ FIMt @u/I~Y end) 011 #d
s&g. 1 Thjs p r o d r e Is Imluded'lnme p
Smear W& q~d&P ~of theW r o m a
new wd with f w h engtm OH, and kWe It far ~ t & ~ aand
l refiarvg 6f the d pump fn 2C
s q u d y on the m v i with it3 do& side m n 9 1.
fae8ngmwa~cl&, Pl-W me#on a f i I e o f M r -1 end 011 d
d, M h ~ , a w c W oW r f h t p drive
O Remove the flywheel as d m h

. *. .
il
:*

\
---
I
d 11.22 Sealarut h a d applldon (H) around
the prlrnetw of the front cover Wc~mwM
2G.12 1171 cc and 1-388 m fE-type) engine in-car repairprocedures

2 MvR $he.
the c m W ay. , mMWiq$.mdtc reMm.to

of the clutch fa&, and for web or chipphg of

the ring war teeth. If the clutch wlr'&M,
the f16:kd
mily be ny&ined urdlj,fhti but
remwal h pf-e. ff the ~ w r l ,wwn
s
W - ~ w w Wft, m y be p ~ ~ l ktu,w'!w
le X
se&vaW, 4ut this.labWmSt bfi&,aRmqult
wtmy@/qto nrpoveye ffansmlssion &me, d W r or-eWnw4ng work;s. The temperature
m rema& b+^tAeddv8~lateis not ~oesibfe to which ~ n e r iw war must tw heatedfor
i
w
hst&tt!~n, .ia cr#&l wd, if no$ done
wum@WC~#e Clardnws of W will W
destr~@,
0 ,Onmudaid with alrtamatlc trawt-ttwlon,
check the drlveplate camfully for sigm.af
k v a l d$ga~n,.m4 91 WrlRe wpcC q y n d the 4mpWun '

1 l3emuethed&has~bdh h 5 , bdt hales, at radlatihgoutwards from the 1 &pfyA&e.h~dbki,fh@nj& yp We rront

or the autorrYrtlgMrtsrnisston as d W b e t - I n
ir@9:bfthls 'mapfer.
cmm, I f qarn-= of thls sort is,fuund,tb
Idiffreplaw must he renewed.
of W aq qd.,sw@. 8 q mlwt~fnds (3-
u ~ & / d $&~~ I I .suppQN').
2 Visyally ins@, the rubber pads on the
en@ndfrm@m~iorr nlguntlngs for signs of
+ng.qn$ d*rIo&Ion (see IDustralhn].
Garah1 ds8 d elww will help to determine
the condtEan of ~thmrubber pads. If the~e'ls

me&
~i!%?!hW
&hqm .
& I q a w q4-dArnOVe the PW
&k &-,%o! w.m W . . N * W
tbe qw.bfbsthe M h IBOW.
4 mq g a
the p o s ~ ~ m W m o u n u
s a r W w d& of on the w& beneath
@ ~~ nllt ahd awWfleYwe! m Q L W
bra&,
3! 'Ub&9Th& nuyand twnbV&the w&itm.
$Support the w6lghf bf he wglne, using a
hoist on W Q h t - h W I ~ l J y l . ~ . ~ w
W, W
8
jack and a MQ& of wtmd h e & fhe hmp.
7 unholt the npgy
myna? .b*ket h m
the timlna coV r & k t an he, end d W

1 ~ i g t W &~ @ r ~ b c k d t J m W 7 h w w link
p @ h i b m IfMBr assembly a &wb&&
8 m h & W / u # p e rbracket ppst type} 9 R W ~ ~
3 '&ht-hmd upper bracket (second Qp$) TO E m M k m m J hUWM&ffMtwy
4 42- mwm
6 mrbmcket 1 1 ~ ~
6 RewBrecket M @&ox m ~ a ~ ~ ~ ~ ~ k e t
 1171 cc and 1390 cc (E-type) engine in-car repair procedures 2C.13

1418 Unbolting the engine mar mounting

bradcM
11 Take the weight of the msmlsslon, udng
a .trollev Iabkand a block 89 wad. or bv uslna
? %1Sti&,$elefl-hand wine nfthg Gf).
-
rf W&lb6 p&Rfon af- the rnamthg pad
mpgeWMwdabofPf-
19, !&&+ the c
em nW &d the ~ W Onuts
m q g he mountkg pad to the upper
E&&. t b n move thb Inner w k d arch plastic 27 With t h lower rnrr~ntling.~hra&&.any!
.M uhlmk the upper mounting hadat from panel for . B C Xo~ the crankshaft pulley. mwemsnt tlmfter hplmser%WP~
t@.Wy,,d W Y ttk~mounHnQ w. 0- ittat thw.Is a mhimurn d m c e A a f
148 rnm' (modelswlthwt pawar stWlr@ or &!
supperthy the # w h d m m i s s i o n , and W$
;2 to k t m W mountings Mamure dimenelon
16 If n ~ unbatl the
~ lower ,bracket
h m ttis W x . mm (rnodelswlth power st&@ between h e "Y again ( e e itlustratIan
~ 14.25). If n-ry,
R&kimg is a reveml of the removal eranksti3Tt pulley and the adge of the body adjust the rnounthg m that the dimension Ts
@fMw but t
m the,marlrriifig n u W W b
louse. %ally, carry out the mountlng
next to *s strengthening rud (a=
IlluWatbn). Note that this ~ ~ d a noXe
thesame ep mad& pwlou8ly. Tightan the
s lower bracket b o b to the speeFfied
two
&dfWmmtpmeedure des&b,d later in this tab into mnddeytlon the t h i n k n e of ihe t0rguk
Section. Mght-M&on the pulley. 28 Wfth me remainlrrg boRs 1-8, m mthe
24 Malntainlng this claafance, centre the Ilmkw &In the hole ih the uppr h c k e f s6
Rear mountingAower link
gearbox m~unNngpad in the IanQttudhQl that th* eka+hcs k3 the >F on bpth si*. ]
I
47 Warklng beneath the car, unscrew the directbn In the mlddte af the upper Tighten the limltar domting b o b fo the I
b o b securing tho mar mountlng ltnk to the tr~"~lcIcet/'battmytray gaps. Tighten W qdfWt?rqm
bwk+ on the subfgme and cyltndm M W . mounting nuts and botts. 28 Worklng under the Far, mflt the w
Wlfhdmw the ltnkfmf~underthe car.
98 If nacmsmy, unbolt and remove the Right-hand mountlng
amwrque.
b&k@ {see1 I t ~ o n ) . 26 the uflm bracket If It has *-Y SU Reche& dirnensh "Ybbee lIl~s!r&l~n
i B RefIttlng Is a reversal d ihe removal b m .fitted. Measure the dimension "Yn 14-25)on mt-handl and 4 1 ~
prowure, but leave the mountlng bulb between the outer edge d the IQWW hkmt
and the centre of AsgtUd (gee U l u m a n ) . ,
-
,
i 6 ~ s f 1Finally,
~ early out the m o u ~ l n g
qdlustmmt procedure descrthd Mer In this 28 R d t the upper bracket, and tighten the
sw-on.
.m-t
29 If lug one mountlng is being mewed, ilt I

the neb mounfhg h the m e poddon as the

dd m,md check that h a dimensbns are
wmA. If more than one nftruntinQhag been
renewed, take the wJght of the
e h g l d g w b ~ xassembly on a hoist, tmen
all of .the maurtting bolts and carry out the
f o l ~ i n ~ p ~ u ~ .
Tmmhiim mounting
H Wlth reference to the akompanytng
@ i r m o n , prs;tlgMm q e turret nq {I) qt-d
ta$&%i~tn'~ng bolt (11) to 3 Mm (2 Ibt ft).
~ h t Be w Wa upper m q u e g Mts (IN) to
@ :Min 06 Ib?flj,&then t@Mgn the nut (l),and
bP-$ td*WTmtorque (see #Immim].
a V&fh;-tbe,transrnissionmounting-pad and tireouhedgedtheI~b@c&ad
tower bra&& and tha rtght-hand mountiw S4,S Ctrecklng the dearame betrweenthe tbcerrbeoftttk~
IW0r 'biaekbt .In plmq cherck that thk m t h h d l pulley and theedge dthe
rnoqtjnq bolts are loose. bady.ForY ma
w s <Upperbmket~ r
23 Rai3lbira the right-hand front roadwheel,
~ ~ t l
T SW@enlng rod
Chapter 2 Part D:
1764 cc, 1783 cc and 1794 cc (F-type)
engine in-car repair procedures
Contents
Gamshaft and .WMtsF3?WW-Valvo
.........
refitting .,,.t,.......I.. *.;
-
mglm] rernovd, l r q e m ' m
.....................:;')..,; .-,+
@msh.&qilseaia-renewal ...................................
. .
;,-8
Camshafts and tappets "IF7P/1. pvE11~e -
engfn4 mwal,,lmpwtIog -.

. '...................... .............-....... ;%i7$

........ .-..,..
m.+g ..*.+.+
& ~ d fest i i- de~~riptl611
@,nbh.@ oil seala :mmaJ
and intapatation :;.
.a,..............-......+. ..,!.
:$
-76 .
gindw M'PP&wk9.eilginiss) - ~ova~,~inspecir&'
L"@#@Q
~~sr~r.h&;jhP/1B&&~e~1nr3)
and
...,. ........................................... .;.,
-' m $ l , : ~ n s p d n eind
I 11 .
'Me#!! .....,f.-.............v:. ......,.,. ........................
: 'I%
E ~ b i ~ M l oinndlin , m-st inq&t~n .and mm1 ..........76
Win~dl ..........,. .....&
and f l ~ : - . W d ,
.........................
ijllwlkheck
iZngh~l6iI
Q h w l A q.fB
.S& Wm&.&ecW

Degrees of difficulty

Specifications
N&, Reliwta "Engltmidentl#wgoiYon page REFa4 for d & l k . ~ ~ ~de~li;'iWon.
ke
1'
mnd
Tym . . . . . . . . . . . . .: .....................................- -
Wgnatton .......................,....,
&re:
,,..........,. *:. ,........;
.
... Faur-oylirrder, In-line, w e ~ ~ ~ h a f f
WPmd F?P

FSP,enginm'
RFarngine
........:......................................
;
. .
.. 82.7 mm
... ......:...;..................................llPi0rnm
,, ,,
;

;;
-

.
..
.
sww
P I .engines except F3P.wlih letter 16.or R dl- &r mine.
n g b e ~...................................................
. ,

M~S-~IXYI ,?>

i h L, a',&R d l ~ ~ ~ ~ ~nurti*~ . . t a.0-m

~ ~ . e n g h a e . w fh y p e
ww%
mp<w. '

~ ~ l l ~ + i n ~ - w ~ t h ~ , ~ ~ , r n h d ~ - & ~ e ~ m ,
.numb&: .< .........
........,.w i , . .. .. .
....i -..li,i "7894 cc
i ....,.,

.,
i.. .;i.

EngM-wfi:Mer C .Q pr S d M y +km~gtirrft4~3 n u q k . 1'W'~,c

Fmd~
.....* ......,...
rn'&@i.i&
.............. .....-..
>w+...i:,., .... .........
......................+........1m+> i;ii i

.?$4$2:&0,4~11~~f@hd~.rCg~
&&#&Id -!&b m-n .-................................
,... -$!$I&&
a h m @irl@.&d' i

& m p W u n ratlo:
................................-.......
w#nn@W: -.++ ...... '9>7::Q
.............. ;
WPm$jjm..ii.i .......................... .,-, 1O.i:l
i r . . , l ,

mum -pow.....................
@.M~~BS:
w:
..*. -........ ............. E8.5 kW (F.hhp)
. , .
; &:5750
M*uh ~ @ & <....,..,.....!.............
- p g g m € #..... ................................
- ,
lpz~~l~7bhp).JSt,5,W0,rpm

vmm- ...,.,.,..............................................
4 4~m (105 IMft} at 2750 ~ p m
J
..
.......
-k@nir: .................................... ;,...,;
ff-I? l58Nrn(ll%4M~atatOrpm
 2D.2 17$4 cc, 1783 cc and 1794 ce (F-type) engine in-car repair procedures

Valve clearances ( C Q ~
FSP q l n e s :
......................
lntet .................. mrn
mms
t .......................................................U0..240inm .-

F7Penglne ...-..:.......-................,......... ...... Not adjusWW

....a. ;

Lubrfastion system
wwtl
.,
..
................................ ....
AttQQOtpl?~
At WOO rpm ......................-.......*..,.....
0 1 pl!Jnp~.Qw,:! r. ..................!......
.-.-. .....
-,"+?.,.....
,y:
*
%
Ci..iC.f_;.B
.
.,.;.5;.5A '1,.
-. ..............
,.
I
.
: i ;.
,
.......
0
11p u m p s l & ~ * :
-w,wnlrhuin) .................*.................
GW-'to-bdy (rtWrnurn) .......................................
~~endflaat(minlmrTii,. =..-; ...:... ..;................ ..*..:.;. .',.;
Gear &Moat (maImum) , ; ...............,...;..... ..........,.
* ~ S n a a ~ w l t h g H p ~ d ~ . & & t ~ .
T i o F q u e wm
~ ngs
: ... .............t...
~ ~
r,r:.,r'.:si.. P i,-z. ~ vP.. .;.~i-;.; ~ ~
gqwtfa,
w ng,
q M:
smm cnrnqf&-.p:$P~giws ~ ~., ..........
. . ....... . <, :... , ;
........... ... .*.,. ....
; ; ,;.

.$ry~@&eier'-R~m~gii~
Brftmdm&- ..,. .... .
:.:,..:.;.:+.............. ,,:,
.,....:*?,...
t........... ,..i

.,..
i.,
.........-................................
,,(.,

~mlng.Wf
[dl$ NW
T i b s k ~ ~ ~nut-..
m ~ ;.l e .:.r .............................
...:i..
& , ~ j a r 1 ) ~ 8 h d # ~. ~..... * ,. .......... .... .............
..a+.

ir r L ; i c,:;
,OMd~,pulW ..................... ..........! :.............. ; ;

@.Mm,diam&rb o h ..,, ......... ......................

0j,pumpW:
.*-;.. ;. ro ;
8 . y . m : d ' i r & l # . , .................................... 20to 25
' ~ n ~ W & r g - w d ) w.... , ..: .;.........................46650
...........-.-..-.......... .......
u;:. ;is..,..
:@ti4g-@,RP-in@n~mt@) f...r..r ................*.-.25
...
&As meted Wlth-itmadWmduitl) ,-.: ........ 5q to,55,
. bi;.. *Ztg l5

...........................I.*+.....-:-,.+.,.+.,$to%
...........................................60to65 . .

,&r*$hlbsboi mmang. fw:texg:

W no@ir@bw link Eb..................................
=J

MgmWd 1~bmCket'ZQbQdy ..... ....-...................... .

hw' ........,... i ...........
; - .- .

6 i @ - b d U* kWkWt~
'oe& mrt .....................:.........
'RQphan;d,inqunth.lg ;
,., .............
RthM~hmdIlinw Mb .................. ,................
,.
, .
.M-Rand m&tlng bra* to 9-, . ..... ...................... :
M - h a m g , b:Wy .. ........
., rnO~&-
.......... ...;.;.....*....;.
, j

w-.mug= . ;,. ,,

.Mhandmounthg;p d -cwt@'mt .............................

@ ~ bolts .[&ad ~IBWb p b~k ~ ~
F a P ~ ~
mw%1 .....+...................!.... .......,..,.,!.,* 30
............
;.i

;....*.. ..............................,....
......a

.S*2 i &$MdQht$r~ 8'

;-,,3 .2.....................................~............ .:*. Wiit for 3 minutes mhhw > -

~ ~ 4
m........' ..... ...........................LoDsen all the W cmpl@teiy
t i,:..;

'*s ........................................ . . . . . . . . , , . l 2!3 I8

.I .............................
.sii&tb:d' .:;....................... Angle-ftgktem by 128"+ i"
rn
st.%wI................. ..;;.............................;...,;... t o
*m2 ........ ;.................:....*.....*....*... ......... hrgle-~hbnby 5'1' +,P 22
Stap 3 .....................................................waft for 3 mhmw mk.llmum
q a W 4.....;..;................................................h a mdl the bolts
-5 .................... . . . . ~ . . . . . . . . . + . . . . ? . + r . . r . . . L . ... . 25 78
-6 ........... ; . . . . . l . . . r . . . . . a . . , i , . . . i ................. Angkt+ghbnby IMea 3'
W Wries with ollpump,drMhmaux&ty-
. ,-
 17W cc, I ~ M \ Gand
C 1 7 8 4 ,(Fplp$j
~ engine in-car rapair promdurn BD@3

are hased on assumption that the engine

' s'tlll~ln$Mted'lhthe
18 car. Thenfore, tf thls
Informatition la belng used durlng a complete
mlns overhaul, with the enghe already
;ymwd,many d the *ps lnclludedhere wll
m<*,
E ~ I &tiwwtption
'%.:AI:F;WDBmrrmes:m QT fdur-Mirter, In-
llpe d&iin, minteel tmsvmly at the front
af the car. F3P en~ims
are of single o v e m d

type main bearings. ~ h r & washers are W

$e No 2 maln bwlng to control crankhrrft

warhhaf't & horbontally split strell-rn Mg-

end W n w , and to the pistons bygudgmn
plns..W gudgeon plns are a press M in the a Qn dl e w p t I& F3P engines, mauxUlaty drawn f r m an 011 sepqaor on It18 cyfhdar
m w n g rnds on all englnes except theF7P don&tde the crankshaft Is atso block and p s i 5 d vra a hose to the Inlet
flhalve) m g h on which f hey. fully drtvm by the timing belt and actuates the dl mantfold,
~ R W g retains
, By &Hips, The aluhlirilwrn purnp via,a -skew $w. t@r F3P agirres, 11 En@ns t ~ b r i t M 1is~ b
' y p'reswre fead

W-,Wthrm ptaon rings, aomprklk two sflapet Is W h @a& ofQe

mrqmssian rinp and a scraper-type .oil sprocket), and the 011 prrr$ap'ls drlvm fm,a
t
altay,plsbnsat& d the slipper type and aza no auldlUaiy shaft is fiH4 (a tirnlng belt Idlw ;fwm a w t y p oil wcppbated beneath
i$& fhe cran haft?W R e&I 'is Thtl thmugh aq
charln frwnthe mMsh& ~~liluatraftqni*
10 A seml-~l~sedsrank- wfllat4oIi '

7:on 4he FSF engines, the ahehafl operates

Bb v a l w via Inverted bucket-type Pa~pets

Is.@-shims located externally. beWe8t?ahe

bucket and the cam lob. The Inld and
.- Repair operations possible with
:$heengine @I irrth0,wahide
4ithust values are.rnauntd verthdly In the
13 TTh~.folbwinQ op~ratlmk6an be ~wrtsd
NW~head and a.re;eachclosed by a,sir&
IVal@sxhrg. 6 ~wlihwt
t havltg !go W m the engine fim
8:,% -the F7f I.~G-v~Iv@~Wiin8, h
&shffa operate the vdues vIa.hydmlb
WhW q mlrs b o w nramwd
#&4y In the qllnder k d i - U a I v % c l ~ c e
B W twtdmat~m~$:
~ me ! ~ ~ p r yq
aa~ v ~ 61 offhe he csv~shetioil &&I.
Msllnd b the front df fha ernqltie aid :are ql Rem0-d#Id mflrthg of lhe camsM&$,
~pqr~atatedby the 94nt ( f n l a mmshaE TM 3 Remod andmdlthg of* sump,
hthb&'imWs.areIn~tln& to the w d the 4 #emavdaffd mWflgoflhe wmm
d s and pkiam,'
wgt~19.d m<~aerrstteby dthe &wifa(hwst) i$ Removal end ~~g of the oilpu~p.
@M$hdi h& 1;yllnder~h~8 four vai~&+two 1 a Qn w ~ j engines,
p no alitiary s m
Irkletand mvo &mq, mi mlr d V$Y@ IsMWI md,the Intermediate shaff housing R e m d uf the m k d m ? dlW ~ S I
~~~sl~ult;nnesusly. (1) is deIW horn ttim cylhder trFDEk 0 ReMW of fie Wr~e m ~ t W e
 .-

4 ~ W ~ ~ ~ by cl&nldgthb
BBeglh Y W aI b u n t l the
~ &ee nat
& Wid up durlq ~ smcwsivcs
~ m, ~
engine must be rqmoved to mmove the spark plugs b e you remove them indicates l e r a t c t ~,wlms;uc a btwn head
drlvedate on models with o&maUc W k M ,.(et m&-&hWd -Id aBo be the
&m&imim - E O ~ Chepte$,
W
*#thouah the onwdtiii~~ & & With an
asterisk-cgn Lw &$$$QU~ wlth ttre e n g h h P.@ W.W&et gawe rmdlng obtained,
the car aRer Wc9a)iof the W R , If Is 4etlw t h h mp@the pm&a-U$'fofl the ma!!lihg
cylww.
7 Add =me snglva,sjl.(&pgt thf$e.squir@
W-fia plunger-bw oil to .each cylinder,
f?lmab.LmeeR@fiR!N'h.a?,">WdW"Wth,e
m,
8 If the .cpmpmlon l n c w after the dl Q
added, the piston rings are definftefy .wm,M
Rp s~mprwslen^&qs not Inqreasg
signlikantly, the leakage Is o~~ at tfw
valyq ar W gaaket. L m w .pa@Re
H*>A wrnpnW~~1 &bug@ will be r@ilIW ualm may be causec1 by bubunier;l vdva SWS
kthk kt* m d d ~fm, nX 7~1-d~ E@C&@ QT mt
1 A ~ & m p M s i ~ ah&
n wltl-tell yau Val-.
mecharbid uanditi9n the top end '(pistons, 9 If two 4imt oyllndem Wd equally low
ring%v@lv&, h@#@k~WoftM @tqins LTn.
- mrnpwslnn, there is a 8tron~pDSSltjll&y that

-
SpecJfWIy, tt.@n tell H the m p r w h n gauge th?:~~~pression s.huld bulld up the head & k t &eW@n4h&i 1s Mown,%ie
C d p n d u i ~ ~ tledkqge
6. b~ worn q&My jh a' h@hg engI@ &6w cmpr-n appamnm d : a o k m t In l t wrnMstlw1
~
piston rl-, ddet~ive%dvms and(& or a on 'the- first g W , Yoll~wedby gradually4 shmWrs;~f@a.am&qsr,wpuldW f y this
b l o mh a d
w$W.I Now Toe p t b ah
l)aqysifi$ &t$$Stlrqugn sum&siv& s W k q cpn&oit. .
at n d d a~ria'tlng Yempmwm, wand tfje , ~ l = ?
piston rings. A low 10 If one &der 1s:9but20 percent lower
WiwmwY be a h w d , brthi3/~&7@~. imnmmmgon thedm -I whI& fhm the. md R & h i n e ha8.a slsabtlv
mwh ldbtuay& ~dspm;i&mqsimft&uh
b,R~&use,
11 ,4f W wmpm@~~b uw@b high, the
eornbhion &hbmm8.:prWly coated
With cartran bpash, tf rhL is 4@as1%
the
qtlndw .h&d Should be removerl and
d + w n M
1%.AWd. ~ ~ ~ t l 0 - 6W~ M W foX the
engines w m e d ey Ria m a 1 are not
$$e~Jfi& ~y Nb fnanuf@Hurbr.4-iawm,
&&g. ln-mhd WB tnfanmthn g i m in ths
@~I Q
p ~ W i t f g~ ~ : w I %W@ ~tbobtai~d
hdrb: gt@ s p d Indimtiurn sf engine
CQndRblW W b f muFWaf &ion> if any, tb
take*%

int&@lnderthateh&€on ~ & a & t h e

mrd@haft'tums.Each piston reaches TDC at
the end of Me compmsbn stroke and agaln
at the end'd B e exhaust stroke-; h o w w , far
ftw -.of timing the engine, TM; refem
bthe'podtion of t4ih 1 p%h # thean&d k
mpmsstwr &mb. On at[ engine8 .hm thi8
m w , No 9 plsbn (and c$llhd@ Itxd t h G
flywtwl d Qftlas&e.
&&&@GtqU4+3
P1 DIsconn* N t h b@twl& (always
d t s c w b ne@th&JecrIfIffihj5
S,&plykth~h-b, bi~ j&up h h n t
d g h t i h d $ide of.the:IW and aQsp~6It:'on
axla (am pJa&ing wnd v&ht&
s u p m . R W m e r n , t t W~~.
 1764 cc, 1783 cc and 1794 cc (F-type) engine in-car repair proodres 2D.5
Remove the plastic caver from within the
$M-hand wheel arch to give access to the
rankshaft pvlley b ~ l t On
. the R P (16-valve)
nghe, unhttsnd' Wms the lower Wt$ng
cow,as this covers the pulley complete@*
6 Remove the spark plugs with referen@*
movs the air cleaner
in the relevant Part of
aft spmcket timing marks
cap is n m myw,tha
In.al@ngentwiththe No 7
. Turn the ~i?kshaftsllghtly if
3.11 TDC marks on c a m s w s p m ~ W 9
F7P (16-valve1ewine
-
Note: This .qesmPi~eis not part of the
m a t n h m s - seheduh, It s b l d be
un@r@ken if R Q from ~ .the valm
becorn=-evIcjent, or if foss af p r f o m c e
.gives +use @ ~lrspectthat the c l e ~ q n a ~
mav k /nw& Suitable valve shims wish
&/mu toadlugtlhs valw ci-S, @a
new v a h . s l c a w ~m ta y b e m u i d .
7 Ware ap$krable, 'disconnect the
kmnkale vsntliabon KOSB f m the valva
aver;
2 LInsmw.fhe nuts.fWn ths wlm cow. and
witbdsy b,@~wrsrfrpm the engine (me
iU'hdkh'rrd~1.
m~,t gha ~f
b?L
3 m e t h e spark plu<a wlth reference to
~ M t n q the
Chh@ter1A b 10, IA W a ' make
wgm.
4 Drgw tl-& valyq po@tlons on a p e a of
paper, numbe-&g th&n 1 ta B frcim The
ftywhd end of ttlLwgi~?. Identify W m as
Inlet or exhaust (le lEi 2!, 3E, 41, ail,
E,fl, 8Q
[seeJl!-hl- m$jr%h@vrth @ t S b p p h . m piston
6 U ~ h g'a &k& i$r @hd on the d Ms 4 qIin/&-wOl B&fat W tbp af Its'
cranM~putlbyboltjzbm tfb qlpuWl the com+fan alrp@; Mth bQXhvalves fully
i c h ~?hxihmhb,br
valves of No 1 cy?ier; ( f l w h ~ d lend)' i . b6tWvalvee ot.No 4
Pro~klm@" may lm &&&atthe
The mhau&t-ualve wlll k clashsg o y l i n d ~ aama tlme.
2D.6 1764 GC, I 7- and'tl;W4 GG (F-t ype) engine m-ear repair prow
afwlwblads of the cmwi thic!mess
'[see '*wlfkation$) b&ween the C B lobe ~ shim acaordJgly.The shim size is stamped
ggd t&eghlm on-the top s f . t h e w bucks?,
and okwk thaT it Is a M slldlrsg fit (see
@. If If is not, u p W feeler bladss
z t t a f n ma .-t b m h and record
.this for use when calculating me new shim
thickness muiped, Note that the hlet and
mt
r
sr? ~ @ . k m ~ @ ? q e , m . ~fthsr n w e d . d m * e is lessthan
fa~jow.
7' With Mb 4 'eyfindsr valve clmrwi~m
&"Fed, Wrh the EYQW$rough half a turn
wo that. No,b ,wltn&r vah& a b "raMng",
then @qk rXle vdve e i ~ c of w No 2
q4lndg In th6 Gante way, Blmllariy check the
mmainInq vdve ct&rams in the follawing
seqmrw.
Va(vesmckhg Check clearances
on @niJer hEylinder
1 4
5 2
4 1
2 3
8 Where a valve dearan# We@)rvm the f m the measured clearance, and add the
'Spmiflpd ydue; thdKl the<8hlriifbt Wt valve .result t6 the thblvlft$s of INox1stlt-g Shim. a Wkwe applhblq ~ m o v tke
I I
4,f IRenwlt toot wr compmxW Upm
bucketsM change'tabpqt shims
F(t sbb at 61fghr-ang& fO r k mrnshsrft
this wilt .qpm ~th;er~~vemmd~dlow
tb.shh to
bwlthdm.
14 Make surwthai ~ a n st~bpeaks ale
uppwmoc*t.~K~-.&~~ssIhg a kippet, gnd
miate the b u o W s r r Withe naM& am at
rlQhCaifIgk.tb8we bmsheft eentpe-link
When W n g the M m $ e m m W the site
markings fabe the topb& bukets b.faw
dewnwards),
*I&:#&a R w k l C i d a-m&&h bpmsqd$rr$
9tlltabb.akemUw~r n d q ,& ~ n - f t.wIl be
n&bssaty .tp r W v 6 .We. @mWAft -t~.~gerlq
amee5;ta*:&lms, as tkUlkd.-a.
18 :Rem~bthe Qr'spBrrrretfwm the
mkshafi putley Bolt.
musf be rqplamd with -a thinner m thlc ksf 17 >RMtth4 SpWk pjUgs With tefGmG& to
Bha@r 1Asm.lB, then &$the vrrlv~.mver,
nn thq h t t m face of the shim {see 'tageWr:wIth a rn,g@WV y
hmmessatyarlr
R s a o n n e tha .mkeasa ventilaffon hose
I l l ~ o n ] . but
, I t Is prudent t o use d
rnlcrmeterb m mum WB Ynre thickmeas of W h e appllabre):
~
any shlm removed, as It may have been
reduced by wear.
0 +he dze of>shirnreauired is caictitated.as
smclfied, subtract the mmaasllred clearance
f i b m ~ es p w ~ l e dclsafanw, and deduct the
mutt ftdm the thlcknes!~af the ~Istingahkn, CaufEWr:Jftheflmhgb#hak w-kr
F QwampSe:
~
mmpb &culallon - clearance too mil ss@#$ wtenslve mqInc0 d q w g e may
Ck&mce mmwred (4= 0.16 mm zd tfibblnhrvah
msu7t RswreY '$hw1bsft
W#d&mn& (6) = 13.20mm s p ~ i n ' ~ 1 1 ; 4 ~ hrtW*Hw ~ B ,
D~~p-Al-o.O.Dsm as mdmn f ~ . a l U P l b u ~
S h h w flit& = 3.70 mm Remow1
Shim tt#&ms required: 3,70- 0*05.=
9-65m 4 D1sconnaT;a b d battery
~ bads (always
dmnnect the n@w lead fimk).
10 If the measured clearance is gmaker than 2
aawfkf~g WW, the ki?*
%wWtsubtract eJ, the speqlfled clearme r n M r n ~ 4Chap+&
0 11.
e air dearrer
.aasembty qW mfmmca Ps the retevant Part
For &mgrla: M-mwA
-
crircuwm c l ~ o €00 e Ug 4 CSgply#ls.hmdbWel then fa& upthe front
-
Di%$3h $ B)= 0 3 0 mm
-
ae@(i&wd(4~ D r n ? n ( l l
~ r p d : & m n c e(8) 0.4 mm
Wththe par-W wppm it om1 axle stands
"&&pand wefiicle ~ p p r t " ) Rern~va
' & h i - M *h.wl
, h
W m fh&kms ,?7tted= 3.45 mm S Remove the plaale G D V B ~fmm iside the
S h l m v W .required; h e + 0,M = wW!:&h fer, WGBH :to h e pranksh*
355 mm Nw.
11 The Bhlms can%be removed frqn .tW $Remove the alternator drtvebelt wjth
laoations q top nf f i e tappet buckets wlthour Mermm to Chapter I A or 18.
removfng tbs omshaft if the aarpaulb tool 7 8lachn the c r a n b h d pulley bolt white
B h w n mn be bommd W e ilktstraarwl], or holding the W k t W t 3b C ~ O ~ ~ I B ,
asrllt&l&a b n a t r v ~
fabricated. have an assistant i-n scwdrivw In the
12 To ~sitn~vwthe &hn;'th$&$psr h r W t starker ring gear W;WougA the aW8w
h n be LpwMdown agdhg:&rnswfih hole in the top of th& geahw bellhoushg,
~
pmsuwj@$Wmmqfi &Wtb&hQ4PO Take m e mot to darhaab the IgMton Bmlng
$en=-
@ slits OM.T P I ~ c ~ thjs ~ &muld
, be l%e
by l&&h$ *lhbt$~h ~rnmft beiw@n tbe 8 S u p p ~ hthe welgM aF the Bmlne. om a
urn ~dbesyW 4 &#!e pad tp push %the ,trolley ]a&, with a p k s of mod inswked
$I@&@#p,ws@R W'la n a ~ . ~ r k r nby' a between
~ %k>jq6Khearimwmp.
iheman&b** 9 Remove thoslrmla .mew and take &f the
19 A r i % ~ ~ e n t e 1 m l l ~ - bRtmhuet t toql cover from the ri&t-hehg engine mounting.
ean be made bu.4dtlha a barto €hacamhaf! Note that the wvar farms part of 'the upper
Irhlng ~ W F . On tlght-hand.dr(w.madels., the
accebior.&le:rrcns tt~roughR.
$0 :Wh#rew th~b9ltSand nqt, and rqmow
wIttl a llp ffled alals~ea~R side ttr e o m the <thi Wrighe. mauptin9 Uppr .b&ket (ase
edge of the buckets. h e r l n g dswn against i f l u s ~ o n s ~ .
1764ec, 1:783 cc and Ii7W:mi(F-type)>-mginein-car repair prwed-

14 CaFK th$ mgine lh We TOG _p$sttIan by

Imrdh,g,a rod thmu\@ ih&TaCsetting plug
hole W'WQ!~ 3). b -.- - -
._I

35 Fullv umersw tha cranlcahaft ~ u l Wbolt, wr mean t h q s p e e iind ~dl~ar~mslaslw

FCI &ova the w k s h a frim the mwk P M : ~ W ~ ? ~ p am
Y $W y .,
nose of the Crankshaft[sei Ulustratlonl.If R is e x m l u e m o m ' k at.. AWmt ' b* the
ti@$ use a, pulier. iplerhsiwerdm; -9
-16,D o u h h h a $ &at the camshaftsprocket Mxlcant m v b e & M & ; & m
iths hewing
elban the
p ~ ~ ; ~ , ~; a~~ ~
~ nyd w
i n ~
n
17 Ghmk @ b eb&b m&d wtthmwsto
e rOnnfnfi &&Bn: m&k t i Pt
I t ~ d i ~%s i n d n
n
e
-
. wt+
Note how4hetiming belt is n hWq U n v fww
24 B a h i n ~ ~ ~ f kbelt
over s p m an& b~i6nbpee Sr$sa5.ofa f g r r r ~ wg d ~, ~
n b h ) . pwtlcut~lyat the mota af the teeth. Rmew
18 Loown the nut, t u h the timing bat 'theM if-thweb any S@I of rietwhmlon~df
fensfoner dm!mlse to retease UPe tenslan tHle nature, or if them C any oil or Q-
mm mp t3ek,,mnr - e t m me nut. conmithflon. Rehaw any leaking oTI eeds,
19 Aetsasa the belt from the camshah The belt must be renewed If it hm compwed
spwkgj Id&r/renmn~ wme~hi,aqlcw Be Wmum rntle9w given In ChapXer 1A w

I
shaWldler sprocket and h b k a f t spmAet, 1B. Atso mami- tMa sprmbt$ and h n s W
*@&crkbM In.$- 7.

R-m
22 GhMthet tire cranbhaft 46'8tjjl at the
TaC w o n f o r No 9 &wvand IqWh
thls pcrdtbn UslnB f h a . d M?ihbq&rtfw
huh In h d c a s e .
a btim ~ a i timing &$tN
' ymhap spc& is>i.n tiw La w
fib WrE;i5n Hwam eW
w-
BIfgg4R1'mtttbr w b banda
s# @I the &eR
wRh&@e on )#e,spro~M~.The crwbhah
 method awn In -h~7~.-antr dMm the
WW~th~.WM'aft,spmckd REst, &en the m-ankskft pulleyjrhoh$ @sp&ped mu?,
S4 Wfmq.ti& ,belt u q i i Ebvpw/~?~~n$ng
Why s M L 4 d h atprnahL fdtwed by the
mBbflsprocket. Be @uI not to,klnk the
bbb.
B
bm&d to the cy n dk &ad, wd Q~,?~T,.$B 14 T ~ die I '&dine ~na ciooyke dreckiqn,
d n n a socket 0 n . h cmnksh8ft Mlllev bolt.
M
q6 Ghmk that alt,me tidng m a r k are S ~ I H 35 R&i %hetimlnghalt ]wetcave!., unfii he, TDG marks on the' cat&&
38, R@K@. en$@ ,mwn#n@ upwf 9jirodw
&pee& fksn terPtpadly Mdm #Is Mt by Check the mounlihg adjuahent wlth c m q m n d l'up$eiptlo$t'm~ ih Pm wtfh lfle
'plrOhg ~th'til~~nm a a t l + c l o c W i .and hW
~ or mt&E;s.anthe vdlh
-&e Wdnkg nut. &a.u&guide) r$~mQ e Wtipn 18. m7.
@wi9Bh cMW .msbn,;it should Juer be 3f Reit Yha 'wwrover the rnountlng, and I 6 1o.cktheF.mgim tm tlw TRG posltbn by
pW#!de io:Durn .the belt3hrough-90.9 wingma ai3b-n the smqw. Remove t r t ~t r o u ~ I r t w H n g - h ~ ~ ~ r ' &th&W&tihg
h plug
flRD.l l'md thldb placed . ~ ~ l r n a @3@ ,&bit and adjust the alternitor drIvektt hdB.*d@@mL
midw b m the auxillmy s tt sbdcbt wlq rqf&jh~,~~xa'Fhbetw1A ar 1B. - 16 Fully rI&&f&-t.Yc~rhnkshaft pulley h i t
(*-'M l i U ~ t e md~ ) -Me %nsionktdld~er W R&ae plahh cdver to the inside of the and remove Me ~wkshdt' pultey from We
wheel We- IUwhtion). The t e ~ b ~@M-haIld r wfidW h . nose of thh orsnkshafi. If it &?@Tit, use a
p@pn m$aW ba,,rltuseduelng a b ~ i l 40 #& the roadwheel, fighkn the bolts and puller.
~~h3tli&spd a lnext to the tensioner. I w r Qe,w to th8-grauM.
hole 17 huhkcheck matthe & ~ p m W
2% WmW4 thq TDC locating rdd f mm the 41 Whrt~sabppilcabte, refit the air cleaner timing marks @re dig?@ wlth the
qllnderb~ assembly with r@epnce to the plevartt pert ~~qmondingmcTrks on 6 wm

=I
W' RMIt ha crm-aft pull* and r-nlng Qf GW~. t&Ghmjc li the laelti8 m@& w # h m w a to
b&M da riQthfulSr.@MmR.&:thisstags. 142 &fit ~ " ~ n n(see
e tC h w 11). lhdj~kta& w;rtloln~&kbbh; mGrk It if
Usin0 a ~ p r ~ p q n ~ W o n d E-? m 45 &&n& the bthy p~sltive[ ~ dthen
,
&aft ptJlq bolt, toM the ohrbhafttwn the mgativer lead. the nut, mtiire the tirnina bit
mnrpl&e twts In the mrmJ $ k e n , gf tenslgms b r m - b release the t&aion
m i a h : On regaining Zhs TDG pldfmfi 'wkh Tt?fiYpWtllfhk t$f@m tknfb.
y,&1~ ~ ~ ~ otwe&tt% ~ T~l X r n p ~ , a the &I% $ram the carnshsff
m i & agan. ' B,- FiW W~WI @ll@shaft ~ c b t
2B Wwk that the tlmlng m a r k we still an'd-er&$&p
$$qN-
&.The brift d e W m mu& mnnr be checked,
-2snd
qe:@qlnd.pcc$rdu1 n tblsJnk or m m k a
Fl!!m$lR,%m M o iB.tywd.
do'thb, f h t make a mark on the engine In k ~ M Y? + tI ++rw&and tsnsrsnw
1lr@M t h the:oW surfw8 af b f i r n h g htt, whsels, and'Wpa hm dry. Da nat appiy
m W y batwmn the YxIllary shsft/i&er m d v e mmr@Qf'SQlVrnt tp ths m1mw
m g n & tdler wh& A f a of:30 N (7 tbfl wh~Is,0th- t
k bMng lubricent may
#k&ui the timing W t muat prqjUce A Remawif the cyhw M
be oontarnimw.Also @eiu~
n ot f.5:rftni M . 3 inl with the mahe and Mock behlnd the belt'imnlng
mid,(&oUld the wgin'sbe 6ot the d&an 1 ?~~OOJ)- ,Mth,,b @ t lead&,
~ bl~.ays
BW W 1 5drdQ.22in.) Renault teohnlcdans dlaeonn* the negativelead nmt). Inspection
2 For em:yatWng wh,r&t~ovethh~b - k t 22 Exmine ths timing belt W t y kr any
9hns pf crackiw, idO3n .offgW$J:vw,
particularly at the rmts2, t h s i ~ . . b s w
the bett tf them Is anf&$i gf d&&i%tirn d
thls nature, or If thew is m y dl or grease

-RP
23 Ghek that the c ~ k s f l a f I&b sfill af*the
TDC position fw Ne 1 bylhdgg and ImW In
3 wtnwa.r?b'dpe~ata?drivebelt with
ref-=to Wmpbflfi &l&.
thls mkra MIr@ the trim rod ~lmkghtCle
hob in the mk-.
 17M 02; 1783 ec md 17% w ,wengine in-mr r s ~ &p m!.gW
white, +Z! G b k thet the timing m a r k om Me
this; w4hft sbrwim~are In llne 6 the
h thg cwwpondlgg marks or notch= w the valve
Ihale mwa
Take 25 the tlrnimg mark h d s an +be belt
wr.: with tWe on the splocketw Tho m k h a € t
on a spFoaket mark Is In the -fiwmof m n m in Eb
*d fe@ gut& wdmater. MB a(rdli& sti&
I ~ ~ . ~ ~ n a g d ~ t rk . n.FitlkheStimlna
n a
iamk--t~1~ ~~fl~lk8G%.s~roe~ec'nret, then
the.auxUiary shaft sprocket, followed by the
!p+vm@-.
28 dmkfth&;&Il the timing marks are atill
'ia$s@d, 4 h m terrnp~~ttlyX d o n the b& by adjustmen1Mth w f m @ d p I w b a ~ k p :
p W n g tha tensieionar pulley on Its braoket 38 Asfit the ~~wrekrww:.fhe mownfli~g,and
'at@hpolnpthe rekalniq nut. As bs rough i m the m w . m g , w
t
g rn
trnllsy j*
&@.We+* pf~&q, it &auld just & 39 ReM and tansl6ri'ftie ~~r drlvhek
E* tP a9 *;w *m!!gh
t&di $fig t%u~Ib@&d app~xlrnatB1y
w
m @fl a

IW
*; ~Wwq~Y We auxilhy ahaft Wwket ~?fwweto c*fer12, Sec;tlWl Q.
anti th%"ia1st Wrab h e fansloner bracket 41 &?it the t l m l ~belt lower cover. Refit the
p M hmt& b-adj- uslnp a b t t *ugh p!a$tlc,mq$ Insid5i i e ~ h % l m, t'$k 8 Full tKe :d~dFvWifi'mlWd'
M fhb
W#@eoIal
huts I& %othe3msb&r, the rqadwhesl and laher the car to the eamsh@tpPt' riGw-B @@4 ~ 4 ' ~ e&W
.@ Rmavvr9 the TDC losating ro@frf m tQe 0w@* sbpwm@; w&$ %ijplic'a'til$;: w k '

42 RMt t h ~dr cleaner ass~mbly dill M e W r M - W m : k e y is Ilk@ to dhp a h

,&&,but&
pulley and ralnlng
t7akfUlly4tghten i t atwi st*.
$pLMqg a secW or spanner on the
I &a&@ff @He$ hlf, turn the crankhaft trha
cpp1ete turns in the .normal d I W h d
r@&k Qhli.~fntrig tW TDC p M a n wlth
407 eyfirrder on wmprmdon, Insart t Q e F C
- k@NWa$dn.
%J&k that the timing mark are stla
T ~ d W,3rq
o makg a marl( on q e vahrg cover
I m fie WN~Ithe outer surfam of the umhg Wt,
@ f e e;tp $9,relevant Park gf Cha@qr=4,
43 Reflt the bonnet with &men- to Chap-
af bs?&l?Ur
thcs ~ i i SO, k
stom'lt d l y , mere am no k-n
~ k&?iw
~
the Fi'@
9 7 % (16-qlve) en@n8, as the ' sprocket
44 Rcmt-1~~4 the battery negative lead, t b n InCbrpdMbs a tab Yo engage whh 'ti76
qfJ~h@J
4 Thii'awiliaty sh&tdler sprodket b~
removed in the same manner Iwem
Nititi@bn). Again chak that We WwdMt
~isfirmlgklfheskrth~~,
s A pullbrmay be necesmry b maue the
crankhaft eprwket. It Is a stmpfe rrratter to
make up s pullw M h g W'lSdk,ameta!bar
Removal and ~$IBahtitinuwq@@fi.wJW BY
i h t t o v e Wer urnin$ belt g dc*swlbd In un@Pwing #+ti. emM@qfi,$uEteyBQl& thB
Secflon 6 or 6. ?pfoCliet is puttdd frdffi the end of thv
prankshaft. If necessary, remove the Woodrd
key from the sl&~fhfM&-~ {see

qplicabta. If neae5ttq the uper and lows

Bar tlmlng covers m a y m o l t e d at this
&age {see 1tIustmIon),.
Fs Unscrew the nut or @$t&,g~~fepopthe
ghing belt lower Idler whelSI;%r IBhslW m
h vakea may m@t.tfy
P&OFPS, WPUWB
Isw-U!~trpnln

7.6 Removing the Iower .. -~ 3 - &

I '
 E1
Make sum that h d l s e a l isttmcmectway
round, with the lips facing inwanls.
6 When oppllcable, refit the ~yllnderhead
backing plate.
7 Refit the camshaft-aprodcet wlth F&WK%
to Section 7.
D T ~ l p U t o Ebnd
r
8 Ramove the dlstribuw eap and rotor arm
(Chapter 5B or 5C). Remove the rotor arm
shield.
8 P~Mlttheoldsealand.flt~newonsas
.. . " --v------.
A$ R h trming belt~lower I d l e ~~ ~ ~ ~ ~a f l e I~0 ,Refifthe.~Wbr arm shMd
n W ramarid r
% wildassembly ti5htmlngthe bett M W Fcap.

8 tpsxct the &wthof the s p ~ ~ - f q r s @ n s

W n W ~ i n difamage.The teeth a% *'prone

kkf!ed iorqult, hokbg the spmeket ushg

one b7 the m&ods described In ~marrlPh2
Oq?.m affempt @-dmthem with solvent, as Rm'OmI
thls mqy g r r thebeartngs. I f wear is wlClent,
1 W w e J h e "tmlng,belt ae dmcrlbed R
the aame way,b d q careful not td allow *e
c%& ti5 tum'vwhde tightening the bolt.

+ P[scbnW We f l !e@s; and repqvs the

Spmcbt end
2 .OnW enginas, m e w thp bolts e d n p
the meMl hck!md pMe to the cylinder head,
@ mm % 2 & + B ~ UWWfmj.
3 'hbtfithe'fBm,;dep& of t h p~11 +a, tRm
pdss it out u$& ct m a l l sCrd@f[ver. Be
E$cW nbf to $ m ! e ?he seatkg or the
u m s l d k d hbbfn6sutfb.
4 Wps-d-mfhe &IQ in the cylnder h@.
8 Smear a IlMe &ash 611 on fhe outer'awfciqe
of tire my,all seal. L o w We seal squarely in
83 M W baekhrg blab hcWM behlnd the
the cvlind# head, then drlve It Into bositlon.
mirgj rnei"Pu6oof dimetet si~giirttjr-less
camhft eptWW - F3P engine than thar vf the bob In the qdindir head.
sap and mtw arm,4 t h damn&
elistrfbuto~
tP .Cb$Mer6Q?r-?G, if mg.e&sW.Remws
fie r~tqanylsh@Y
S Sefn~f~$ W '@!%&@ epcock~t with
€ b V ~ n ~ 7 .
6u nw q d remqve tb &kina plate t"rom
the qllntjer b&d.
7 Usl$% dlql gauge, measure the cmshafl
&ndbit$ Bhd wmpare With the value glven'ln
fiw! S ~ O R SThla. wlll give an indrMon
.of tfie aniount-df wear present on the ihru8t
swfps,
p M& Id~ntIMiiigmtks on fhe ear3lshqff
*s ep, sq th,& t.hey q
n Mf@dth
thdMe pwHohs and t hSame way found,
9 Pqre&dy~slackenthe hewhg cap Mis
Mil "lve sph'nh prwrrrs fs m W d ,
RBmove the bolts. and the bwrihg caps
themsdvw Isme M l u s t m W q ) .

Wmn
ie mmMftbearlngcap-FWe110lne
:*..lo.llPtrng ~~~-
4PWlgh
 1764 cc,1783 cr:and 7794 EG (F-type) engine in-car repair proc&um 2Drf 1

-.for No 1 cylinder [fiywhwl rng will Be

pohtlng upwmds. M out the caMehah

4gh
teg&ei with 'the oilawls Inwbdps].
the Pppats, each wRh t€sshim
( lustratian). Place thm in ampat-
m* bps, oar 6n B she& ofcard m&ed Into
W d U ~ n sao , #at t h q may. hr@iiW t4
bet ortghalrlaatlonl. W W down &a shlm
-
thkkmms they wltt be n
wvwWB cwmnc& a
u t a b t any
i n t w e
r%kpet$bn
Kl%$&@nFtwtk mshcift M n g suflaws,
-andscamlob- far w w ridgws, pwng or
9Wb& R e W ~;aamshafkW avM&.
18 Benew the ail seals al the ends of the qg
.wr@haft;a$a iwmaf ww. Cut3rWe yle
f
+&ttwnbw.m WTB ~IWQ thatn,, and
>starsthecmsheft SQ that Its Weight* npt
maon ihe.amIs,
. _ - 1

d ~8 ,m n e
*w-*m ~ ~ n in Ng d e S ~u m y ~ W'JM
~ for mm, w m r m >UPW h'oJl
betweem the mmhdt bearing houslngs and wlth the hd&Q ~ ~ , & i d ~ ~ ' ~
lhesd bearing
. m C g or other damege .means that. the fhs oyIh&r hesd on relItthg, and new valw pJiwTo-m$h4&VW &wn mtll alr is
-&lh&~dWd W be R- eawrgwk&s wifl k~
mqLtlid. fmml nd.
:%# thawpet buckets.md sjtlms for Removal
+~rirr&-.@t&kg @IdWPM ttdges. RmrFw:as t Remove the timlng bert m d & m b d In Refitting
*-: .S&b1~6i 16 ~ ~ t t h i ' h y d r a u t ~ c t ~ t o b ~ r e s t o
-Reflttlng 2 D k m r l e ~the $cmkmtor cab!@ nnd wW,* wmfa r @ m d .
'
&\,Q@i@etappets md fit them to the b o w pos3tlon it t~ one side, wlth referenw ta fke t? @r tI@cawhaft bearings. Plaoe both
@@L%hlchg~ wwe mmd.FltfhaCCII& +want part d a m 4, gap%~W& twetW wlth olt seats, onto the
ahlrn, n m h d side downwards, to each 3 Remove the spark pluga,md distdbwr @llHW: head, The oil sede must be
yith t&dns@ to the. elkmnt Part of Pb$thfi& 8b that tRw are flush wlttl the
OII tha camshaft hearings.. PI- the Chapters1 anct k Cjtlirdu head femm The cam l o b must be
4 Unbolt -the spark. piug tube ho,uskg ff6m ositloned as noted W o r e n m w 1
'

ihe top of the wlw c o w .

! %7%kbhthe rator am shield, rotor arm and
, &it?i&or cap wtth r e f m c o tu Chapter 6B
,5 DCbonhet$ the arankcasr ventilation
hosesi tk& unbolt the valve cqver fMm the
cyllndef bsid and m w e ithe double gasket
CauWh: If the cam lobes am not
p a w n a d comd!y, the wIye5 may he
foreedhtothepWonswhmttteWng
I
u -
-
,@irrnay b In Lno ssahns rw j&trW. ~#lmffghtm&
8 Ramve both ams shaft spmckm with re ~ p a bh e of.^^ cd~npoundt o the
Mewnw.tq~m 7. housing wnW f&xm on the cylIn4er W.
? U h g ad-rneawe @? mdfloafof Also apply the g@mpnro,nd tQ 4he inlet
~~~~~ a0 vd!!EeWwe smdw at the ' -shaft ' e ~ d@%I&'#$!:&ale Ft an the
~rneaf yithg, butit ts s u p s & that the whe
&en for the M P (8-valm)mhe&beW as a
Gide.Wbylllglie art f n b d n & hqfimroynt
,of wear p@&trn mf&&t wmcs.
8 Prwmit.dyt y ' b , m ~ !x&m ~M
h W n s b o b 00 Wh hpuI~~;rhti~$kp'V&+
spring pressm Is Itere#& ,R@~:@kWh~tiok ,.. -
md Me housings.
o ate the posit~otrof ms m r n . . ~ b ~ i $ w
wQifll,&
lob& for No 1 e y l l n d @ r " ~ @ m
polntmg upkrds. Rema$& tkii ;@Fr~&i
from the cyllMer head, tqmthg ~ 7 t ht l p n
&Is, k is nof n&ewq,to ,Mwt#p%h,m
She- exhaust m Mhis a obtW.&..oW to>
drive the dl$trihutor- ,~t$c~$%-%rr.l h l i
camshafl ptug from ~ ey$lhd7. a Wit the ~pa+.plu~~~+.-howsIng
'trr the
10 R m o e the hydrdullb ta$q~ts,noting to$ dW;u'$I~e
a w q , ~ a ~ t~Wn& s a
wMeh way round they ara Wed, and pla*
them in a cumwrlmented M, &,on a sheet
ofGard marked Into sixtwn 9mihs, $0 that and 5.
they may be rrgfrtted to their origlnal locations. 28 MQnnect Me aderatoy cable wlth
Idealty, they should be placed in a refwnceto the reliwant Part of C h e e r 4.

! W@,
W the HT leads.
compartmented box filled with engfne oll, ta
prevent the 611drainingk m them.
27 Refit the tlming belt with reference to
Section 6.
 t h M e body,and fmm tbechletmanlfoId'(see
AW c * ~g w valve
~ cover G@w 3. the mlev8rrt Part of Chapter 4). Be p r 9 W
gasket and .q#kust s8811ng ring wUI he b Rbiiktie We Urki&Ue$ d t h WdrenM t9 for fuel splf age.
12 hamaw 'thB spqrk plugs-and dWIbufer
q p with *~mm -tp-,th0c e l e ~ n tP & , d
en- Is w ,
e hatfey wRh r&femn~&
io Q Wnswew the nuts from the valve c0Veri
and wEtti4raw th& cover from, fhlT- en?&%
bonnet wlfh M&W to' R$mouethe gasket,
0 Disconmci the acmlWaFw W R and 14 o i i f i the the..ternpwatum
~ ~wfpnm
coding w l e m with MefMm tu posjtlon "?tto'on&'dde: with reference to the gauge @en& en the cyhd& he#. W b
@p#tpf I& or 1R Alga dm th? cylinder m.
redem pa^ QT C b p i ~ 4 l l dlmnnw the el 'lqf~m
~ b f md*
n
b W by t v l ~ i n the g plug Iwf&pn 10) D ~ B G U ?@@wJi=w@
~,~ @wpi~;r.e
fr?m M-
I v;riiing.
tRg &M-hand rwf&qe We ~ q b eRefit . h m ' i f o l d , d&xdb~"in~tfde~ant q5 sppliwe, disconnect the rnuffl-
t l i ~phg Mk d d n i g . af@-4 pb#fioin the k n d sen- bn theknt of-*
0gntl9 w.
16 6iaiFormctthemdatartop *Trom'fhe
thmmsw & r U ~ l q .
$7'-Wig a,&Wb RexBgrjn-WbdM socKat
hi$ sbG@p the cyfinder head &1nI@ bolts
haff a Wnht a % @ b l h ~ ~ ~ ~toaIQ F d I
dmwj-t in 1)iuwoPl 34.29, Whm thb W r o A
ffbw hIlW,'m@v$m atbk,
YB ~ t h e ~ n d e r W u p w a d ~ ~ ~
C ~ H ~fI! *& s t u tap
~ I br~ck, ~ ~it %~W,*S
uslnpahanuneFwd W a k m f d . L b notW
w turrl'lf ?kci's t;i"@Wqi by wb goQwdsJ,nor
attempt to pr& It f i i using's scmwtdrlver
In&& b&km theblackand h w d ' f m .
ImpwPionn

th@p& - thk Is ~)artlcylaifyImportant for the

011 cfrcirit;&a tsmcouldblock the 6H supply
W mahaft or etf- bearings, Uslng
adheslve tQS3 and paper, seal the water, 411
and balt holes In thq cylinder bbck Clean I W
piSton ems in the same way,

scratch md other, Btn$lglqIf Blight, the$

may be removed camfilly . w h aflte. ~ o g e ~
"*us *mwe 'b*red 9
maqhhng, bhfhhlsa &dq1MW.
2t tf warpage of t h i o y l i i r haad Es
N'SF~BQM, use a m - d g e r t"Lche$k,it-for
dlstodon. Refer to & of thk Chapter
necessary.
-
b,
1764cc, 1783 GC and 17434 co [FtypeS:'~ngime-

2Z Ctrsan wt tlie.hk hles In the blmk Urwx

a pip cleaner, ora rag and wrewdriuer. ~ a k e
in-car repair prt>~~&W
284-3

and w e that all oil Is m w d , otherwim theKe is

!.the ~ Mock being craked by
a p ~ b loflthe
'(4& hyd~aulk prdswre when t h ~bits &e
w w -a
*
10br
23 ~ n e t h e W t f h ~ a n d t t w t h ~
31% Wnder block Ybr damage. Ifmneews~ty,
it of W U& COVW-BIZ~ tap t~ out t h ~
hrmdwtnth btockEand use a @@>to clean
ihWads on tha bob.
#&mbkr$l
lture
Also
Lni

~uki-
24 Ensurp zklaf 4he maling faem of the
~ ~
@*et-a~~&
~ shead aare spatlwsly
bQlth
mtrt$ybrsndWMqwwaWinsvrrjout
t@flelri1~m.
k
t-3hia WdSO
. clean,
~ ~
& Recome
I
f b W'fejwM,
t h s a ~ + i o r cablei &&rig
past of ChaFlfer 4
@&$&&&.i.y~e~tor
lo.
a-
p+ijpB, ,
- linder head

e<@#h
oabie and
lrmrenc38. to tM
2S Ghwk4hatkJrr ~plstonCsHllaiTOC,~
41 Ref3Wtiming belt backplate to UFSdghb m W& @ h a p ~ ' 4 ~
f the 1Y ~ m & the ' W t t e wtdng harness as
m t b m b hWcorPaat-09 m,d WCt W'dWe qlln* hwd,
d2 Fiefit the camshaft spkket wW neewsaty$i&#np lumtas to avoid oontuslon
cylinder e m lobes pointing upwardbj.
Wlidlfipi!Um$&wrong, i%bmlsa r&li;of 43 R - d i tp W l q n 7. whgn .r&Q, md reQi@$e#y fuel
the timlng belt with reference to inpdagnbh . ~ m @r pith' tefwehce ta
cket
rdlts
that
*
*~m5drn@bfOm
S e a n 5. tha devaht m*<.&r 4
3$ m M W dylindw hedd gasket to the 44 Ghe& the valvt~.ckaranms if n&m&ay 12 UDBQR tii"e 6ii&t1tttym ~ n p I n glbkkert
6bdk i d w i t ow.thedwds. MaK$$wR from the Intel,wnlfol$
bian $B?p
Z7
mt way UP.
the c$inm head onto We bloc&
a
%
-Ian @em sair dmir or air inkt duct.
Wfl4 .tne
?a, ~nbm
q l n e W pll, w& mhwge b 'rtpg.thwhyst ~
the&m.pqd&~mksl
rnan~f@d,
Ithe &@i$j Rover fhe'dowk. Clqirr lfi g r 18, 14 ~ ~ t ' &i&sf & e ~ f i ~ oFpfShlel&
ld
wds 'de WhtIy 6lI the cyllndwlmd Mk,batf~an
47 QMIthe ogling system whh Mrwm to 15- ~mmer-tb radlatur aqd ooqt~bgfan with
try ? f M m . $ n dunder W h+ Inw*ttlpr Ch@r I X or 13. ~&mp Cha@w&
nor g* $n&eightell ttlem tiPIq8d65ht 48 Refit the h n & wlth refwn# to Chap- M qbhok the M a bracing struts from khe
'ivw # Rlf&lag -th&sequWe shown, J p h I q IeF 11.. m , M @&I Inld mmhd.
5. W-bob to the toque speclaed fdr Stwa 1 4!J Rwqm& Ma baby pmltive tead, then f7 Unbolt- spark plug tube housing from
Ie~lwdw,RBPW the bY
f&&nlng the h g t e spmHed fot SXage 2. the w&<& lead. ~ of We
4 l - 1 top wv&We UlwtratIon}.
and
t8 UnboR the vaive cover trom the cylinder
h4-t? the gglp uslng a cornmwi~lfy- he@,and I.9tnwethbbWp.ga$lW.
king &&able @@a, or make up a cat&& f0 U$lng a T55 Tofx. kay) propslvely
LEeS rn@*Pvt w the ang1erequim:
bps
'the
+ bait,tfiree minutes, Ben pprqresskfely
u m fhe! w1Indy head W e half a turn sr
a tlhe, hr h e reveke ordal ta that shown Jn
@ebb all 491w In the rev&& of lhe yu,ya?1$ lt,& Mwn @ ten- hw baen
@ is t~titmlng squenke until comptaY.t$lyloosit. r e l W , m o v e all mhr' m.
!brls @&+Bweys 3 @nd 4- Mote: A new qlihder h a d $aske& YEIN CQW @ ufttjIeMIndar h a u p ~ ~ ~ d ~ a r r d d i - t h e
ater @#hi f P I I o w ~the f l g h € e n i ~ - q u m q ga$kets, and *U$t down* sealing ring $11 hiler block, ~f it is stuck, t q i 2 t u r n &
[the $&#I W MI&,to the torsae @eEJfieltfox wiu i% m$d& &m1SWng8 bslr10a. hmmplr and @ o e f r W w d rk n&?q
CW to'turn it IFf b bi- b$ W,o dowstd, lior
st"g
:dl
%i ,ii@Menlngis anled w by turning Removal attempt t&prlsp it free h n g a serewdrlwr
bdt h y g h thl q l e spedfiad for I R e r n o w t h e ~ w t t h ~ t o C h a p tnwted - m e e n the blaok and b a d fww
I the

,f+mnwJh
* Tbte @ ,need &r 5R.
Imrarin-up. 2 Removehe bonnet with referemetatohap- IhSPadW
M i s t o r tap hose $a ?he 'ter11. a j I@ ' q t l q af- the qllnder head and
tlwtlwst hwshrg, ,ahflgkiWQthe,cllp. 3 Drah the coathg s y s ~ Including , fhp BIcsskrnq# w-y dean befom refitting
9 Ffiea w.ppliwbler~ r m o ~ the e d d b c k cylhde~block, wit# r&mnpW- 1A: %&I%& UHa &per ta &me all t m m
~~m'UftrftrPIU!3> or 18. Thp M w k drain p l @ - ldW&-t"&~
~ -7

SS h n n m t theImpmturegaugesender dght4md mar b w b f *tj $p$y3

@@W-d~d inwon ~ t e ,9Fialahtm t m p - 4 Drain tke olt &$&e~e& YW:~
*-. .
@-:RMt#he valve gdver, WWa m w ~ &6 W&*
CPlapter 14rrr Y B.
the ak c [ W w
andtlrntbnuh. h c e t a t i w rqhntw
g Wt the sRark plugs and mrlbutor cap, d Remod uh;e tihiria Uelt w
Ukh&mm to the relevant Part of C b p t m 1 Wfiorl5.
m.3 7 Dimnneot the ~ ~CtolMlp~."Wm4M
~ 9 t
SB Mhey were mmwed,. mfk the inl& and manifold, as d e w r i m in t h mhWnt
~ Pwl of
$*bust maqlhids with refwencd .te the CfMptw 4.
rekthnt Parb of Ohapter 4. Uthawlw 8 D J m n & the wankcas wtlIaWn hoses
@annmt the varlom sewices to @IB Inlet fmtn the valve covqr (seslllustrarton],
mWM to ths:thdla b&y. 8 !%-&ye the d&Th)ubr QELPand spaPk
@ QqcpmeEt t h a m h ~ sdoynpip8,
t q&ga plugs, with reference to #a wtBvant P#t of
W . d i n g ring. ChqWs5and1,lneccmary-
2 0 ~ 1 41764 cc,l3&heafimd-1784 ce (F-type),engine ihwr repair p m c e d m

ot g a ~ l dand c m , EIIKWSO clean tfqtops scratches otherxiamage.. If sl[gHt,they

of the pl-s. T & & q a i l a r cara with the may be m o w d cerafuny w1th.a ffb. More
aIlfmPnlum cyli asthesoftmetalk d m darnam bie r e p H by
dmmwd *a sure that ciebrls rnachhimhfs Mblh-*wBedstjob'
qhmn* ~ I f & 4 @ : . ~ l ~ l r n p r t a n t f o r t h a
i?& if waq3ag8 Q$ the' q#ndm head Is
sw#GW, use a stml&&ige to ehegk k for
dl dhh, aWj&~$ wid block the oil supply oHsSorfIon, Refer to~lPaP8ptE 'of th5& Chapter #
@ ?he -m8m
Wrings. Using ,n-
kdh@4~.+3-& paper, seal the waw, 24 asam& the bolt MBS
In4~1$lv&ustng
antt #kl@l@kj
tM cyM&r blW. GMrt the apJeedaaaer,orarhgMrlscmWWbW
~&@&&vjn m.mev. S M *at aI 01l is &hWW h is
a p ~ ~ s iofbtha i ~black
~ hing m C @ d
hyCOmllF m u r d when the h j t b &
tightened.
a6 ermfn1the k l t fhr- and the tW&&
inther.#un&r.brwk fopdamp, If-nmmay,
up@ t h 8mmd&-SlZ&&p Chaw gut tb
thread6 In the block, and use a die €a&an
t b t h W h a n the boltsp
ReflMng
sp,um tH@ #a mailng T a m of fhe
FyllnW black md head are spptlmly

'Caw: ,He ,em&aRs am w n ~ &

p w q i i , Yhk La*:m~.lbe f-d hto
a m*.
'LB F j t An~ : cynndef
~ haad gasket to f h ~
bbch l%Uy@ther ddmls. W e k [t
%Pham yay uq,
2Q h y w .the*@rhdw head ~ n t Xo ~ Qbla*
@ri&hg it ~ ' t & ( q o ~ d l k
39 .%rn~d.b@ hmrf ww, q l *
Wf,Wpg@:and uhW_W!r he@&. insert tM
bolts, and t!ghfen them f i w * @ h t .
83 Wlw@ m e ber:n& ,ohown (shb
f![u~thttont i,@ ti$ J, n the hots :to totbe
~ P $ F ~b~r@ 5 2 a g ~1. R e @ @tkie
-urn@ b$tlgMlng.the an$e spe~fiedPot
W e $ . Measm €he qwlq u r n agmm,er-
BClljr-d~)l&L '$auge, di 'wkb up a
cElrdFMtempk'te cyt to t48 angle mqu\$dv
$2 W a t t - m rnin*, W n pSg&ht~
slaoksrr .all the bulb In fhe reverw of t&
~ ~ 1 "qquenee ; g wnUlhm@etialyI b W .
I%$,& &WBa md 4.
AqaIn Tbff owlhg th&
13ght@r1fh8 bolts30 the
mae 5.

Z5 Refit hvalue, cover, togmer with new

gWm, mtl flgHten th6 b o k to the sp&ifibd
tow.
3a ReRt the am plug W ~ Hauslng
B
d u e aver, and iighren8 1 bolts.
tb tha

W S m ~ the k bwlng &TUN b the fniw

in&lbld.
58 Rern thd adlatoy d t R rewerloe f D
Chapf$r*, M - d o ndtfil the mollngqatwn ak
Urrs stage.
 1764 cc, 1783 cc and 1794 cc (F-type) engine in-car repair procedures 2Dm15

) Sacure the starter motor mounting
bracket to the exhaust manifold.
40.ReRt the exhaust manlfold heat shield.
R
[ 41 ReM the alternator mounting bracket.
42 Reflt the engine wiring harnws .the
i 'fualliljedlaru'ignltioncomputer.
'5: 48 Reconnect the a@eleraTor ~ b I + . w i t h
d r e n c e to the'MeLant Part of Chapter 4.
44. R d i the distrtbutor cap and spark plug$
$. with mferencar.t8ilk W W ,Part,of Cham
the cyllnder block, but leave two trolts finger-
tight a1thQ stage.
1'1 M m e p@sUonof the englne right-hand
huritlr@&d A d o n to the upper bracket,
ph$n url*qwI$h8 nut. A p c h a hoist to the
mgim'Who byks, -amd raise the engine as far
26 Reflt the bonnet wlth reference to Chap-
ter11.
27 Refit ths plastic cover to the hslde of the
right-hyd wheel ~ c h .
28 Wit-the rodwheal and lower the car to
the ground.
2D FIII the engrne with fresh oll, wlth

14 ba@h d[o n d move)~~~e

;
moufding bolb, & 10wwtheaukhrrm to the
extent Pwmmed b y 3 h ~leWR
) of the bolts.
This wilt give the extrg m m neceasEvy to
Wlkrlmw the sump.
$6 Remove the two rmatrilng boitsB,then
bm&-rhe joim by sti.IKingtm sump wlth the
path of the hand. byer the sump bver the all
pump, ardylthdraw it,
Remfng
rs el* almws ~f'wrn
mmpound m
~ 9 f f t .wmy
t~ wlth mfereme td Chap the mafln'bFims of Ime-sum and wrnlrc&x
ri ~ i r p l & w d m d uM I K O . & ~,
a ahablequlvelent to the sumg M n g Wsa r ~ i ~ c ~ r n ew et ~~SJ.BIIVB
?amtt i m p w that the sump b po&bn@d p&M@ Wds (alh%iys'd&on €he
w y ' t h e ' f i & h e , and ndt moved mmd lw&praQ.
aftet the past@has fquched th? crank*: Z thdhfhe pnglne oil as d W b e d In (=hap-
LoWa bolts d i dowel rods mav be flktd fer IAw 1& Rcsfn and Qghten the drglln plug,
tem60rarllyt o he@ mttleve thk. . usha a new waSh&,
19 'R5~bmt oil d r b ~ k afrom the oll wmr, 3 J&k up ttm front of the car q d support on
and c & b I wiw & e & m c ~ - d e f f s r ; ) a x l e s t r t n d s ( ~ " ~ a n d ~
~ n ~ ~ e ~ u h P P methe-w-handtA,ntm:' -
LIW% sump'ida pmltion,insert the M I & 4 Remove the plmk x;over f@m'.ihsi& tha
and tlgh+n them $rogtaslwdy ta the wheel archfor awes t p h en&;
Sp#AW'bqM, 5 R e P i 7 9 ~the &net w b8 iin Ghw-
2T Lower tl$w mQIn8 onto the rlght-hand
taWya d W n & t h e m@tlW mouotlhg stud, <andd t %e nut. Make sure
twq1. ,
6 R W ~ ~ Qthe V ~crk *W B W M ~~ ~j f h
that the nut: ie ra the &rW pasitrph as wen
removed, then W m Bn It to the specifled
ww%
P2 ,On- m d e h fhW with p e w steming,
reconyeah&~.'r(~,"f:fi8
the car and support it rtgmmd side of
'Jwkfng and yehfcle theengine dM&m.
the fight-hd front 23 R a t me qnqlm-to-ggarbm tf-bar.and
a m r aqsemblg, and t l g h the balk, nq ifid w w 8 l b Y m w m .
24 'M the r& et@n&a~unFirlg'lihk.
B M th&ar d&&'Hh 'W&'mrb the
B # &IQV~ the exhaust d m p l p a and heat
fqr- to the q h e .
the bannrrt ,as dtrsCriM iil *ant Part of Gh@& 9. Chw44
& p j U wp $qqmp'Ca tg t.h& MeVant PBrt af

10 Working m the right-hand side driveshaft,

tb alr &mar ~ m b l wlth y
ttlevlwant Part of GhaptwA
w e m p - n t =-g
- b* id-
from unclerm mr) F7P (16-valve] m
m 8 ' 8 ~ l W spunch ta ddve out the roH p h
1I hm (butdo not mwb) the lower hft
mth~ the fldht-hand swim1 hub ta the
bottam k tb &spend9 gfnR. S ) n m and
h e fh& uptw boR,thm tHt the &el hub
a-nd &con$& ,?$ ?rRr.ssh@ b m .the
$eatYjpx sun gear s h d , '$UPPQW W
drSvqh@ o w W , m e side
f2 Unscrew the belts securing the sump to
the tylinder block, but leave two b o b *er-
ffgM at thls stage (seeilluslrdon).
18 U m r e w fhe nuts and remove t k four ~
s t W attwhlt-tgthe sump to thwgeerbox.,Uss
e
twa nuts tightened agalnstwch .other .to
mstuda.
 IAt7 Airply a bead d seaht to the sump &-@ *u&
I&~taiiavihg
' mM& WG- -F?P (IGwtvB)-em, W m
i 4 Minarktheg~lUOnoft4ae%gInerf@ttW Long bolts or dowpi rw may be fitted
m t i n g stud in r;elatlon IQ the upperbracket, temporarb to MIDd e v e this.
4
tkiitn unscrew the nut+-Attach h M tb'th jq TQ pivent piq r i p ~ l ~f@m g % dl pump
W n e I m n g m am tallthe &@IwC+Wir ~ tfwe areas c l m bdcm
and $ . r & - t ~wilj,
as $bible w&out9 sttainhg the Isff-tiqd r&&iO~@suw, Psrarp IdF9ven h m auxiliary M f l
T?q!W- 2I1 U?the sump Info p w i t h , then tnW,twd
15 Rpmovq.ths -fworernahiqg bdts* then diapnaHy+olepaWeh l t g and fingar-tighleg X;Yemlw
*+' . w g@m
_'jtrJ~t,~W P Wthth~ wl'h
at thk shge.
piim %e hatVI. b w w ime sump &ih* dl fi lWdandtightgn the fDur8hrds attaohing a $4;
4 ~ 4 t l q g . ~ 1 ~ ~ ~ i n s 13# t l 8
1%
p y w , and W m w lt. tly g~mp,tol the gqr4a3. U@ -two nm 2 ~ : ~ . W . r & k ~ . b o Iatt S . M~,E
ilqhtened -Inst encb Other to tighten the at *&pump &Y, and Wlhdraw .the pukp
q a& from the cramkaw and d d w g w @a
I 6 C M n rlU tram afWhg oermwundfforn Z! Insat the mnainlng sump bolts, q d Iwmh).
- t h * e ' ~ faas
g of me 8 ~ b cvn-6 trshtep nern prwrwlvely tq. the gppcifiM I ~ B A
If MdY @ W W-YKOIMbfi;r,
t@
la
%-.
e,mf"ting,,@ws(~i~$strap~onj.
toque.
IFit Jhe4 u r nuts to the studs, and lighbn
.fhd g q n E~S . W # ~ ~ M thm b ths spedtf~adtorque.
R is rnp*thaf
fi@firru% and nM m m mufid 24 L ow thwI en@@ pnta the rm-haw
3'~ki~y
P@!&WM*
r
th~.r$q@@g pab and Mt off the
4 WfhTlrBuu the idler gear and the drhqmd
e%fe M fw&&?hq W&Dk_cW, rnaunting&dr and Wt the nut. Make sum
;#I& allm-(-g$tl~onJ Wafb the h&$eafm
uh@ Me 'nlrt'bh fhe same pssiIi?n $S whqn hdt IbqmtRSa-In its m e pwttlan.
. mW@ $hen
, tlghtan fi to tlla specifled 5 'WW b retaini*dlp, and k m v b theall
.-i
w- pressure raid d v e spring ddher, sphs
W Reconnect the rlght-hmd driveshaft b Wna a!@ Pl!!W.
thq gearbox sun gear shw, md m u r e w#t 6 clean Wie m$panents, and cwefut!y
new~r;ollp i 9 Apply 6ealirrg m p o u n d miffe%~,$.@k, jhnp hWy and relkf
eadl end OfhmU plns. M*pbtimr for my dgrm of scorn or w-
m mflj tfie upper bolt wurtng the &M-
Rand swlvd hub ta the bottom of the
R ~ ple
is -ddmt:
e
W pump,c o r n p b ifw ~ & J v e
$uspension strut, then tighten bat' b* to 7 If the emWnf3nte apmr w b l e ;
tha spe&%d m t p s @mhChBQter10, measam the ~I$Bd&ncebetween the .pump
27 Wfit the ,eKhy&'dpwn#lpe Dtqt anu gege ustw wre W&-&+
&isld wfih refmm to the rdwant Part af -lirdum *tis Q ~ W e m a t ?.md & ~ k
Ch* A W a S ~the f &ti,#er & w i i l u m ~ .3 I
28 h x n n e & the mar ewhs mpuntlng link, the clearames exceed the spy4hi'id
- md tic#te~~ thp bolts to W-sPaF:lWl$a& mtm% w pomg rrdir~tW *W$,
$6.4 W o d e d v l W M the odpump,, 29 Refit 4 ha fierod 0 the aubMtw, etnd 8, If the pump is adstBotow, -ht8 the
W h M ftrb bob. mp-onemR the ~ ~ ~ o of rr m dM w
r 4

1t%7a onpump g a r - t o - b ~ . d ~ $m,lb-*al- mm

m - ~ W W . ~ v1:m&jb4, -
m ~.w-ahd*bbdy

pump into pwttlon with*
&im WPivegear. Insert and fplly
e W h l n bnh
~ ( ~ , Illuzhdign).
e corn@& wqh rndtatn. blot$ that* &I#
tocatimp :ciaweb.are in
oII pumn IntB W m B ,
the ddre chain with ,the
?chainand sprockek k - 1 ,
'
3 ,Remove the sump as dwflM&W@t$-
13 w 14,as applicable.
m; l P
1 78.3 GC and t 794GG (F-tyM ;engine in-car repair p r o ~ ~ dg s
- - -
W-M@.'- ..
Jam frob tna, cyltw nm,hotlag %tie ~ ~ r & & M ~ , ~ & d ~sprocket ! t ~ ~ ~
lomtbg doweb. Where applicable, recover on474dl pural@~kQ - -
We sp&ber frbm tha crsnbhaft 30 sign the. holw,$@@&inserlthe drlven
23 Recaver the oil pwnp drive ~ h d guide
n sprocket bolt6 :d*tlgh$gr! @em m m l y
bl& from the Ms locatlw dowels. whib hatdlng the w o k & atylVpith a
the its s e ~ h $g7 ~spm&@ s~:w&W. ' -
24 U ~ S G ~ B W - nhl-
to the on pump huh b e a &ew&iv0r 31 Ttm~il<w&&oxdd km.cWdWmhw
Insert@ t h r 0 u ~ hone of the holes in the the front pkte Is rern~md,mP ct
E 6Wi In
sprocket to.WttStatbnary. Section-16: -
25 Slide the drive sprocket from the 32 If not +y done, d w i h e kontdate,
crankshaft, and the driven sprocl<el from the and scrape off all t r w of m t -frorr) *P
all pump hub, and withdraw bath spmnk& plaWand&Indwbh&.
dprobibf Is nilt keyed to the mnkhaff,,twt
&lies ah' ~Mnlrsheftpulley bolt MMg
'tlgtif&&l M Wlamp
~O the spm&et.lt'ir
v19t+h& ?hemwaft
puhy bolt Ts mwly
ilghkhd on ?&g, &wk a
h
ta dl pump
may no?fun1on.
P& chain end w w k ~ - Noie'%kF.ai@matic t t a m l s s f o ~
notposw'bbto m o w re
models, it is
onaRmef
so access to the left-hand ldrl- d j dl
26 h i m e the $due chain. sCh& wear om
4ii ]Lidgad by hhiafditi$ 'th'e'bhainhbrlzbdly
&m i n g how Par li sags. Fmnt (pulley.encQ8bll wl'
27 ! p ~ t e h d ~ @ &@ h the s # e If N&' G#F 4160 WgO :w&su&&?~
t e d w+','hsokdn im the dterfrtxff~~WJII ~ i w + w m ~ m 6~
@POF~&.If $. ~f~5;kbb f0 WMYV wq]h&&&<
sprurcb and chah as a set, dnw old 1 k m o w We a d n i Wa crmbhaft
cornporn$ WIII naurwmrntogs9rer. w ~ ~ i l W ~ - 4 ~ m
28 Examine the chain,guide blmk for wear, whh m&y&:&&&ii~& 6 7 @s
and r r m e w ~ l f e ~ v e w e w r a w t d e n t , aoullWU.
 outwards. Ma@ $ure,m the ~ $ !Wls4rmt 8 On models wtth mtmatlc tranm@Bgim
damaged as ir is lbded'oh ihw crank&& &wk:%e driveplate .caefulfy fw SiQif&&
t i Ugi~fga nX~taI&&, drive the ,011, s q t drswrlian, and .for Mrllne cracks am!nd;th!
%cpretpinto the bok, uMl flu&. A blm4d boW holmj, or MtaUW butwards f&W@
W d O u t W ,pa$% tlwZh$- eITg &: mmre ~Ir:damap thk+wrtis fpynd,,.4hf
&-may ba W-ln$eEad. drive@& d b e rmdwd,
9aBp&;~;aeM4rivwf* with
mmm
7 Clean the Aywh~IYi$lvspk m
wqr-i-fi ?aoe~;t$p
dd~&latewIhk~W&f&~@
IW!NF~@&JT
.:&-
~~'ow-*-~d&
8 ApHy a fekr arb&- &f iWs1hg1YuldvW3th
threade ofthe newboitq; M the boltsf anc
tlghtsn ?them in a dhggnd-squanmW 3hc
Note: O n - m m m mmmlsslon moms, ft is s p m w torque,
8 Unscrew the bolts securing the -frontplate ~ 0P Df ~ S & ~ b B A w ~m M . m h 0 p6flt-fhfhqClutch as,deWQbd in Gtl- 8
to,ttrecylinder blmk and mWl@W the @ate, so m u w l afa a ddmplate fs not pssIb1e or* &rn&ic dhdbed li
naihattaattttsloeartedhdaveIsinth~ 'wim the enaihe in: &id. New flwPeel/ W E W itis Chapter, a$ fipptlcabb.
I&+at hole I O ~ W (& 1 b t t W o n ~@n . ,dnqlate m ~ mimm g S U W ~ rn-d-
8 m ~ iwmi t h M , Y~~ u x I ~ & & , mmW t k W g Wid.vI/I, b~ wt&&QnfHM@.
oil pump: drive chah:gul.de blo~kfrom the
d& If ~ 1 ~ 1 0 ~ ,m~~-i
4 aeranthsfrontplate,mdqoffall~ 1 ~ ~ ~ 4 m a B a s ~ n ~ w 6 ,
af W a n t from the date and cv(lnder blocrk.
5 @Me pwY the old oil mi dm the
ah. ,2 Merk the:&wheaUdrlveplatea In d d o n to NOW ~ n wgms e munqn 6 em pasrr~om
0 Fit a new s&al so that It is flush with the ths ,cmw9ftt ~ f f $i j i ~at at ~lsbnwIticraj,, drtd fi ii
outer b e d fhe front plate, using a blmk 05 3 @B ~flywhddsiveplatemust now be held Irnp&kt- tb m& exact -Son of W
w@. Ensure ~ sEds of the 4Is $MhnWM
t h aperr vhf the balls we Iwsenild. Tom@ mpuhh&$ bLfd& mtpovirrg ~t;m ensun
b
iIwW*."tM pm$le. this, lowta a long bolt In on# of the m W M p m t ofthe emm-X.
~h.dMcateW,oll t@, Apply a b d oi franp?liSdpxl #pvflUru;l bolt holes, M.&W
m?hg%e 47 In** wld+bladd m W v e r in themstarter jrrspectm
*
W'4l6QMNO
d ~ w pla'te, .nraWn;g,&re' that the dllway fir@
cavity 18 not Modmd.
m, q u!,a${ecls of bent mew bar I &ply fie'hand-r
engetgsd wRh !he rlng gear.
then fa& up th~.hnrr
of *Ear ad.wpporbIt en ~01iesmda Iaer
8 Rm&o front plerta-andJ W t h ~ . k W l h 4 Unscrew the mounting b ~ I t s
and wkhdraw *Jm&qa& W F @ ~ $ ~ Y Y .
bdb:, lTw iw@ b o b amund the J L seal the flvwheel/drlve~latefrom the crankshhft. 2 %wily InyW Be w b b r ~ c l asn tkr
QW@ ak iha 2 d c l a k and d Q'#& -
~ , C & W I not to dmP It It is heavy. e r ( g j ~ p s m f @ l ? nrnpuMngs,for s l ~ n so
p&Wtkaba~&o have w a r d q m W y d r n . I ; o r w -we ~ ~.Wen*m. clgMng aBndl,df$do&wn. 6q&l use ofI
dtwibpasto a p p l f ~fo W r thms,as Inspectlron leer MWg4p la &mine the condrtlon o
t h y prdhde Into t!?~ ~ k ~ . the' r&Wr' pa& If thwe ki qe,sI~
PrqWwt7ghtpn mar m n l n g b o b In d 6 Examine tha flyw%e~Vdrk5pl&te far &mMg
movement in the ntOuMW, bt' if the v!bb~
db$aalsecprmce. WF UwdUkh fac&,and for wear or5ehIpphgmf hw daerlaratd, th$ tmyntifig &Nhd LH
Q RmCe sump as m d b d In SeMm 13 thedng gearteeth..If2ha,etutch fa~sls W, 'fen-.
or 1A, as applieabla the flywh&may he machifled>~ n l i l W but
10 Refit the crank&& spmcket and timing r e w d la,pmf&able* kthe rfng gear la-worn
belt with re8atence.t~m rls 7,s and 8 (a8 or damaged, It-may be prrsstble b renew :St Rlght-hand mountittg
applicable). ~ mb aff H @,@ bIS b&l@f&ftta.a,&&At3 ~ n s c wtbs
dm@ OF engineqinp w* T k t?pm4uw m a t ~ d , ~ m w e ~pf h s
Rear (flywheeUdmlate en@ wmy fmm.#ha.mp:@ Qe mmUng. Oh
to whI@ the new ring,gewmust be PEK
oil mat !ilsblbtign Is crttlcal and, If, done b g drive models with, the: F3P &u
11 kmo,B the flywheaVdriwpl'ter as -ratel$, the hardnee d ;f, Mkth'idll"be i3fnslae, note rnpp+~pver h.o1ds%M,aar
d!3@i tn wtj~n 17. destroyed. atm cable in posttian (me llImtmUo&.
f2, PW,eut f i e d d all usim a srn~ll
scr&rhw, W i n g care mt to damage the
wda&-Pfw,m@fiaiZiZ A M p I v d y , the on
s d &a$ W ?-~QV&< drllling tryO small
halWQlq@F@$ ap@t(? @amoptloptl$r,and
ind"rqd&&fwm iti"thm~ pak
&
d ad@,% #fi~dilb$@$ ?&fl rnrtUle oil
&, b puh$j!an~&hCSf& him,
rq ~ ~ w r s rwt .ru'tjw~g'qrpm
~ y @e
m w .If bt~&&d br rdah ln'b&e
whwe the @d s$al was fitted, Yhe new s?ai
ahourd be fmad sllahW less dwply, so that if
n b WI a r unworn
~ put &the suHac&
19 Wipe clean ihe oil ssal ding T b n dfp
fhe newseal in fmsh engine oil, md I& It
WW hC$Wlk&t~% With m'dw sI& fa~ifig

I,
l o w mounting bracket and
mlmr from the bmj (am
cwnpbnmts uslng a r m a t d
nukmd pad mwntlng nuts
- -
r---- -
1783.Cc .and 1794,mWJ%]
engine in-car repair prooedW& mS19
4- - ...w-a ~ , w . t t w ! ~ ~
mounting nuts F7P (I&vab)~nglne
Transrnlssion mounting
l o Ramewe th* bgffeiry , Md&dUed h
GfkerpXsr$4.,
11 J&e fie wdght pf&qnsrnts@m, . ~ l n g
&frolbyla& i n d blo& of W d , or by uslhg a
&kt o~~thyld-imnei ?n@e itfflrq ep-
32 Mwkth&posrdonofthemouMngusink-a
Wbrw dab d:palot.
* U n m W ttw'mM nut and ~ W N nutis Q
semuring t)re w r i t i n g pad to the upper the n& mounting in &.w fisttion ~ 4 h e
bracket (888 Ulustmtbn). old bne;and check that the dime&mb &re
14 unbok theupper m-hmting w h p m car#&. .If m, tttm one ,m~plffh@mWarl
the .body, aFld:mmmthwmcrulltim pad (stw w ~ & w & t 8 k the ~ e t g h t DT the
- 7 -
iudm).). emgin&#5mfssio ~tsaemlirly6n t hoist,
IS, IFnsCwpUir., unbLR the. lower m e t - 1 all of the mountin$ bolts and cany wt
from the t a ~ , ~ I u o . .the folbwtng pmcedute.
j 4 a revdrsal of the removal T w m h d o n rnountlng
16 ~ e ~ l t i "ts
procedure, but leave the m o u m q nub and
b o b j~use.Flhally, ~ m r yout the ~nountthg 2 l M e p to.lblustri3ltion 7 421 in Pat C tlifa
adjustment procedure described later In this Chapter, and mti,@tmthe turret nut fl and
lower mounting b6R (11) to 5 Nm @ tbf 7%
win. Tighten the two upper mounting bolts (114 tu
Rear rnountingnower llnk 20 Nm fn, wen dgMm the nut [I)and
17 WorWng beneath fhs car, unscrew the bolt (13 t~the wne barque.
bits sqcuHfig thd Wi mdunthg llnk to the $2Wkh the msmlSgiQn miwntlrq padmd
brackets the w h m e and win* blaok lowar brecket, and the right-hF1.d mounting
Withdrawthe Unk fPom @er the car. lower brackyt In plgce, dhe'ck *hat the
18 If nekessary, ui-fbelt and remave the mwntlng boRs are I-
brack&S. e3 ~ m b e the rlghthand front roadwheel,
I 0 Mfltt4ng Is a reversal 03 the , removal then rmove the .inner wheel arch plsstic pard
wroeeBum, but leave the mbuntipgF b o b f w p wthe c m ~ ~ p u W . ' W k
wat,
loose. Flnally, carry out the mounting ail &tralva engines, t h w is a mtnirnurn
adjustment ~ G & U M d885dbsd h f h~f h l ~ oktamce of 38.5mm (moMs M h W power
WIQ~. stWrg)w 34 mm (modelswith dr condlkning
2D.20 7 764 cc, 1%!3 GE and '1794cc (F-type} enghe.1 h - c ~repair pmcedures

1
- Gbcklng the Wrama ' .G~IW&@fhe dhemlan -b
I

m ~ a t t p u R . y a n d . a n ~ ~th.o u t w ~ a f t h c m W B r n e n t ~ l r n R . r
when adjusting fhe . m g hn m d n g ~~seandthecmtreoithestt~d

or power skewing) Wwm the cmnbhaft TllustraUen t8"!25),IT mcesar$, adJust M,;
pulley a d the edge d the b d y n& to the 25 Unbolt the upper bracket if )t has already mollntlngm thattbdhmdm i & t h e m ~ '

~ a W i 3 Q t M i ~ ~ r o d i l h s H t ~ n Wt'1&
)~
been fitted. Measuk the dimension between rwcwded prd0usly ~ ~TTm tlih
g
valm neglmi fhs Yninlmurn clearance' b 29 Yha out& a g e of h s mwemmt lh*- wse h u I W ~ ~ b itothe i sspdkltwqua
mm, W t i W tmhwn th8)flade Caw3 war an@ th8 eehtfe or Chs maun'tlng stu4 @em a 3ww4h~mim bob ma&cedw&
the mkshaft pulley a d the d g e d - t h I-WYm). lr&kk%x~h'~htiie h'the q p e r br%tc8c~#
gw
nmto to%WMgthening rod h&W..Zhts 2B RefiPiFthe upper bfwkbt, and tighten' tha t h a k - f m g lw~ tll@ &*m *5$lq*
d W m e e daes-n&.Winto mmiddrnthe Doks#Ibtrhg.dtto tbspBcfflW toqua
yMnas3'ww3w61~* on tllb pulley,
a4 C 4 M a f n tan
ln Il ckarmm, cernlm h I&-
iS8 i ~ O P w & tI h l i i bdts I-,
Band ,mounting pad In the IongEtwdIIlal 8upp&g the wgl*Man,
dlraetlon In .the mMdk of the u w r b W & 'fis jnaufitings. Mwsura &I&
-4 W ~ h M
$ncl-aTIw
TIgHta. fhe Ilhfhrinaunting balta to
27 W & h * ' b l o w . mounting bracket a d s&i&r~~tqw.
Worhlng .under the car, r f i t the
ft mountim IInK gnrl timen tho Wks Yrb
~~ tM.sae.
l ,

&'&6~~~ts8*W$t r y gaps. ?@htWl th9 b m . t h e sutsa:dgeafthsn m m e g t h b m.R y m k dhenqion Y' on the & M d M
mountm nutrand bolts. c+e wd U ' w mt@~of-tham&Mllllg stud (w rnoilhltg,,,andadjust if n t y .
2E.4 Engine ~ r nand.~werhaul
~ ~ : procedures

klves
Hea@,&m&er:
Gtyp wins:
Inlet ......................................... ;........... @J mm
'W&t ......... *.... :.;.,.....,..
Y . . ~ ; . ;
- .
,-,
..............
, .

wype~pngine:
.IRxbt?.&.
-&Mi& :,;.
,.........
.................................,................
m.#mmta.i2mm
...................I.... .............. @.@.mp * O S Z . ~ ~
; ,,;
g~~~
ftd&-a.:;. ............................. ;., ....,........,,... 3 7 4 ~
..................................................*..@5mm
- - -
Biw:eri$["&
i@Peal~lites:
....
:.lilkW..i...h.., ......*.... &.T-mm
ri.ih...+.;..+iii..; ;..
,Xxbaust-,.,................................................. ,B-i5?fim
-mp?MhaS:
Intet,'...-.................. ................. ......... WAD-mm
.

-
,
-
. - . - . - . -..............:....
,
-&haustii;.i..;-.i ;; g8.5mm i...
stemd[ame&r:
G~:W'Etypa6ngln&..... ............ .,c .;...,;; ;..: .::. P1o',mm ..,.
b-@'p.*;
-. I t e l .,....i...........:.....................;.m:.;.;;.....:.;;-.;.5?;8,+04.ai5mm
-..
Ftfpti,M$kia$
,...........................................
i ,..... 5-97 *o-D.pia rim
F3Pdnes ........:...................., .............. 8D,m . . !

;.....
ym ......................................... 7;o irim
length:
VaIG3~q.W
,@m-mlt~p .........................-........,.............
,. .4;2n-kn
............. ..*.................. & Sofigute speclffed
........................................... 44;vrnrn ;
W<%'&Ef .................,.................................. -
w'Tgu&.?q&fifid
,

' ~ , b d ~ : i Cengines)
, ~ s
.............................................................
&nW,.-.,,T., 1~?2a8mm~~lam6d~,l,r'ps.8mm~d~niod~-&l73.5~inm~
Tmm (c-@W8 ~ - )
t%mal ,dlwrle@t:,
adad ... ..,-,.........................................*.
; i 19;O ,mm
uwm&e ........................................
.? ................
- . ,
19:2 riun
Auxiliary shaft (ear@F-type engines)
End&@ ,,.... ....................................
Tarque wren& settings
W w & . W A . 4G:wQof Ehis Ghaptk?,,'&eisp#cibk
.toPart A i~-typeenglnaj, Part 'g (D-type dntenance, wilt d Ilk& jive many
ehgril~l,?Pait;G;[&iype engIrieI ~dFM D (F %tiMan& rirllids Qf ~diabllib k l c &
... Wengln-1 of-tt?s~CkW,q @ $ . w v ? ~ ,dsnvemily,q negiwtd engtw,,pqreguiq
df thls P&: ari :d$@rh&l ~ - & ' [ n I@ . ~ ' .
&=,be ull cansulnptl,mp an l'n$Wm
rmwathi~
~~w,@
.pan:of ~ h l p t ~ .w;
*I
.pr-dw-fpr
n 2t h ~
tbe cy?nder
thai pkt5n 'ihtgs, ,wvsakkm d , ~ s &
vatvw and mtve gu[de@'are h! nwd
I
~ h e a ~ ~ i : ~ ~ ~ an$h€e$nd~ u k n ~ m s s zrttanti6n. M& mire thai all W&sire-n'&
,eqiWaOoqpmn4.
mh, IM&,+&~; ranQeg -Ma*im rwponsible More W ~ d l n gm$t , W-:ringp
.and/br.Quldesare w d ~ ~ @ i;e~ginW N o ~

sbpby-step p d u r w Awptng remvd, ovwhauted, w a nurnkr of factors rnwt be . c ~ w ~ ~O ~~ ~B ~U ~~

aitll Mang 6t irriitmal
WWdfi, ~ d t W i t k CprlSltier&. placed ~ : o i l p m s m mm ~ dr ,~m p m
qIhe High mileage i~ not wmssarlly an # with t hV ~ U ?M ' F i tbthEpMilWbn&'
The%Itewln$ S W Qhave ~ besn Wp#ed lndlmtinn htsr?~ W wislr-i, while it i s extremely I&, the &In md ,&-end
on assumption !h& the W @ R h@,~ IowrnHeage doaswt W u & the wed for an bmdngg m / o r me 011pum2,arepromu
been mwve,d fmm the wr. F~ hfwtmtim aVerhatrl:'Raeju&diy ,of:&ddn~L probably w m out.
mhm1ng.In-cw engine-r, as well =*the the mast hnpfYa@conrdfiwalh. An erralp
removar w d reWg of the exbW WMih ;)iss.M
Lass of pbww, rmgh rurlnIr@#kii7ocWL ~
@Qtar And fmqum 011. and rnetdb 8nghe noises, ewemlw valve gear
compon$ntanecmmy for the owhaul, refer filter changesI as-well as other requird noke an& Mgh me1 :mmuWpfloir @f slqd
 Engine removal and overhaul procedures 2E5
.

the engine. Serious inju~-?

areless actions. Plan &&idt %&B
nd you will find that a jab df this
ugh major, bs a&inMsh@d

w@Jy in lw~than-K%rfsGt candftfonat th18 engine &fore bqlnnhg the m e 1

~ I n tWhile
, the 9 ~ is beWnverMubdr
1 ~ p w u r e w[11hdp k&p WIS~tmn~ u r d
$,wr th~p~ents, such as the dlktdbubr. qgm@j,
a l t e h , a n be ~~~~u~ &I -Ins holst ~r k a m e will &o be tbm& =&$A;.- on
Fell. rW 7-@ *auld be a IIM-new n w & k a w et
b qutpmnt is rated ,@!q?W_WemM
m
' neglot *ill gJv.emany tmubletrstt miles. in $.me(qornblyd weight of the &i engrm=h 8p&~a, bbut M*
mots O m I r s ~ l ~i ~~ t m
&d
&S me ~ 9
d f i,
m~w
,
s m
~
~~m9
f n
fengine
s and trgwmbsisn.
~d p ~ l t avti
w
is of pimay m s l h o d ' b n a : ~ . s p , & ~ u i pm
n ~ ,d e tthet ~PM- h p @ ~of e 8 p j ~ d
e;s~
~ l e d l ewid im/iyP~pifi&h@ M
PuPnp MUST Pe W W d w h ~ ?;fn imbed h hftlw the-glne out of the &I&.
1s o*uW ?M * M be #me , w e&:~m$
and 1 1 f t 1 ~
-ma by a.n&ce* e p p ~ w @e ~. b
wfl
@/I/ @
:@w$ 8mWIy,,tp eas.v@ that ft: ls mot
y, nqw Hfhf&m@
ahoutd be avdtaMa vine and -tpdmw,wn %&E,*,@
$@kk
'w a WB.
the 'oil pump Menever the -Ins
BBSM
A b , If is 6-&YO& Id- fo aid frpmgomqrrp mdre e w r t e w would fmmqwinad an, rsMrl$, a d w i & , w
IS alao be blpful. There ars mahy Instances wig 4e wuiW h W tfie en& dfier.d&e.
&l?&auledled when srns pemn cannot ~ u l ~ ~ y
B* ~regln- me .enaim OVWI, t$ad pd&m a11of tb_aprationsrequired m e n Ramova!
lhrbugh the emire procedure to famillaria rrRing the mdne out af hv&bIe, 1 Remoe the battery wlth mt8rance to
N ~ l YALfhf 'the and PqUlmriWntcC Of ~laniheqpepwtion ahead of 'time. Arrange Chapter 5A.
Wa@b;-CIwhaullhgan engine 1s not diffiwtt tf for*fir win, all of he,t m ~ and s equipment 2 Remove me ra&ator with reference to
b
i!odb:&II~w 6111 of the IrIStWian8 earetulk yau wlll nee& ~ h o to r -Inning theJob. Chapter 3, Slacken the wmalning h088~cUgs,
h a ~ s - t w tools w and WuiPmmf, and h a of h cqutp>mnin v a r y to pMwn and remwe We top and bQ#m h o w 1@qe
i- ~ y . attentian to *I specificati-:
w w , tr, can btim-nsumlng
engine removal and instdlotlon safely md ilhsmarpns). I

-
PAW an WM wtive we On addition to amengine 3 ~rairrthe manual gearbox dl wlth reference 2~
I WwhIcCW ~tied L up f~ a rnlnhum d wo haid a haayl-duty floor Jack,mcahplek setS to GMpfdr T ~ ~ 7 DQr B m $ ap@lcrZlb
I - hhwwldly,.ff p a r ~ musf s he a n tcl an of spaonera and sack& as d e s ~ b dln 4 lf &a&~Me englae 411 with
m $ n M W w0.W far W W m ~ ~ ~ d t l o n t n gT, o& a@ w6ikw f@q(If9wa, wooden Mocks, ~ ~ ~ ~ ~ & ~ ~
OR the ~ d l & l l i W ObT wfis, and f r E h and plmQ of rag%and ~b&hlg SO~Y& f~ 58 R ~ Q %B P ~my0f wbh re5Sm~b
I w t h q V a n y mmw specW h l e aRd p p t r i n g , u p ~ l l ~ . cmlarit ~ ~ L , and fual. If the '6ti&k'El,
&ptjpmmare obtained In gdvmw MQ-M h d l t must ba hlrad, make sure that you
,- N?& c-m.hs dune with f y p i ~ dhand C I t o arrangp W it in ady@~e,and perfqrm all of
1 ~IB$kQh 8 number of precision msarwirtg theopemfima,pnssiblewithn~it bafaiehand.
. lp S B B P & . ~ U ~bPrBt~spseffng~ fa f h i s w l ! I ~ v e y w ~ ~ a q d t i m e .
hbbl!qa4f they W P e m n d , W n W Plan fcrr th& st$fhel? io be ourof use far
I & g \ ~ w ~ p mWIIIb handle me Inspect@ qpite, o ~JIIIB,~n~eni~i~y~rIng,~vy:~~s MII&
fl P*, ofbr ardvi~s concemlng xequ~rdtn garhorn sbm of m work h ~ c h
) ; @cOndMming and renyai- N Q W , & ~ ~ the @ do-lt-ygursdf~ wjmf aq~qmpJ@h
I W-ynW,t4e en@* has, @!I eornp/BP&'y without, spacial equSpmen5. These @ ~ e s s n W4w h e m - m ,
W&, m d d m p o p ~-#U,p often haw a busy W u l a so it Wcl &,.a &ha out q e d d l e mll pin emuing the right-
L' cs &OM, have m InspBCw W F B
&W*&&..$hii& WpB
m

I
.
1-r
,
4:.
fiM8Whg' m w h wIH m,md
&YIM~-~
h~$s$oti%Wly4lW1
daa Dng- the iop hose (arrowed)
fromthm tfiermoseat hwstng
4.2b Disconnectingih bottom hose from
the coolant pipe
 2E.6 Ehgine remayd:,qnd? ~ ~ q h wl
procedups

expaneion tank and ths water pump, then

rewf~~a,hmeref~~~8t3rnbly,
21 Dlscse~nn~ot tha aumtefator sable, and
where applbable the- ~h;hohg able, with
r e f h c s t i r the m h n f Pml of Chapter
Mher d l % ~ ~ ~ , t b , M t -
+mMg
the engtne, or, It the ertgine.ls not-M n g
dimwitled, d h M p W the wiring from the
mnneion box on t h left-hand
~ sid* of 'the
mglm ~ ~ . a r W ~ e ' to t t r
the eng1i-m Make a nbt8 of all c o w s ta

--
ensurwwrwEt Wltttng. TtpwOflng IncMdF
mnnecflons to h a following components
awdfng to mgdd (seeiUwUWons),
d Oll~resw/tck.
hwd driveshaft tcy the difbrenti4 sun wheei rod end. and dtscrmrmt R W m the 8fub axle.
e i . Mok On s g >law ~ models, tlmdI-rUn m a
~
~~mrfr-3
r &wh@armu i i h g o a 8 Z r a l ~ o i ~ s eC~) r l$vel
at$&&'inner &d ofW ftWW ts &4&4 tboL @SW#rwr.
@M is
the @pIiirsd'evlrlof the drly&sh&ftl6WP 1S~nscm
tlie~bllfs6wutJ~gthe I&-hBnd
spmnB to retain A ln h-3ml wn -1 driveshafihner WBY b w t fotFre gepl+ox.
s h , C ~ - 1 g h ~ * ~ t o14 mUn&rdy).; ~ ~ aPid rwovG tho plrkh-bdt
andmng'thsrp#-phs when Wrldngon om secuAmg the front left lower baIlj01ttt to the
of~v&mlws b&~-$&i&W &Id c@rrfer,
90, b m e w the uppsrhh9ecuring the rfght- Y SuppoiWthe w&ht of the.stub axle carder
hard Mrrts y q m r t s ~ o n " m
to the' t u b $ye m grtv'iaft an a W I W lack, H m rmmW
W W r mwdb Mat the nu3 L an the brake fig bolts .and smarate
, - - +he stub sxle
dipm&&)- S@k@ the louver bolt, then pull W a r ?Porn €ha.bottom of Me mspm:don
stn t%.drirj:%Aaft and disenQageIt froin the &.
sun w h d . Tfe the drlvesh* to,one si&? l a Withdraw the left-hand ddveshaft and
tak4ng . e r a riot ti) skah the fre~iblkb&t ebb ax16 ~ e r ' ~ ~ ~hakem&y& ~ ~ r b x ,
b ~ ~ k ~ . that the tripod rnrnwne~~~% m m h in positbn
11 U h w w :$helwo mounting b o b *inIn,g oh tk8 Indir end 0 T thB d r l e &eriv'!8~
the M-YId,brake cJlpw to the stu& ax!@ #rtny may'Pall Into the g e a W x There my be
&mWha 'cadipirta th8W @rfn&, t&hg d m &I&,& 011 &rq the gawbox, so @osftfon
~&Mskainththehow - p sml~~nblnernn-theflibwto c&h It.
12 Un&rm.the nut frm Ehe Ieft-hWd tra& rt s - w b d fhg englm!g-
;:- assem&y brtneeth thegearbux pn a tra114y
ja& $d'blo& crf h o d .
40 On W Q ~engines,
B removeihe fuel inw-
HiW u
W ds U w " i b dIn Chaptet $C. 28 D~SPO met f i e d ~ d o r n e m
r e with
n M& ~I-B -P,
&.the i a - h m m 4 n & r rdw&&b Ch+ter~n.
&wWx up@Y mduntlng tjr&kWb&a$ Z7 Gqf the plastic tie -and pull b k the
mwnting onWbody (tomableitto'bedhd rubber Mhen dmmt the gbmtimp
in its Wnql mMon],than LWOR arid hw& WFJ from the lev* bn the !$&~&OX
the bhckeVmaurifing from the gearbbx a d unsmwing ffierFut mid iemodng Wte bok
body, referring if n&ssary lo fhe @emt R m w # l e b u d b f t o m ~ t R e W . D a ~
M n iiiPartR B;C;~ D o thlschspk
f s~'pardethe gwkslihf~gigskod at tha clari.1@,
20 D18~~antWGf
gni*- &dmmbrnlurli, &ho&z-(@ **-
/&W @!ae Ulus€mtlwls). On D-tVpe>Bn$n&+ ~~~e
~ ~ @ l it will k w n e w ~ q
the Wlm, ? ~ b l , , p h ~ ~ odwrwtsq to adjustlffie~
gdar I&& pHin on mfiflinp Tlb ?he
4 5 s. -- - thewiringfromiha ' md Wo!ona,ib.
r d w tfbh o d dlps, abd d l ~ o n n d ' t h ~28 On &@fie h d F-type ea$nmi mmoM
- ~ p ~ s w M radlatoF botfom hase assembty Tram the theV&au& downptpe wlth refewiea tb We
 Eng&&remowal and overhaul procedures X i 7

1 :*!*2@ng1*:& mwwd UpwFlrds from

the ea$tfe compa&&n'f tagethar d h the
aufomerk tmsmisdon, and then separated
on the bench. Downwards removal together
with ttte mglne subfmm is possible, @giC tQb
method is fiat M M ,as /trequires ,fhe
of a specid cmdle and hlley. Bfom working
on an engine fitted wim autornafic,trans-
4m ~mmg ma englne and geamox 4m33 the c'uich bellhMsmg mission, read the note $hen in ChapXElr 78,
1ss8mbiyfrom the engine comparbne Plate Sectrbn 1. If is necessan fo validate ihe W -
313 Unlg&qd m v a th6 dukh bellhowhg throttIe position ushg ;special Renarrlt test
~ P W bw,i t m d o n l . lnstrurnent after the transmission has been
40 Yh@j;eW. 4nd hqavg the mgirte-to- M P d . A s y & @ q , , p w I I W &M.e w!
\ge&~ nuts :bd bolb from around t tw u . I , . .r0. .. .
"

&arb+ 'qH@ffap tl@ Mer ~ W rThem . is Removal

m .$a* motor. Mote the
no n w d to ~ h o the
bqgtlanp. qf yy b T a , e whlrfl May be I Remove lh& timhsf' $s- -a&&b&d 'In
wrd by *bd&and nuEB. Chapter 1'1. - .>

41 Ensurq ~ c W # engine,and geahqx arp 2 move ths as CW- In

adq-L&tpLL & ~ & &fhen o&c11ty C h W S;A
W j W d W q, $W<V m
m @t@nih 3 Rtvnve tha I cleanerer&emWi h
.m$urh!gXhfthSwh$jhr &he @bm is n~
S"
.4.@~@" g PP thra Inn@ghdt wttlle,lt Is
gngaagqii m %heclutch fricttan d i s 1- mar t e W @pliable), anb m sb e ths
+iTl&flon). exhattsl downpipe wlth retereneet to the
rPtlevBm Part of Ghapter 4. Recover the seal at
&#ttIng the rear flan-ge and the sealing ring at the
42 R m aAtqve&alaf removal$ nofing '*a? nynbld dame,
the tojtdha bci~rits. 5 If not already done, apply the handbrake.
then ihck up the front of #hecar and support it
on axle stands (*@ "Jacking and vehicle
mppaq. R-VB both %antm ~ d w ~ l s ,
8 Dr&n ~ t b C c ~ o i@t-m
Q ii dss'dbad in
c) ~ e fto,iha
k app&abfg C A a p h and a ap t
e r 74or I'@, "- "
&tbb 9s # m v a l , 7 Drain f h d~ t i t ~ W ~ ~ffuld ~ asI ~ o h
9 Check and If m r y q@st the engine m a d @ f?tra&rd& py 78.
mczntlnps wl& r&m& to ?hefelewt g lbo& f i & ~ & : l ' & ~ < ~ t~) &r

a) where ampric$Me, use nww dl pins when

~~~
m n m t l @ @ @ht-hW
-6
and s & I * ~ B - ~ T c ~ ~d~~w&@& b

mwhm
e-BM
a m e ME~'@;CW
$4
** ~w
td C M p r ov IS.
8~~

mr*
.rtl C O O M ~ S ~ ~W t mh - w ta
q t & r IAN fB. s the stewing anns
s t e e r i n g ~ ~ r o d e n dfrom
oh ttlb W hubs m both sides.
11 ' fidkiqg an.each slde h,turn. unscrew
'*.Wrn@ t f r ~ W b M ~ r thCd j rM&ljt
swp@pn*t ek suylvet &h b@m
W$!gnot M w ~ ~ ~ Q w
~ P ' P I ~the @ w i v e [ hubs a.utwderE.anp
@ennW the d~lvwhaftsfhm W output
TI8 the dfiw$wf&.to;'~~e:&e,, .
&&Em, *pmr,@w&g--- *
I3 UpPBR +WWd Y ! i G W L Mldw $m
p - ~ n ~ k & @ ~ ~ ~ o m l& d I
bmc&@.and am mbUn$@g b r & t L
rnustr&orl).
14 Rertrb~bththaHw'lng pump WWI
to C e f i r r id mi&k h ~b~al~F&achEd,
engine and pmltin the pump w w o one slde.
 2Ed8 Engine ~brnw@!
mand&~~fiad
- - -
bJ ~ ~ ~ W W Q
c),C9lllerrwlwi:
~Savtar~r.
Aftembr. $M TD *at@ the-Wmmbsion fmW $he
6 *#mimh(a,WWY&& M W r w . englnq,-i& unbk!h~LqnPb-wmnl@lgh
# F~mi~.$Mon
qsf6iwi ~ M a C w .
hj l @ ~ d '
0 7%- &am&a h@:~,t@
bPflite
wimw?-rn .*e--

$ w w e-191.
QN md~le.(&4m-~b@.
, pmwtlwl agmt 58 A@& a b q e m & runim plabto the
2l W h ~ t a a p f l W e=a
damage ta t h dstrbukq
~ cap,m o v e it with kmsmissh9R brdlbumg, in d w to k q the
M m n c e b Ch-58. brque wnverter in pasitlon While pulllng the
22 Where aflplfe$b!c, ryfove M lgnltian W#s6if&on frpm the e@n'e. Thin Is
- - -
mpdulawith refafence thi ~h&& B. 'hnpcrrka&hcause th~lmqweubm3&er~mldl
6.18 ~ h a r o ~ ( G a t r d H ) & i n W 23 On mbd8lg ffot,qtllgpu with air con- hB ef1.QuBIp dammed ltlf 18 drbppd, The
t h e p m r M n g h w - rrmdebwsth' di?ion&g,.m w s the iii]&on cornput@+,and mhlnlrrg pi* will ri6~mq Hihm
auto& bammi=hn dia@$n~qt thg' m&t8l-plup ftom the fuel refirtIngm,Wwniah, in a p r d l w h w ' w
M d l s w?thair alrWMonipg l n J d o n daps (see rd4&mf P*of Chapter,4). torrlue odnverbr eng@&d wkh de
24 R r n w ? h m p q g w and d-h thafuel pump,
Ib Rmve4he compressor wlth refem'aBta 37 Rmwb4het etwk~motor with Mweria
Chapters, l&oiflg the Wws atWhW. Do not injemn h a m e front the WaeI
open any refrigerant Ilnes. Pmttlon the 28 Dlswinngot the speedometer cable by
m p m M r o v e t o one $id@. up^^ tt from the trakimisslon.
2$ PWmn'nw the accetemttrr cabte with tran%ml$b, and remwthe sedlrag ring6
W rrrozl& reference to the ml~vevgatPdrt bF Chaplr 4 (see UhmWtMn).
16 Remove the expnslon Wnk, elecWc (ictudlng the wiring from the kickdbwn & 'LhWrWadr$rno#"thetrarrsrnWon-to-
coallng fan wembly and #he md&or, switch, when thss la lddon the cable) (spa engine m s antt b*, and withdraw the
together wlth the folded defktor. RBfer .to Ilu- bammlissbnM-oh@engim,
Chapter 3. 27 Remove the waporarh~emissbh wnMi
17 bkonneet the W'ild and m m h w e m n mnistqr, with referenceto Chapter 4D.
w i t h ~ t o t h e ~ n t W o f C h a p t w 4BB . Remove the automatfc trarthmission
RBf,OtPw
18 Disconnect the brake servo.murn hme qmputer, fogflea wltR k maurlting. 40 W I o g k.a reversal @fm d v d , nang
fmtv me Inlet M d . 28 0 - w the gear pntrol HP1e. $&jiilon%r poum.
*B WU~\h;lrl~
. ~ E ~h Q M S from the MAP
19 ~ ~ s c C W ~ Qthe Copn@ a hold to the mghe lEng eyes, 4 DMttrrr all nu& &d h o b ta the sWM
' ~W w ctwmil +lxW bhed vdw and taka thd of the engin&trms- ~~8

(a+@&1e) wfth #%&$W'~Q , & ~ t mimlw,

P ~ P A C ~ ~ W ~ ~ M 31~ Unbolt . and m o v e the left-hand k1Cw @Wh bl~ $ ~ f W f i o n s l i n
2n Eithefdsconnact.tPfemW& hqpWrorn transmlsslon uppsr mnWng aaaFkcWWW C tw 7'.
iw, or, if p e engine b ntii h a i rhbqt@jg fwm t h transmission
~ and body. ,PI &r to Ch@W 9 &#Ing the h n t
sn9
dlamah led, diseonnoct the wifi~gfrom Ztre 32 Disconrro& the right-hand yglne
the bzdwcallpw

-
wn-n box on the left-hand s* of the mounting rderrtng if nemsaq to the 4M # ~ W ~ & " ~ & ~ cmWWIS
~~WSUB
anglne compartment, and tb% the It#rst, end to approptiate S a m tn Parts C or I? of this #M f m m l & n m
fd&ebngWw'~
M,el?girre. Ma!&-nhot@,ofall w to
~ ~ I ~ ~ to
bewi~M$them
:ep~urec o f l a reffutnsg, The wiring It~~lucbs33 W M the help of m aasslstrvrt, sbNly llfi emW.
pnrpctiatls tn the bll~wing CQmpbnBnfs, the mgtndf~ansmIss~m assembly t i ~ mthe 3 M&e s u @ B y t t b dowels
~ rn
&@hg t6 m e . engine compartmeiir, tWng c#r;e_ rl@ to M . t a W@ne MI&-
mct&
4 ,@I pmWmwn&. any cumpone& an t h &t'b~rIdlng
~ ~ -.
0 s9pplygmseB t h e m & ~Cotofih~
1 mw$qn-r,
ngine/ - - - -- -
I body B Engine overhaul
- - ' -
Buring
C dismanfling sequence

the
$flla hi h b ghqp B'eifa~W 8 ~ e i hIS. ~
ikiCj& oil ~ ?h&+fl~ti@Vdrfk&ab
wh be removed from the mglrre, =!hat
kmgtne skndbits rn be @hteha hto
.to the w . 4 d.ttwS;ylinWblock.
ap the '$-'MI&
PE]~ hof 'available, k-Is @sitiIe to
hg the WB the ernghe wifh st M c d d up on J m!x& UP;. '&Mdwt on the ,shim
L Is m*w&eddl ar on fh&flow+Be e m - 0 D1lPJ-P~ &T.*F!
'could not Q tip or drop the englnawtm

F"
#.The

the
l&l&$Jma&-w*
wgo~ttgw a d h a ~ o f i d ~ t i m c i
@ g - - qths
~ cornp~dwtt.~ m w xnyW!llwI
fibMfirSt in 0rder:tolae t f a m h m d WWe gr!, af w:qoi"rve
&jne gust as they MI^ ff-youw "r&~wmQf6*+~d*ie
drwsemUy hnd
m e s u m thatyou ha*
3 ~ 1,wqaq.
s Refer ta
andof thls
mane overhaul faurseH), rnrlWWfIrnar#rn

Motet Mw ~d ~ M G ~ @P
w m r-a I ~ I
nw:bkr &m the manuhtwew and hm
*~*m,~tqmwcfm
sarrm s b d i s f to& are MUMfor the AII engines
4 Udngawlw spring wmpasm, eompmss
m. rehaving 'tw & ~ l
b e m ~ € m d ~ ~ t h e h o can m bet wmved.
,
hsplA callaEs
valw sprhg In turn un8l t
w m t s fmm fhe engineI pay dose R e b the ~arry~resswapd
&i?Mn €a W i t s thbt may be hdpfrrl of me&& tb p h c k s e a mondItlmd head
IH the EE~P,~~ringje.1 an@ s b g sw
@MBdt du&g d f t b g . Note the fieed illuatratiahs). tf, when the valve sprihb
@i9@l of.gasWQ, smb, smm, PIm cbrnprmor Is &rdwdown, W valqh
&phs,,MbmdMwsmfIItms sprlng 4 &useh$rmmrl~mtlw9prtt
% m @ ; m I n g a."dm rn* mkh, ~ - i y ~ C i yE-& ci engines WC!t muy tap Me WJ? af mtoot
~ s , , m n s l & ~ d t h ~ e n g i cylhrdef
ne 4 R@nrSlVer the rocker shaft and ret&rcOng aver the cap, wlth a tlgM hmmsP. This $Ill
11w
-
pistons .and eonndng @(sl, nrrotdwdy dorm
,the-.ayUtYCMr w,
. fm.*heFp,
d 'NfhdmhthB all sERtl.fbm-*he&p,aP tfie
F3P engines valve gGld?, then mmmw fife valw thmqgh
&lr~p, J I >pvp, and €lmlng, beit. (where
-el wlll have Q be removed &. 2 Withdraw tb Wpatbwkm (If natalready W &mb&n chamber iey-od.
'&bw &e pletnnlng a complete oWgpl, the done), m p l e b with shims4from heia'* 9 l t . l k ~ ~ & ~ ~ ~ t h e v d%&&W
vm-d
Waine can be dl%asseni$litd and the inbmal id tha h W . Plabwthh srt a die& bf &rn~mW w i in m R mmkt
mmponente remwedln ths following order: ardtroard numbbmd l'to 8, with No 1 h e ' W & ~ ~ U R @ ~ &badly ~ WOIW*
4 I M t emdr exhaust m W s . fl@he;il<e~d.)F%$ $&a tcrwrnMlh WB '&WWh'W,dr@WW. fithey wgolng to b~
strim Zhichess size on ah* oard -almngslde
&& bM, 'ih' -6 the S.hlh%a a#-@
accidentally knocked pR" tkir buckets and

T&,+FhmwIngthe oll seal from the top of 7, ttre'mb,c~npwssnis in a

the valve gulde polythene bag a W remafa4
 e?fwPw- -gtbri* fP- bY
we#R'ng mytea ,md~m&~Rt do2hU&
W.rn.8~ - ~ ~ . ~ ~ . w i o h 6i t1 v *
&an%&&$*&. '@hid he,iB@m hi#s
srrbsidei$ 'the wafer ~ihkw d n sodlirm
hyd-de {ca~rstle-a), whleh m f In

slew, if* vah,wDqew 'CtiHmWat thli

3-e, meaisure M e .$tern diameW.at
check thal the wthderhoed surface Fa npt se~fled mhlt~ U B I ~EI m t & ~ n p t w (w
Memm in the
i R m b . n ) , Any SJgfilfi~~srt
dlsfot-@i (see l l l ~ o n ) W. it is, It may be
posdMe to haw It WW("eklrnrne8'9on ~~~ InrflpW.wearMtl~ w&
a l l
.
w w~
p.
h e c-~yqgip. yuhw d6 n,ot &m;
he ~~
H e r~m g m W , ' a m . *
d 01
~ ~ 6 o u lany
,w
these ,onditiohs bs
mw bgetmf3wad,Ifthe
7 EmrnJne *,%-valve sea& in ~ c of'tHe
h ydws am ln&i&Woy cendItion, w a $k#
i - T h ~ ~ ~ h t a n l n g qtlndw hmd and
vaI~%~~pa~wrrts~. fieypwsd by a detaw m~Cbktdn~h&&, If tRby.+re=Q*gVwJy WW.Wbfi~sgfWi,t h y , W l d ba.mQwd
[Dap . ;5RfP&&mpmha-t~ msurea
I n s p d n , will enable you tQ d&de: how plM,,or+ked or hum&, than thy will n d
to bgwm@d Wmut q,qghs~p?~alqul
e. r my,e<anlysHghW ,$W,
$m %
.," &*MM,
ihts W FO\;rake.&RdIng Isdad out m t s f ~ w s ,
b i rsm,ouiM by.y~drlrnQ.@a w.9AmPkce th@"'cyllh#Brtm@ ypsldvdown ~n a
a@ 5-8 together vlth cosma, then fine. be?&; w@..a WoCk OI woad at meh end to
dl t r a w of old gasket gdqdlfig mte as d W i W h Phcr fbJlowltg g I v a ' c ~ ~ f a k ~ ~ v @ c r q - s m ~ .
t I Smear a Of tawse cabrundurn
ling. mmD~$nd from the - b
ff fB9 yaw gUdes am wbm, indiated by a past# on the.M W f W , and press a suction
&&to-slde r n a h aP the vdve In the auide. gpklc$ng too! onto the wslva head. WIth -a
CoWibUstlon{ehambwsand porn, than W&I "W gpi+ mat i~ w.A dial gwge r p y s ~ r n l - t madtm, mnd4heY ~ V hdad @ to- Fb
V?&nif? Wad l b ~ @ ~ hwah
ly m n ar ~ be used b dethlnta @a amount of slde play se&, liftiqg the v&v@ mmasjrmaUy to
hsdwfk ofthe vgw. w k the fft us!ng a new idve yedi$tfibute the paste fw
4 &rape gff py heayy c 4 m n deposits that If In Wbt, t~ decide whether it Is the value or lIlu&@lw).!Wh a+duKimttw m ~ u r h c d
m4y k v e ' f ~ m e dwl the valves, then use a prW&d dh\ @lh Me mtw, s e t and the
v81wI w1p.e crft the paste dnd repeat .the
a
w,.Valve guides may ,@erenewed using p'wsd$w l t k f f h a L ~ m m U u r-9, n A kkht
prwq and a suitable mandrel, making $.urn spfing ,ynciwthrvalve headw4U m y
thatWhw d the mrmt hw,The work JS ea& tf@ o@BWn.Whm a-mmlhunbrom
best carrlhtd but by @-I -m$Ow ~ W ~ ~h gU OY II$m grey meet firiishfIsproducedan
~fispectfan proasti& before conducung wit sP&dlst, mca if it Is n& doWlfully,.hete W h W"e V$Iw and Sat, the grindj~gt
smites of.an engine overhaul s ~ e W s t IS a riskof dm'wlng tRs grllnd& hqd. dpePatloh IS.nornpW. i2e-wmra ~ Q I Mdl
Valves
on
W a m i w The exhtnrst U E I ~ W S ~
WWr W #B F?P (1.8-van(e3, en@e 9
.e Inspect the h.wdvery mefully far cracks, flIIed wfth3wdlum,and titist l&
2&Vkl&w
Df @rd&mtleakagel and oxher cAspd.olc a w r
v -maIrvly,they 6bwN
lf amcks are found, &.newcyhler be cut In halt'md then immersedIn water damage and dlscdqr~on,.end. aim m b r e
W k b o u l d h e bbtalneg. thelr free length udng v d e r erllpers or bY
t&@~a.~stmIght-wUgeand feeler blade to

- r u r yr*
freei ten
W2' ~ ~ i ~ W e s p im4 is . ~ h mp'(f+wB)
b &gm,mlne.b
f'lydmulfcfa- fbr.-giip&thg and wear
 L

Engine mmoval and overhaul pme@eS mi 1

p by
bing,
pn it
i has
Piurn
p in
brig,
p
Ieck

ious
Iand
Fj ?&I4 M l n g lhW n U c with oil &48a Rmo\rs the ra&wah&eecuring
:boItisfmrnth~~. .. .a;$& itr~i:4h&li&&'~
pm~is.. .
$(see
p the
r@E the

DWS.
on a
ld to

durn
dion
0.16~ .. .
and slide the rockers from the 8.10d Check the rocker arm contact 8.1h Checking the internal diameter of
kh a shaft, keeping them in order surfaces (arrowed) for wear the rocker arms
0 tts
to
[see
' ridges. Renew as necessary. if new hydraulic
tappets are betng fitted, or if the old ones
rocker using a length of wire (see
illustrations). Renew the rocker arm or the 9 Gylhder head-
DB IS
the
i have been silowed to drain, prime them with
fresh engine oil before fitting them, as follows;
rocker shaft itself if any are suspect.
17 On the 0-type engine, inspect the rocker
reassembly
the immerse each tappet in oil with the hole rollers for pits, wear, score marks or any
light uppermost, and use flat-nosed pliers to move indication that the surface-hardening has
eatly Note: A valve spring compressor tool and new
them up and down until all air is forced out worn through. Also check that each roller ~ seals will be required for this
valve s t e oil
>ken I (seeillustration). turns, freely in its respective rocker (see
lon operation.
I Rocker arm components - illustration). Renew any rockers which are 1 Lubricate the stems of the valves, and
dlng suspect.
1s all I
C-type, D-type and E-type engines insert them into their orlglnal Iocations (see
18 On the C-type engine, inspect the
or a 1' 16 Check the rocker arm contact suffaces for illustration). If new valves are being fitted,
pushrod ends for scuffing and excessive
I the pits, wear, score marks or any indication that insert them into the locations to which they
wear. Roll each pushrod on a flat surface,
the surface-hardenlng has worn through. such as a plece of plate glass, and check for have been ground.
Dismantle the rocker shaft, and check the 2 Working on the first valve, dip the new oil
straightness.
rocker arm and rocker shaft p~votand contact seal In engine oil, then carefully locate it over
Is of areas in the same way. Measure the internal Valve stem oil seals the valve and onto the guide. Take care not to
tsure diameter of each rocker, and check their fit on I9 The valve stern oil seals should be damage the seal as It is passed over the valve
rr by the shaft. Clean out the oil spill holes in each renewed as a matter of course. stem. Use a suitable socket or metal tube to
new

, and
dngs
Lheir
!rigs.
pr of

PPM
tting
bas.
Note
pd Is
b not
B the 8.1 1 Clean the oil spill holes using a 8.17 Inspect the rocker rollers (arrowed) 9.1 F i n g a valve
wear length of wtre on D-type englnes
 Ehglne mqsval and overhaul pm&@s 2!@:13

10.9 .an0 anvegeer

e wmWs, am. lM 18 Place a new howlng gasket in posttion t b cyljndgr~o&,@epingthem InsVWarder
~ J t anc!
aft thrustplate. and W over the dgwals of the eylihder block (aee of removal. Identify them for locat~on.
ulrtra4ions). lll~str@on), If a J&4iilq@ JW ' ndt ~ s d d 6 Ynscrew and remove the y,.*tv
a
, lyabmd of GAF &O fHH0 &urlng the camshaft retalnlng p i e ta
p ~ v h s i ym
~ ~ ~ & ~ l m R Wtinder w % block, and carefu&W&aJY 3.
1s LfbtMly. lubtlwe the oil seai Ilps, and m s h a f t from Rs tocgtlga -
men '[@mp;~lm hquslhg In ptkcs. Refit and . .
tighten the hou~lng rebinlhg b i t s l~spection
@&@q@p &rn
@ W D ~WUW#.
I
14 lhbrloat8~?heoll >pumpdHv@&r, arid
mrrnqw:irn.w
I6 lii6fi'ths W.'low-tVRfrrg belt c w e h ~
thg ~ y I l n d ~ a % %ghW€hhMts.
a
18 Pmion a new O4lng seal on Ylria 7 If ?he ,camshaft,Is sewiewble, ! y n ~ u W y
-dtJlcleg?mverpt&ei 8t'.tfw plate and ascure reflt the sprooke, ahd M r e with the
wrtb rhe* m l h l b*. ~ retaining M. Using a feeler blade, m q w m
$7 -Refi..f)Pe;aux4ltq shaft &prook& and the thwclear%noeb m the ~mshaftretainti4
tlmlng belt. C dicrbed fi PArk I3 D tthl's pJ@edtheayter faced ha b W g lournal.
ChW. I f the c i e a m w [an&iMj 6xcstKls .the
speclfi d dimension, renew the rewnlng
p ' h . To do thls, remaw Zhe mCMt, arid
draw off the plateand refsll?lty d<tar+ng,.a
suhbIe pullw-. F t t * ~ h w ~ p l & @ ~ad
oallar, wpy s hammer m 6 ? b to^^ w
@br Irrb-#0ai#pn.
ihe c m h d t
B m i n e .<themncUtbn
Removal n . F~ pm w thf$
1 Rernwe thcrc?jndar,M, timing chaln and N ~ R our .% JE. ~-;1"d&:
~ f k ~ : f P$Ft i of: ~ ~ ~ ~ 0 ~ ~
this Ghapfr;
2 RermoY@:tm#mr~'r
wltw r#qrenw t<o'
ChapWS&
3 Using a sI,t&@lEl w@Sgewed WG, the
.ai.A-1apersd'~mM
distributor mdfivwar,
rod, qwt*1 d~w~Wmrths"QI1stilbuw
aperture.
4 Withdraw the mfdllowws from €heWpd

t0.9b Driving in the new 011 seal W.IPrlAuxiliary shaft housing g W d

poskloned on the dowels
2E*14 Engine rern@ya'@ wwjlaul procedures

-I WWng frorn,h enginf3 7 WhcJwW&Wnimnjhs bottom ofthe

{* ~ U ~ M W B ) , Ilnw. ~@p~&,&;pikbnW)asr&pwth her
18 ~e5~RwQ~f9ar~Fn'fo
mesh @th the
~ m a t p P U ' ~ p , ~ ~ . & m ~
$Ah& WMti~@~&h&&'if:will Wate . - -&I-- -
d & with its slot at
e l w i s e , p ~ b i qnd
ri~ht-an#l@sto towmnkd-d centrelns and
&m-'wy*->w the*W*
wjll'&~s&'ry &t a %&I nut on the mt
&m&,j6**~ or awm& m
b & ~ u d u & & ~ ~ . ~ r i f .
?
I 8heF&i@.utwwith reiergnce to
CimpW$K

--
W,
-n, w-mjng-
1 With the @ ~
i&wh
~ ~&
: a dl
,E-*?W~ F-WP*W~W)
F
n PWP
d i Wlth
I B the t~mj
and fw't@at@
~
( Ws and Ltjrp~
y,";$vp.emT"mcl
"8.
md*,
q p-w?gH
lw@@ mfDu0w dl a d msiqg p b
lqbdc@e,ihscam dllowers, and insen 2 ' R e B#& &knhMt& that Wa 1 b W d
ed Mo Wetr bflalnal b r e s In the cvlinder ow [ h e a + 4 p ~ ~ h a l pasltlwl,IQ sX Ihe w ~ l ~ . 3 M +%I&.
bbk.
v
Cow& Minti33'k *vex. tf the blkwd can 2 Bebrg the urankshaft is removed, check
w-~&w%Q W ~ y k ming
~wcMW UW
* chain and rod am not already numbered, ;nark the& ihk'gfid.oftha*,mafi
ww In mnt@,W
Wlth a ~ ~ (see H l uc~ o n )Mark
.h ft> ntrr*).
md ~ f i n c k h d as
, d-bd In A of P@h tbR W W W W Y@bW e r .qd'W&
tbk-. .~ ~ & , h ~ ~ l a n h i hU1y
c i f tthe
't4 Mihe-until
FA+f
No1 p l e n (flu-
aildl b dt tM tbp of Its pompresdbn 3 Web removing the big-md caps, usaa z8mfhiigY
w*? $4@e@he.gmq& R e r d w
@
can k w6jidM flh M d amount,
+be
w e . fe@r-blade to chmk fie arflount of sf# play
-betweentfmaaps and .the orankhaft-webs and giva WIi ~ ~ d W $ ~ bw~M. thow oew
$3 Ww6ut~o'yrngg
t5a ~mkshm, padon &bB*gred
@e ~ l i t oSO @, i b ~dbts are at (see4-W. =-natme1 WwM&s
~ . b ~ ~ ~ a n ~ t h ~ c r 'dth
p &M' ~44Unsccew
~ s , and remove the big-end beadng cm h~used. hi?& the cmbhaff fully
gp nur3 @twpe and Ewe engl's) w bolts
ID-type <andFWI mqlrrm). Withdraw the
QW,8~mpCto Y~-mBII b W n Q , horn tfics
'mnHwtin@rod. W k e b q x wlh a d e n crankpln and the thrusiwasher of the centre
gr--~BII~H # IS(WEQ('. maln bearing b-type, 0-type and Etyp
8 If:mly t h e - M n g shells are M n g mdd ehghr*) (see IIlustmti~n1~ or between the
b,push i h mnectlng
~ rod up qd dfj t@ web d Moll argnkpb and b.Wwasherd
mkpin, and mmwta.the upper bewingdikdl. lrla.2 mdn b W t w IF-- cans).
h p l the M n g shells man$cap together h 4 Idantifwatton numbers shautd already be
thdr mrrect - 'a Bthey amto krmkd. w?ont@tbe es#i main bMng w>
A mi, rmnlbw@\~~apand cwkcaseudqa
.@meand E-type engines d e n t m c h , as w , u m e fmhe mnmthg
0 Remove the llner clamps and withdraw &.and Gaps (kee InWtmthn),
each Hner, together wkh piston aria $U ~ a n d m o w t h e ~ n W l ~ ~
mnneoting.md, fmm the top ot th& cqllnder mtdhing bolh and withdraw the mpd,
blmk MarkthaI m uslnu masldng
l SQ aornplete Wth b6k#lhg shells (see
@w side f&wtheaywheel when that they may be refitted In thelr ori@d illustration). S$p hcaps wfth a wooden or
-
,dttEed C-Qw englns -
I. coppar malU If they are stu&.

1&2 Wg-end caps marked;krttfl&:centre- 129 $#Mmkhg+h,Mg-& oap-91de play tS2 Ghe&ing the crankshaft endim
Punch with a dial gauge
 - -

Engin&mqwal:andoverhaul p m e d m 5

2 Scrapedltr- qf wket from the cyllndw out md the h~lesr-ppd, Use nrsvy plugs
block taklog w e not to damage the head ybn tha englna is ksembled.
Pf'Rhva the Zhmshashem at each sfde af 4 N: the block Is extremely dl*, It shpuld &e
bre"&tfh hkdn b e m i (E-typqalid E-me> &yn-clwned.
$gh$s)br Wemain baring [Ftype erngiM), b A&r the block has beearn a t w - c l n w &
rWWwthit balm shll upper hdms
M - t l P B cmnhpse. On D-type .engglnes, the

d For complete CIeaning, m e corq piqgs

@ w m d ,M H a maJI Wfe-FvStd$?ri,

u~lr@a W af grips aFre

*mm!xeilo#a Al'eXremal

of-the bore
 2E.16 Engine removal ahd overhaul procedures

I socket,with an autside dkrnater that will iust YOU wlll also nead, m a parrlffln or bnlrlg oU
and rags. The:hbne -Id pe. m o w w'md
I , lnptnq&'dnto the holes in
s.ll../ P ~ S and
thb block Tiphtenth&'~d&.
down the cylinder to prbdu* a &asshatch
paWrh, and plenty 07 h,oq!ng ail -sllould bq
~ ~ i 3 Idhlb,
d. the ~tosshatshllnes should
41 If the ingins IS J@ &1ng to be Intels& at a'p~Xlm.@ly a 68' wle, Do not
m m b w ~ $ # l ~ , ; ~ : w l.cfTa~&
t h takeB,& mom W i l a l than'is necessaw to
mw?P
ptas*ic bag to kk= ~k.slw.w$ produce the requW Rnish. If new pistonscare
m, being fitted, the &ton manufactumrs mav
speciry a finish wjb a dii,nt angle, so wir
instruatlons should be foll~wed. Do not
*IflsJectlui7
WSuaIfy check the bl0E.k for cracks, rust
and ctmmoshn. b o k for stripped threads In
withdmw the hwtefrom The qlInrlq while R is
st111 bdng tumd, but stop it first. After honing
the threaded hal~s.If there has been any a cylinder, wlpe out all tram ofthe hon'h-ig oil.
hlstory of Infernal water leakage, it may be If eguiprnent of this typ.e Is not 8,M&bl w if
all q W e s .om mom wrthwb!te having an angi.ps ov~maul xou--ge not sure whether you are competent
PwqwyM q@p S P ~ I ~ S ~ mthe ~JOCRw I ~~p q d
$@@*i&ake ?the~ k , y o u r $ & f ,an .engin8
water tuns alWI dt$fhedl& equipmwt, If defects are f ~ ~ n ha*d , t f i ~&-hut apiaPst will ~ e v ro&tfw
y work at a
I ~ dl pachlnqd ~,urga@o block repaired, if posstble, w renewed.
$ $ ~ O U Q ~ I Y - @ JW~PP fi'3&!*
W a ~ i a h ~ ~ x z a s t - w i s voh.
~ ~ift lvou
~ e 'hqe
13 Check the cylinder b w d i n e ~f q 0j-t C-type and E-type englnas, before
-
. w d ~ l ru, s ~tto kvffing wd scoring. Noymdy, bore wear wi9 WWng th@,blfm&r iihem, thek p d b n s
q~
1 1 ~ mU
t h ~ ' b 1DPBMS9 dl 18 BOW 0M.d the Oil be Wi.d&lt in .theform of a wear rldge at the must be c h d d qa follaws, and pew base
b$.Me$- w,Tt'& I&Xgle marks the Hmlt of ~W-rIn@fiW- 'C3n me C-type aglne, the
pst&?w., sea$we 9 fl$Lsirq-type gasket of specU
W d n e W q e p protwctfon T h e p ars available in three
XO?.

s w v l e n & & ~ B i f J a+ ~ q u Q q,dtm?el~r%f wt~ W ~ W tWhmses, l w c u d d blue, red md

6 We bl%$ not w UlFty,<Ya~,W
adeque& ~ I W i n )&g ~h w m& water H@&
+,# m:e$ @&.rjiPdertb ~dd$ea&€l),,aeh
h * W f &rnQ & m * Y
~ $ 4
hot% P&W ,W43L ihe'h-~>e-r$r@+
$wi
~ r Y $ & a @ ~ @ g i r & the
, seals are Irt
I ~ W I-1-~ '
wid WW T&*b d time, md d.w $5 M,wm,eqyp . w h qytWer's dl-r at 21 P ~ I $ W ~ T bwwb@Q
, h Resd1ess of the G ~ W ~ ~ the
t h a i ~ u ~job, R same three hcatlons mmss the type 4 $ 8 % ah' m ~~ - r l n ~ * -
~ o used,d be s h to dean all oil Wes and ormkshaft MIS. If the difference betwem eny
gaileribs ^very thorouahlv, drv the blbek of the rn6asurerirem Is amer than 0.20 mm.
&mplertely and c ~ a ~ mwhiked
dl surkaw I n d h h g 4Hat the cyllser k eka&slvelyout- a dU gau@$$r8 W W and Wk bh6,
wrn'ii@ifoTt. ofg.round or taper& ~h m W i a l aidfan ~ h &that, the pmtwion of:thclher gbbve
7 n e threaded holes In the block must be must be emsidered. the wpm ~J#K@of the IcyHnder btmk is
46' Rd@M fMs p r o a r e Tor the mmalnlkg wikhin tk+wifl& l h n ~ r F s ( 8 8 8 . 1 ~ o r l s ) ~
qllqdw. Check all,of the l i i y s in -Re same manner.
I 7 l f ~ h M l ~ a r n W l cba ma d l v r o~r and r&?ard the prfmtrwbns. If the p m - m
sewed,or iitfiey am &-vf-m~nd P . h m ~ .m t h p , ~ w . mh , wain
@FDm aW@$edfhieada. It ~ d b &Uee , or tapered, ham the=Iock re- tising.@md e n instead of the blue
Bon,&&k@d Bd to olear the hdes of dibrls ( D - Q p ~ d dF-type e r ~ ~ ~
prodwed by t h t ~(1mtjan.Now 1s a g-ursd etit)&r ~tnehr p ~ a ~ d .~ X k $
Ime to ckan .W'6%hrds on the head bolts Mew pistons,(ovwkeIn. !hepsqo! %&m
a
or ~o ew sn m e y ma MOM ttigh r e 19*,+limit2-
W?

..$ M
the.dtffamnca , ~pmtnrsbn f bstwmn two
owlt IIW,,rW.llwwb d ~ ~ t W itd ,
lamherd
.>.
tg h m h a n g @Warn to bFlw this
tor

WIN.* baqlp.
18 If the cylltdwa am in reasonably @& dtfferanc&*wIthInIIm#% Thp~Btr,N~ns rnw
wnMt!n.ah~n4k m@yvonjyb~~~~~ b besaep~up~wdwYnwardsm~
maw the ai-n rlnaa- flywheel end of m$md
18 If this b the &a, the b o w ~h941dbg Ba Refit dl d e r h a l components and
fiorrwfln bi-der to&w tharaew rlMs Mb&i In se@m.

rod assemblies - - ;c.1

A
, - -$$
inspection and reassembly

1 Bef~re
the tn8w~#opprmw h l q ,
fYlab l w - m rM w m W l e s must
M b e - ; d e dand
, 4h o m a 3 .piton rings
m6WWmfhs@hna
2 W l l y apand the ~ t -8
d over the tsp
q F Fpkbns,
~ me,WSEI Qf.two or ttwe~~old
WMblades wilt he'helpful in w e n t l n g tt#a
rlngs dmpplng Into gmvas Itsee
illustration].
3Wmpeaway21n~i3ff-onrbon~
topof ths ~ W AR .
hsnbheld wlm hrush w n
 and overhaul proeWP~&s, E * 4 T
En'~iWa~~m~va1

[
- veow
+>.
W otd 'db l W ' * ~
<thepiston rings
qalo . ~ ~ ~ w e ~ w w m
clearance
' 'C

:I&>bfine emery doth oan be used once m q u r e the pI&n hg-bqmomdmmm

I d&3,md~~ity
of w e +posh( kv,e ~ I ByY $.I@cllng,'a.np~, pwpm ring-in
g m w n d meiiwrlrig the clemnce with a
rlng
fwgi.. U m (w il!uptp7on). .Ghwk the
alewame'&-.thm ~ . . f a u ~ d a ~ m w d . &
rlng In haif* do this, b groove. t b wtuer we sbecified,but H the g&ps would ~B~oT:W.~P'&.O';M~ mrn for
~ 1 , f o ~ r only m ethe carbon dwsits; rneasumdclearance b~excessiv~ - w water eompres~irlll h%$; &edi@a$
:&,n.Qt$m?m abl m w , ojck or wml thmg.j,o
y -gew ~ t mwill s bffkr;i&tf
af the ring groovss, Pmtwt yQur t h new ~ rim.-lsm&Wv Xrflkh the rnwt
$ i 3 h t ~ . tm,shtap' l k
~ikalycause dirtremainingin the grows.
11 Check the piston-to-bore/llner clwance
$%ny rfepmlts have been mmoved, by measurhg 'the cylinder bordiner (gee Reassembly
I IGWWthe .pfstOru'c~nn~~thg rod ammbly
vdtjl pamHln or a ~ultablssolvent, and dw S a l o n T i n %%& tl~.~lston di8meW. Measure I 4 Instal! me new r t n by ~ IltMng
~ them o w
&'hu~hl$.Make a u ~ ethe oU return M e s In thy ist ton bmqthe a& at a 90@angle to the fop of ofe pjst;an, H m n g with the dl
qq&& aidesof the ring g m w m dw. the gudgeon pie, apprmlm* haYf ww cgnlr(5l.arapar ring. Usg fder blades or .
I , &If.fh~ pistons .and cyilnder bans am not &wn W eMrt '(seaHltrstWon). & b E t the stripe of tln, In the m e ,my as whm
mcsssively, and If the piston CWWW TWrn thp bmw'lIner~dlari&r mowing Yhe old rings. Nots that h e second
-n& need to ,118@bbre& to ~btEliwt h dewawe Om P and F-type mrnprmion ring 18 W s r d . Bdh
ns can he re-us&. Nomal mglm~HZh'wItsgwWm W g g w Whran coinpression drgs ,must be Wed with the
In +heSpwikations, the blockwill have to be word "Tap u b ~ m e RIri . ~ ~ B X.WebUI
harrdllng the mrnprmslm rfngs-:; t h y will
- 11
m -plMq~
'mm?rffi@,
mf
q m s t

dX
M'm tha englm Ismasmbled;
Surfam, and dlght -Mid mwplmmd d f ~ @ W
B mp ringJn .It8 groowe. Mew & and E*meengIn&,new pistons and liners b& l
should alws ba W d we s ~ l k i ~ j n - r n a t c t w
P w WhmW h@WW
,
toofar (seeibtrdod.
12 d h k the, fit of the gudgeon pin by 15 With all the 'T~WIn
ring#&&
WIHQb$Bf@
1gw b.ii-OM.
W
-

,
k
;tRa
WGWdly Inspect plston for creeks t w l n g the piQtPF1 md oonnmtlng tad in
Wmd-t4~-skl&
1s 'M&* th& ]If hew PIS-4,
ert me gudgsm pin bases, o p p m k dlrrrations, Any mtiaeabIe, play &rtibiiaa haw b m rnWW-h
at tha p b n dng I@$ ( b w e n the ingidatm w e @ i v l t wyr, which must ba
@k&rlng.gmws): c~'@ed. If $he @om or o s b n d h q M s
b L m k f m ~ r i n g a n d s ~ ~ o n t h a damb to bamqwed,Jtte wokshmld b W.ed
WWsMrt,h o b In the plslan crown, and oUt-by a R s i r ' a a u R , gor ~ anglp o~ertwwl

-
8$&yTare& at teed@d the crown. lf.the spmajlst, (In@ ~ l b m,atf f,t ~FSPJIB-~tye
&HC sWmd or e w M r tho englhe may circllps, m the @st?% aqd caomr n-dai w
bnglne, thg 'gudgeon plns, d ..by
n g rods .
WlWn d W n g from overheating andltlr
be ~ 8 p a m ~ w M t difftm. mfhe
&&#mi mmbuliltlsn, whlch BUS& a posttionuf the piston r&v%?o the m d e
i@-f~*W -*=.
lubrlsatinp sybrns &oil& bh dismantling, and .I&@ n M ~irbll@. 00
ehomughly. A hole th the piston -b'lld
4e an' 1ndlcaTfP:n that abnmat
mbrrstim (pre-lgnrn) was m m g .
@i% $&hat&the &ge datp Wri &bwn
3Ww&Ily Wdam ot kn&hg tdet~ndon)~
.*d*e-1 w,
pmkms the m k
mb m-, at fitha damagewlll m u r
muses may jntwe iht& @r ke@,
InmmfueIIair mRtarre or (Wen appliisabl~9
'jE&WtgnRM i~mlng.
.ir'OoWtbh qf the p W n , In form dsmall
k i i w ' i h t cwjant le Iediltig Into -ttt$
i;.mbct8tton-~hembw,W a r the m n k c a s ~ ,
A@Cfi, the cause must Be GQ&&~, .or ihe
grbblem may pet?@€h the mbJff &neb
10 If new rings ~e b'ih~g thM % &I pkfons,
 surface. Any roughness will be 3 W h q ~ e r n r n !$e~ beafinw, rmow
aocsmpanled by ;&loirs -b&,tng wear) mm.wrntt-a-mh b l a g # ~n t a i n m n g
indioates the.fha$ the wpkshafi requlrssmps, tv
mnn& r w wcapa
and lay them o t l t k h a7cSEemsurface In the
I 4 ~ernoie@ burra bm-$a m b h a f t oil same gene$ -3,
~ M h r ~ ~ f ~ This~Mll'engbL
iengine. ~
ols.ulzdr location In the
. to match any
.you

4,art+d.&WfcWy~ W ~ them g
engine in a Wety of ways. Did may b6 Mt In
the mplne dMng assembly;' or- It m y pas$
thrpughfllters or the orankakse ventilation
W!?d Bmay g@ lntOthe 011, and fmm the9
4 M - m Il3-~ G&&- ~$NT@IS ~ltt-~f-t~,Und.T&Q the Into t b bwjngs. Uwl chlprsfrom W w
~aftioumals rneasurem&t at each sad of the journal. near wwatkm and wm@t gglwww am often
present, ,Abmiv& are $e&rns$' left b
m@n& -mmpnm& after 196ondiflming,
~ + J @ I $ w h Bpe*auPr
n ho%mmmq
clewed mlslng t h p~r o m ~eanlhgmetRtidsb
h e d l sed jcumats es apptkable at m1BUax We Ww, m e f&Qn &jaw
i)' ~ h e &
each 6nB of the crlmk3hH k r W e t and o€bha W ' u pm M d W lh ttw e* begring
I, p .e n mar' qnkshaft a M d g It Mth
,>.
&%aqF: I f 4 h e . d has w t m q e m d v e rWtflU, a h Wiip remghlS@.La@
E:wlahl@.
2 .

& M e , IS tf@3d'U"ni"al,&%n&tft,ah ;s;s@ti% mtW&.Wll sndl eMb@lIn the M n g , awd

MgrnInqr Wear eye pmWcHon
;w&u W n g ~ o m p r r r m
altfde
f i *n, @e,~iIl r j w ? l hQ
&&.&RB~ br sim~tar
o&&I ~@&lWii who wlll be &h'b,adh wilt wore w gouge the beariw ~ Y I jB & d .
If 4^ @pir;fS <po@lbI&;ot v3hqhr a n W TIte be& wygntlon for thiseause of bearing
cyarnlf&~Weuy.
~ n e ~ b l y ~ ~ \ l e nrsgulart r nmghe
d
oll,and8ltefchanges are ako recommended.
6 lack of Lubrication (or lubrkaomon
brgakdaw* ha$ -asnumber of h t e M
causm. Exomtve Wt'&hichthins the oil),
1 Eventhou$hZhern$h md H g a d Wnp crverlcxWlng Mhbh squmzee the oll k.orm ifw
shoUld' bq ddiimg the eegjhe kmdng face) and oll Wager (hrn excesswe
werhml, ,thea-berarIngs ehotlld b r&&d harim cl&mlaes, worn oil pump or high
.fat%~ot&e$&tih~thri~ aa 3fdy f ~ r @ rwmt .mgine~speecds).allomtrlbrOte to lubrtcatlon
w+lbgbtY 'lnformatlbn a b u t the ~ondiHond brmkdawn, Blocked 011 paasngm, which
th'e",k@Ih&The.8tse of the Wing shells !s usually we th@muDt of misaligned oU hde8 in
e m p a d on tW back metal, and thler a he&ng&shell, wlll 'also oil-me a Wing
mnfornbttqn ~ H d be
d %Wen b'fhe:wppl~r&
'Thdnew&el14 @a mustrawon).
P B@#flgf@lluregoguru. bWaus$ ofla& af
Itibfi&%ofi, the p'resmce of dlit at other
~fordpp+S, "pvetJWdlngthe'ehglt%Wd
abr&slufi.l8betfiwtmtlon). RegaMlm.6f'the
sause of beating-Bilum, m$€ rSf m M p j
W"hth6 bfigrvlsIS r&wmbled;io m f tt
XkbwIQgthe mlne)+uts wry .hii,loa& m
bearinns, which Zndls-'Io& m o u t 4 k c a l I

w h l d p l o w s fine m c k s in the m n g
face (fatlgbffaikrre)),Eventually, the bearhrg
r n ~ + I ~ Ioom
~ t l l in p@pPw"aM War~qay
from the & m i baddrlg, Bhcrt-trip driving
l W s k coc~osian01 b d n g s , @@aqp
fmuffident en&@ h a Is pradu* ta.&ive
Wtlihl-wnden8ed.p wdpgasep.
FW md~6fts W e & in t b ,anglne oil,
forming. acid 8.od sludge. A$ Be oll is cwW
to the englne bearins, .theacid attaoks:aod

assembly wlll lead to Wring fallwe es w 4 .

lght-fRting,Wnga lave hauffidmt M W
011 Olwwm, wd wJI rylt~.h.,otj &petion.
DjM ,OF tofeign V@ticle$ tjappdd htiidd 'a
beating,$hdt result Jn hjgh .spots on.%e
W g whi& l a r(lMIurb:
 -
Errgim,mrnovat and overhaul pmWut& E.1 O
-
move
mng 18 Engine overhaul - .gllr
..
JP . . - -
reassembly sequence '& ji
I .

cap$ , E
h thd
h ma
l an$
rdlnd

hwd. In'addttlon tp-all w q a l twls md D

a. threaid-&Idno oarnbouhd will be
Pning n e g d ~;k-tubg
. d RW &ing c ' r n p n d will
0ttrn< 6180 'tie N-uifed mf rt14 lo~ntfaces that are 'onthe E-typb etf$ine p f m d anW
-I m8ln journal
ift M without @Ms; It Is recummendedthat 4 Prass the .bearing shah with tha oil
Bjwt C F 4/60 THMq w e (obtalmbk f f ~ m hq+qraoues Into the, rfa$weafflmthe
%pit dr@mIS used, as It is sp~iatly- qIlnde~h8adkNate the fatlowingpoints.
JO~[$
b&
-1
~~daw~o A r
pwposa.
%,Inorder to -6 Ume and avoid problems, 4 Om the G&peengine, the upper shsrk for
dry. -7 . - ..,.

~5 %gltlh h m b i y can be carried wt in the^

WIpwlhg order.
NQS I ' m ? 3.main m n B s are ident?caI,
es a ~ W ~C ~IT ; W s O S4, . d - 6main
i mq
lmali
'*d'Crankshaft; **I;
bJOm thw-Eiypw&e, NQ5upper mir yii t q . t l l - ~ < -
8 Wth thq&adnq &el$:b poahi-i ,Inthe
r. -
Brlng be&rn&QJk~ d#wWkWPl t h ~ r e sIn
t~
tha&&heas.andl pump plnlon lth&&kg m s , % ftthc a p . to thqir .nl$a?&gd, or
! and pmyb~sIy-wt&Ib=tim+ lake,-, not 5is
brtng c&WW&hmUstf&@the~ingM
e n a ' G f ~ ~ ~ * P ~ mtyb
~ W tbP1WbgaQe.
.
$lne a ~Starthlgwlth the centrg maln bearlng-md

Fi
C) Ondl #@@+ff#m ~IginalIPlaln W n g
shalIs,ate bin$ m-d, h s e must ha working outward, tighten the original main
~ t o - W t w l @ n lWWi0
a? me bacltrg cap balb ~ r o g r s ~ ~ i v stol y their
specifled torque setting. Don't rotate the
p the bR3ckand
9 On ~ t y pG~ines,
$ ~ttw original m n g cWWait at any tlma durlng thls q s w l o n .
shells am Mng u W , mwm thaf No 3 10 R$m~vethe bolts and &I& lift oTf the
prve main b$qriq cpps, kebplng them In order.
main b d n q shelI/thmst w&w
a s w W y Es #ttedthe wiginal way wnd, Don't disfurb the Plmtjgage or rotate t h
as rn dqhg lern6VBI. ctankshaft. If any of the k r i n g 6 c w arn
1 8 1 ~feting
. the mnbhaft and main d l f f h to remove, th~m from side-€o*Id~
M&ngsbn the F-type M i n e , a W p n h a 5 B~fom l h ~c~anbhafl
, a n be permanently w& a @ - f w d mall&.
b.be made whether the No 1 main h w h g Install& the mn
bearing running clearance 19 Corno'we the Wdth of the, ~ c m h d
&p fa t~ be smiled uslhg b i l s d a o r ahophe the,thk caq b dona in efther ~ ~ o n ~ 1 ~ f
P H butyl dam to-b
~48n m S & y -U d@bTnlnethe ,corm&
&, of two way& One m&od i~to fit the mdn
bsarlnq caps ta the.cyllncier blmk, WMthe
h $ h m a d b d s t a d b f a l n h m ~enauft bearing shefls in plats. Wrffi the m p mtalning
on the Plasflgage mWo@b OWahW m&
M n g runah8 deww'(seeP-n),
.1z H ihkde8r#nce b nDt ak.8ptW1fM
b.0 &IS, pime W B w a r i ~ m -n m b o b tighfendd @ me, a~wiflt9dtorqy, bearing shdh-#-my'be.the w ~ g g - ~ & & [a
mhwrt any seals, md secure it wlth the two maasurs the InYernU diameter af each .*F I ~ilH
N ~ I V ~ I Y - W O.I+F@ ,*ha
@$#nImboffs, Lwate,a t w i t dtlll, d w rW. &wmbled qf-b ~ r l n g&ells uslng a
OthWsuWer lmple#tIentwhich will v a m k did i&dqror i h lmlrmm&&. If
@jn mas~desea^ gmva. ~ p rnw-, ti^ the dlqnste~! e e h wfl.$spo#Il?g
-
imatmant this dlmerdon 11s the &ciaareal wenbhaft l o u d Is m e w a d mi tfien
~t&i ,q*, fi ttitjls dlmenslpn-I?1-s ttwy~.grr subtracted from t h bearing
~ Internal d i w ,
WWl Zb 5 mm, n 5,iO mrn thlck si&.sraal Q: the result wRl be the maln b6arlnn runnim
W.It ~e dimemion is more than 6 mm. .a. clearance. The second {and mow iccurafe')
methodIs to w-qAmerlcm p e a t ILarwvn
{astslastipgan.Wils:@@&&q@1~4kk@
of DBff*j,;s:pyTidS flw Nk l h ,I$
c~mpteewbtm=rrWL*@*&-~
jog^.^ wnm thq @fi ig -@&be& $p ~
d h d l o ne
f tths~&thw&f br+E&Wtad
,wjth a . g w M @
k*. TI-& wnnlr7B +is
mi8 g auw PlB@igaaeIs m i m e s ~~~b
hut mqutd~Btem sf:the
lo oEiin'lnrfie'.UK+
&&an q eP backs
,bjFi;m . tfrer bearing &talk m i targw sperctallst ehalns c(f :qualjty mmdtPr
&, . o~j

ewes In both fhk oglrii'e& ~ B ~ o L W , +ti~~tame+of'a &cW

l b k m d* ' ~ ~ , p s . In your w, The procedum for using
$ - ~ ~ ~ 1 & f h e&ells
b6@ without dl htii PIasirgag6 Is .as Ibltows.
Into t b mps msudng, that the tag on th.e 8 Whh iheuppw m l n bearlng shells h pkrw
,shefl inthe h t c h in the cap. mefully W 4he mkscshafl In wsmon. Da nut
 pwced~ms
2E.20 Engine mrnW!m@tq~hauI

&hhfdb IICWP. dl th. F t W ~ m ' Ihs

b b&&&rut of#& wm \h. b$art0p..~~p. Ihd 6 m m a
*I mtsterid from the cmrii#&-md ~ . W -"-W flush w k h t h e . s u ~ 4 f t h e ~ r m k a e e
b&fng'&e~s,uslng a fingemall or aornethhg b) on the engIhe,a&y a thh cogtlng 20 C W k that the c&a8 Is fmto turn.
dmllav which is udkely to sixre t k meUs. of w$/60 m/xosealanf to t hbuter S a p stpms Is nortnd rt new ~ornwnents
HflelmWIno c o m d N o 1 meinlxwfngcap. h@~? wn RtW>but-..them mu& be rk~
e)-hwwnAttcngthe butylseefsto No 7 merln Jammingprjtigh! 8-
W Y f u t l y lMmWe-~ankshaft out of the 21 Ghsck Yhe m&nkshaft Etridfloat wW1
rry1~dsrblouk once mare. r ~ w n w f 1% o ~ ~
Ye Wl W&pt>D4ype ern$inrss, m ~ a ~ ~ 22 Fit thas r W mnksliaft oli seal h o d q and
ob& .&it& hWrustwehem to each,.;i&. dl Pump ptyw angina+,pistons, flywbrqll.
6f the ee~tremdn bearing ( w e and E-type rln-late, rear flmlng,aov~..md k w lCrfate
englh6s) or No 2 maln h f h g @=-typee@n+ 6 r q ? m &w .caie the seals with er Ikqe (E-Me F-type anglneM an&W 4~hjm
mure that the ollway grorwes on each sll,'/Md W . a 3 M ?CAF4/GO THIXO beltlEhaln. Qn &tm&wqpjm, bear.In mind
~ s &the bearleg.
~ m e ~ uht w d from
Om D-type engines, the t h w washers dm fhrir *ltowlnp) po~i>(W. 1.
-nI in No.9 mdn W h g uppar shell e) rn ~ . a - W R b h . n - ~ w i m
- If 8?s orlgind components are W g MtW,
W s u m m e bearingshdllRthnrs!
k&d, use thi bqik as a g~rjdiby^--
m m h m r ~hmds,then
mw&aria
mbd ~ ~ . d f m # @ . & @j&~~

p d n ' g Fhg-@!Mly IHu p m W ~ h .

$ W h m s l h iI@tP to be usedun
ma W3 7 M n W n g i j n the P-@@
engine, do mt'prew fhe atp Hght W n
Gpmlly. ?lp If '0uw m n r n q h Tear ~ ~ ' t h 8Mt'Bwe - , i ~t m ~w k ~
m'a<
wws ~ ~ab w M l I I I we
~~ ,that-* fi& fewtha+ o f r n mih
WeQddlWe, asurn that *?open $Id@p f t k &a&& bp&ic& MFk mtered. Now
rnl*ln'ta th& wdm. i&t the sealent into each o f 2 hcap side
1y *ally Itrbribafe each bearing s h d In gmves untn k eatw~the space below
@3 whd&r:b@~K. and lower the crankshah fhe cap end completely flus fhe grooves.
into mfhen. Whdre qappileable, aheck h Y 19 Fitthe maln bedng cap &Re, and tiqhten
them pragresslvely to the specifled tor- In 1 Cl&h tRB back bf the Mg-end b w n g
the st- a i m h the S~eciffcatlons.whe6 MISand We mzessdn theconnecting rods
?8 ~ t b ~ Ithe
d sbwing~shslk,then flt-the app~i.c&ij3-e 1 1 1 4 o n ) .wmre ~ l i t y ~ am Btg+en"dcap& !f ne%r s W l s are 'b~lng
W i
Q Ilr theifnu'i;lbmd or previously- seats haw barn ffttd on the F~typeenglh~~@ k t , ensure that dl f m s of t h p f&~
n~'Ibcat10m.Note tha ^fOlt~WfngPoi Tits wlm theprotiUdlngy d s n?& w[thth&&&ce gr&&eSare&leian& OI? using pwafin, Wlpi?
&!i$sm]. of ihs Crankcase. Wh- $lhmne sgdlqd h e &ells and c o n d w rods dry wKh a lint-
d) ' & : W O W ~ 1 l l ~ ap4* , L M k Wn tree$, wlpet a M y .any @ A c w Beatant fww.

.ra,m.riiqg,~~mm& t - a e : ~ , , f a c e nfms.w oil

-jwga:
usingan angle wge d.hausing wfth sealant.. , P+en&w
 1 .'
Ertgi~e:#mowJand overhaul p- %WZil

-- - 2OA fitting a liner base 0-ting q . 6 The arrow on the pkton crown must

*
out in the connecting rod . (E-type englne) ba fadng the flywheel end of the engine
'
, " h - :I -,-?--.:-:!r, r ,:, :I ., -
big-m@bsrrrbg sfwtls Inh-the q .k$qb.q@,hwt: 14 YRw&k. Iublik,@4bq @~a~bd~.lo.urna
mh ~q
mds and cape In thdr aprfec~ B w&.&& t.lner~#eallO-fiir:g
In psltlon, ptaw and b&end CWng th&. Refit?hskwrjng
WW Su!vtW#e logation4- are Nu liner, @&on and aonnw$ng loel
In the cmnactlng 53;s8~I@bhh.-Rq,l ~ a b in
n ' & 3 d ~
block. Ensure Wat b e arrow
on the piston
~ f ~ ' ~ , , ~ ~ n ~ & c l r m ~ rthe& ~ ~ ~ l d . o f
'@-We
and &type engines eqm% a@ flat & the liner Is
--end bearing running clearance pos&&"p~descrlQed prwlowly.
10,To measure he &-and bearing runninq
place 3he four liners face dowh R e row an aWahm, &ferto the 'iyiforfnatlon ,Conbind mm fwkr bl* em p m s k W y ' ~ W We
W kW. In theb m m t order, Turn t k f n as h Ssctioh 19; the same gened pmcedms gaps bdlmbn the linew I886 @lustr&n)). If
appty. If nbhe Pl&tlg@a m&od ls bBlng ukd, fhJsIs not the case, it &y Rs W&W'$?a
.&&say $0 that the Qatson the edgsa of ensum that the mutIcph joQrnal ahd the &-. Interchmg~anc at m m of the complete
bp.1;and2 are @wards>WR o ~ a rand , -4 errq bearingshals are c l m and dw, thm pu/P p k W l I m r assmblres tu acatew thTs
$& an 3 and4awtowatck each W the aannmtlng rod down and mgage it with deamtpce.
'dp. Flt the p w i o u s l y s o l ~ e dbase seals
wp
ithe
englme) w 0-rlngs (E-type a h 4 to
d ( m hIlner IlIMon).
qwcranfcpln, Place,p Pwga@+&rlp orr the
crankpin, Cfi'eck hat the marka made on the &type a d F-bpe engines
cap and llpSI dMng mmvB,I am 9 to &c!3 mg-end bearing running clearance
4 Lubdcat~ the plsions and plston rings, then other,, then r a t thi cap and r&al$ng nu?&' check
p1.w eaoh pMon and mmecting rod
Tighten Ute rim-m me &fid prque. D6 45 Lubrica%e Ma 1 @stonand pision rings.
M b t y ~ W k respeches Hner, mot rotate the crankshaft durlnq this
:&-mg with wem,bly No 1, make sure operation. R e m e the cap apd check- fhs and W k that the ring gaps are spaced at
,@t&c plwn fin$ gaps are stlll spaced at mnnlng chaiance by r n m r l n g the
120" Iht&rvals'fseaeh other,
b &I* $9 each ot&er. Ckmp +Replatan rings PMgagwmpre&usly dwbssd. 16 Fltaring m p r e w r t o No Iptston,bhen
N nga @on ring compreswr. 11 with fhEl liner&ktm m b l y haf$kd,
in$& thL-plsb and connecting tod hb Wo 1
g;;inswt the piston and connectihg rod retain the Ilner using a hoR and washer cyllndw&Mh No 1 n n k p l n at Its lowest
@wmbiyimthe Mom Iln$r,murlw wewed Itito the &tnU& b a d b& ha!@, ar pc~lnt, drk% the @stan @mTully Into the
#at the armw on the piston cmwn will be mllnderwlfhthe woden handtad a hammer,
uslng liner clamps (semIlluetdonl.
@dngthe ffywbeVdrivepIate end of the 1 l Repeat the above Isrb'Wurks foe Me
$ the q m a tlrne guiding the conndng rod
q k e (aae IllwrtrauMi), Uslng a block of remaining pfston~and;bner~mblt~$. 'onto the cranknln (see Itlustretion). Make
' h d or a t q m r WB q a h ~i t tt h e end of
h e WnnNting rod, tap the pisfon Into the Rnal M i n g
Ib& myl the top DP the piston Is approx- 18 liavtng w e d the wnlng clearam of n
f o mwsure the blg-&d hering runntng
hately 25 mrn away .h9mthe top d the Hner. all the crankpin journals and taken my elearmce. refer to the infomation eontalnd
r8 q b p a i th8 p ~ c d t r r efor the remaining
*&a plshn-and-llner aswnbltes.
~orrectrveaction newsaw, ~ l w noff all In Sqqi&. 19; the wme gmwd p r c d u m
trams of Pladgage from ?he bearing &ells mly.
Ifh.e'WPtaX$m,qeth& k big w,
3 ~ u r i , t h e m k ~ h a R s a t h a tI
t: cmkptn. m ~ g-& w .the cmkph journal and the big-

20.1 6 Drive the piston arefully Into Iha

cyllnder wlth the wooden handle of a
place -
hammer D-type enghe shown
2E.22 Engine mmivd.and overhaul procedures

md W i n g ~h&~&.ioII-m md drS, then ~i?Waf?

,&i&.tl*rlCa&i 1Wit,sur6'thatit Is
engage the bonndng rod' with the cranbin. ~ ~ b e f ~ @ ~ ~ g d ! I ~ q ~ & ~ ~ ~ y .
Place the Plastigags strip on the crankplrt, fh
b p n g cap in I@ pmviousTy-n&@
'wftidn, then tighten fie bolts to -the
specified toque. DD not rotate the crankshaft
durlng this opsratlon. Remove the cap and
check the running clear- by rneasufjngW
PlastlgagemPmlously described.
- above procedures on the
q8 ~ e $ q tthd
&ing prstor@anWng rod assembles.
R d &ng

a11 ,i@e m k p i n journals and hkm any module w . W 8mil'Wrdlsr;Pnnectlng.

p r w t i i e action nemsiary, clean off 41 the DtS W l e plug WI D-type
:m--
''tk-&!.PI&iQ8ge from the bewing s h b engln~i,as appllaaHd 'we& t h e B ~ ~Dn l@
ths staH9'mofor until tfw dl pre3sure Hght
:wUb$lp IuMeate the crankpin jaumds
Wng
!'W>-tjs.rn ?RBfti.tti&
&@Jh,
Q-
a Refit thhqwk plugs and c o n e all ?heH7
k q i ~ n omws.
e m r l w mmct W R W
& ,pvtoud$ tlj&Rbed. TIght6n We'W g %!kLih6 eogim, notingthat this'maytake a
GEpm*"tHf!?3p@ ts
odq w mdumtfik hIi#lmgsr$ti& usual, aue' tu t
wfuel pump
Fully open
&g:'B ,

1OPC
3
.
2 CoolinQ, heatir$gand air sanditloning systems

- -
UuWnsl.
2 The system fundianm63fdfl&& .~-&s
engline Is c#$, wlant ES ~ l f n p around
d the
I l i e C-g system whematle-
Getype engine 'ryIIIn& b b k dhd head paelrgek
aoollrtg
a
m
~cyllnd~rbore% coinbklsth
I QYlhdarmk% $4 &stridtar 'W Ydve seat% ZM ~ M

3 W w the eootant r&m a p&&edmd

mW&tuqt,the,thermpmt'o~mk,Pfd ~4
hot woiyt.pwses h w g h the tpp R m a to
pr~$pt&;~'Ag W
Jhe m o J @ t f , c l m ~iW&
the radiator, l€fQ~$~ol& by 'tPie'lnmhofair
wWn fhrf %er i$In motion. Ttra UrAow is
supple~enid'hwe-actibn of ofhe etewic
mollfig-fanwhsn nemwiry. Upon Wahhtg
the ~ m ~ f * r a d l ~ f ; t h emtmls ~ o ~
to the puppSiv@ the ,@rator bottomMse,ayd
the;eyeted&zd.r ..
4 &%?lie cm wwfm kip, k sxpmis; t k
IncEasM v'o3um~k abatilrndWed in an
expambm Yank: Qn the G-type mgiwe, Me
e%pamMOarik Is *mtd*,sMtply rmif~lm a
amall volurnp of wlmt a the ternpmtws
Inrile&mand rdbrnhtg tS ta,* system a$ ft
cools dawn. On atl M er m*.s, the tan!+
mw, c6qtlt$lfeom ?~fTw@%g-md
the h e that the q l n e fa running.
0 cdlng fan, tnourkw mb
K 1
4f
m
L E ~ ~ ~ a ~ ~ c
located m the sl& d the rdW6 k e
pFdetemhd ~ t a n t ~thepM c~ h ,
9anWts d m JWWng the fan vla a mlay.
6 The erxrlihg system on FTP {i'Bfl&llv&)
ehglne models has two pWm4pa'additlwd
components; an enqha all m l e r frnl)EIflM
under the afl fllte~ja d an;ayxlliary warn
pump @&mbdbter In t h i ~ Chap#).
7 For deals Bf the air rxmditlbning system
(when fitled) and #e p m t t a n s & s ~ ~ & a d
with I t refer toS d ~ 15.
n

bask pmdup~. a@Eas, W r e mmnrernctw

work, rn&a sure ahat lhe nZtw h o w ah to
hand, dong with new hose cllps'Jp-m&d. It
I s w d MMMto c&mlftt~hose dp$@ the
same time a~3heb&s.
2 Draln the c~blln~"'sp&brm,as &SG@BH h
t=lb C ~ l i r r g -c: -.La- sn- ~ h - l ~ o r l ~mhgWooolant
, lg@flt
far reuse. SqUlrr a lire p@tWalhgall mto
sm ii'lust~am7.la fat ki#8 the b e clip If they &mrusty.
 G o n F i hwtingand air oonditloning *?ms

l the
I the
kfter
won
m
Fa 1s'
tned
I the
@to

C Is
Hric
hlng

,and
L
i the
I an
~ths
$a a
kure

Ek dl:i
I

-
1 . 1 ~Gaoling apt&^ achemalie F3P engines 3 ; ~ogting
~ system - RP ~IWWI ,em-
S& il- 1. Id fit keys see UIustratM I, R *&pya

R@we the hose cllps from the h ~ s e grease,'Whieh may attack the rubber. '9 Rechee the tfghhes$ of tty hose cl@ on
w&med. Thfee cllo h e a are used: worm 7 Fit R e hose ellm aver the e W c f the boss, an\j "ssw W& m a f e w Rutidredn i l l a
Gcr, 8Mq and "&r$e-can*. The worn- than fit the hoae b e r its stub%~opti~$?~kgp
lpb rel- by turning its w e w anti- Into posliton. When satifid, id&te1bn8
5@eBw&e. lW Spring clip Is ~ p s e c iby Wghm the M e GI&.
e g Its tags t herwith p l m , at the 8 Refifl thb t;'o@lfig amatn & d@W&f;itl
"9*
W f Ime working he ~cilpp w y f krn ttp Chapfer I A oor.TB, ~ u n ' t ken@%.&
&e ~'5Wk
L k e stub [rpee ~ l l u ~ k I o ~ ~ ) . 4=~f ahred ~ n e -thatth~m

, p m ~y~e,~yrj.4pw
r rg to D@ r e m m r4r 1
a&&%d~af m;brEt tfmn 48 hours, preeautbm
;@wtee,4gken ag~insth?temal mrrosion
m r~ris!3itw fadlator wltf, dean *anl
dtyathw$h&&blowin airZhroughib or
.BnlA,wm~ wP/w tB,h* w.

J a a p w h- clip r w i ~
self-Iocking pliers
 3.4 D'kconmcting the radiator top hose

JBrn@nl a&:+pmo~leaks may be m a d wlthout

$i"icWqtha rdlaw,) using a d w t . The
4 'piwnnect the batkwy nwwve ler?d. gea & a 1- MII h d l y be'idefifled W t
8 ' ~ m othe s cooling fan as .Mrlhed In or c$@lne d ~ .
B&ivn 6. rt &eq-%e &Mar matrix 09 flies arkd
8 'the wding.q&rii by C ; r r ~ n W V:y I&& mq&d,M& oriby hhosmg-
w6 mdiatqr M o m hsrse, $we- ttw-latlt 3h
8 a&n&i&if it Is fh for @*. , '-#gm
: b : W e t& W e dlp~j.anddisconnect the 12 RHl€tlq18 a revst~alof removal, b d q
&ing .hoses frrod-the ratat& (€W zn mid,Uref&Hcrwlng.polncs,
,ruuatration). a) ' F " i c a rlmbf
~ t~ dartwe the ramlator%
;$ t i o u s be Niiii, dlawr rnourrtlm bolts w w m s.
rtmm mp;rrrossm%t&r. Note the:mibn ~)M$B*P!W?*~~*~OP
.at &s&,'iiZLjUlj.Eing(SW'arg%q.tfm aamii $nd ~ ~ b e mbonnet
r ~ Wtbd
!move UlWtaMW3): ,pl3*flpto C h a p I I.
:@ If: theatsonr&t ~ , t + ; p p cmsrp G) OR oomp/etion; M I the cNIng eystq'
Pngmbfw may Be r@no'ved ta W & O V ~W ,as,umdbadin Chapter fs\ or TR.
' b ~ ~ a g t s w d th~Is-M
ll. FmI16-
h ~ ed) n e m&s, wt$@ t116in[& m m i q
, p w & the i W p r ~g&ppcwe&Mckh r
aaougb to *leaf the nr&s@ibw ( ~ e +

Illumatbii.
7 On madeb wffh alr cdndMonln0, mpme
h 3 cpndenser i b m ths-dlator by mmovIii*riq
the two 6e7ms. Do not dI$wnne t M flmovd
W a r a mp l m 'I WBh-the anglne cold, d&in &me @oINt
8 Whem appllb&(&, utlscr@w the, ,baIts~ m\hm s#&r~ ($& Chapter j A or ?BJu d d
-.ha hfadlatar pbUc riuctinglshidd.to tl?e @tp?nshtank Is mpV.
the radiator, and have @ ductlngtshield In Q Rel-e fhe smp which cures the
l$wm d b r I8 removed ~ hose LW
expanalon . t e n l p . ~ D l m n e c-the
0 h % s l l ytift the radiator aW its bottom h o w ) ,&-I& rsrno* &e tank.
mountings and remove It. Roeover the'
mountings; &new them if t h y am poor Ihspepe@0r;r
.wp&Wl
&--I , Iseeru-nel. 3~learithelmkandimWt!t~d~
@ ~ ~ # m q e . .Renew It C n a w . .&ko
In-#he w;H .Wls:wIden~a4h#aat@
has b~ vantd thraugbdrs,mw3m-K.

n)!(f6-valve) en- ma&&

 Cooling, heatin:g'Wair conditioning sys@nis -.

&+In a housing bolted to the left-hand mostat e m b l y , notipgYhaf ths thermostat boltkig w?ter, or does n ~ fully
t chsa when
F! ,d .thcr eylindq nead bmaath t h ~ is-lmegml wtih thif myex. m v e r h'sahliiig r m o v ~ diYom t6e Water, then R muat b
t t M d r sap. Aceeas can be fmpp6vad by Hng. c h m d d and a new one R M .
mdtxj ae djswibutor. cap and t b iair 8 On E-WPQ lUl9 F-type:qglnes, unbQ the
ma-
@t.w air lnl~~ZnlnWn&, c o k ' and 'mrno~e+he themmi&, then
mrm@ ~,&:@alj?~
~ n B l u dg m t l ~~ . f~I R e f ~ is. w
q er r q m d d rempval,
in mind tha folleriir]m~ o t r & blhbtdoa.
Tdng
O To test , w b t b r th8 unit is seNtd@abl@,
suspend il on a string in aamcepan of mld
water, twtlwr wlth a t h ~ o ljtj&@s ~ .
water, and note the~tmpwzawat which the
thermostat begins k! open.,@,6?lnwMMW
the, w a W unnl the thermostat is fullv .
. onen.
,
and then remove h Irarn the-yaw.
10 The tem~srzifurea$whkb the thermostat
should ~ t ~ ropen
t iq dmw an tke unlt I?
the thermsiat dbek Mt start t~ Q D a!~the
 8 F r € i p ~ ~ wrmW-plug
W anddimneat It.
e S W R ~mm
t
~ Y B $
~k@@rno

hametan. %%fan ahauld run.

h n *a t
h per! a pm619111
of ovmng 1 T ~ B laeatlbn 07 the temperatura
dpdt9.thmfann d ~ p q i h gBIB, w:,wWI gay$e/warnit?g ljght smdsr unit varfm
WP- b H w In pb% fiIs~,$qg-; %b&&3[nkb ma&. (In Ihe G W e enqlg& # 1 If@ w&erphnpfs Wi, ar is n&A
thwmtatic awhch is:&%&ye. Is on f& d t h water~ pump. On b Q p s ~ @ hIt mAu rce renew$d,
5,,IEahe:;fBndo- not run with #a '$Id o In ?an&,, it Is l~cat& In fhs mar of f.hp &me mngihe
p k e , thens *a fault in the IWXM%~*?pp4paht budng, On WP q l r t e ~ $, is
w@ir, q]@uN,(Including l h s fuw .@, A IcTc@@'at ft-k .l~-'frafldfmnt corn,er of tip Now A new gasket WIl ba W M m d on
6hF4bbb,fh,m), e r on W 1%-valve) dngin~,I IS
~ ~ ' i head. mwm. -
1

b @b awhh can be tested further after S C F ~ W into

~ ~the thermostat houplng 4-
re&~.v&Iby immersln~It In a heal@ water PMd@on). In all ems, the p r ~ C d ~ arb a$
bath ,&ek to S ~ I O5,~ testing the
thwmrnaf), and ushg a contfnUny t a l e r to
hpera%urgat which the switch T i n g
'
&&.the
,miltacts Dmn and alcw. 2 Dlsaonhmt the rnu&plug from t b mqder
unit (8- Iilusmtlon). Using an ohmmeter,
Bwwml measure ttie resiaanc~of tha.spndkr;, arrd
wrop$r@ tt with the values given In fhe
SpwiRcatlons. (f the value~~ is gr@&
dHer,e#f ,mmWat speciffsd, the w d s r is
pmMfy~deMl\ia.
2 D h m ? b w k W y nwwfive IW, Wg
'drain the 3mIhg *ern as dmmlM'M
Ghaptei IA or.TS,
a-F@hl~wthe bkr(M0T dHvebelt as
d m i in'CMpbr 7A ur ItB.
4 UnssTew the bolt Wtch s&m tkie
alternator adfustlng arm t6 $beWmr mirtfr
bbdy. R@hW$the- bk, snd &g the .q@
dear*
5 SIWw #le cllm and dtwnnect't&
h u m fmm the pump.

: - > #
wv8~11n~
@ 8&fk.f#+ be movd 8opktio*q
wing amwg-geflll Wd W W M m g
s y ~ a s d ~ b e d I n ~ 1 A w I B .
I

-
 CoolingJheating and air conditioning system 3
.
7

iFme##Ine 4 u m ~ w q vwo ~ n thev

<Nqte: Srrppablle sealant will Oa ngtrI@d on p a m m g nwd''&r* B w ~ ~ n d e r
@ t w - w y ~ . MW.
c. el Un&w andmoye-Be &bmwIng
,@my:d bse ppkver@vHn~pompt0 ths mwnting
'10 RJworinWtheW s r y n q m i d , then bm&f&r,qb3.m~ W p o w sbdng
&a tlm milw system as desorhed In pum axrb@ppsto o m sfde. M& s u k
7 g n m ~ & ~labr i~k~o~inpis~po~toavald
jB-8,Applythe handhim, then lackLup the &dInitQ1fhe @p.
w,8f8*wN. s w r t s w m b on+@ 4 Unbolt he @hwgfaedng pump bra&&
.s+dls (w "J&i?
vehicle
l~suppoflj. """r"'q@m,
1gp Remcrfe Phe fjmlng belt as deswlb@ in 14 Disuonnect th& coolant hWeq from the
~ k wBP.
I r U m r w and remove, upp& wNer pqmbqnd, where applla$le, uWrew bj d l 1 the wding qvhn
>t@ematcrmoundng boll, and slaclcen the the M P wurimthe pump adant pipe ta the a s & s b W in Chapter 1A w TI&
J~~
alhxnatg~m'surktn~lbraaket. E4ypa ewinea
On models HIIth pahw stewing, p w m d
43 15 U n m the nutand washw and remove
'wsTiUm& the timing bwlt mmer pulley {(Phis Is Note: Suitable sealant wlll 6.s requlxad wr
! , UIEFwwef
3 ~ ~ I I G a b kremow R B C B S S ~for
~ access to one of the water -?2.
pump pullw, with &n# to plrmp'Wtuing bolts) (pee WlusWlon). RemowaI
C W h r 19 h c t h n 23. r$ JUribtttty yaterpw?p+ram the. tyllrrder XI DW~~ft&tth~m-k@im
bbck, ktha pumi d k , s W b it aarpty drdAn$he wdIpg sysbm aa d@.bd h
with a pl- ar hl& m4W Chapter $A 8 S&,
ReflMng 22 Rern~wAhe$hllag.b@t,qsdeQr&@ in
17 Thoroughly filean ill sealant from the GGplw2&
mating faces of tbe water pump md thp
qllnder block.,
18 H W w @ e ~ ~ h q ~ b ~ n a ~ ~ m
the pump,applykfhh&# Bfbsth528or
a sul€aMeequivalent, to tha wdihp s w
between the water elbow and Whd'pUfig.
Simtlqty, If the @m&@pe- hm'ben wmve#
froht the pumpd b w , &I&* -
Gdhg nbb
that the ptastcplpeIs? putdVmin the dbgwr
and rdles on the O-ring as the only knm bf

a.1- ...then
pw+th~~pta~tb
-
prpe~nto
W &bow D m engine
B.IW l ~&
-: ~. . .
@ump'~m-&wengine
r ~
3.8 Cooling, heatlo@.and::dfmnditioning systems

S Ttre 'pump E.ik@d on .#ie IBfthaiM $id$

of the errgkre bay! @wards the front. Access
&be hn@We$&+movingthe air olwqf.
4 ~ l s m n n 4 'the pump rnuttl-plu$ W B
l l l ~ o n )blscm&c$
. &&coolant h o w f i

On daplhbn, *Ill qnd bA@dthe pwling

system a s r d e d b aSn Chapter fA#I'1B,

@
*Y*

M IS,
-
L w t a the water pump on the ~$indw 28 Remove the Itttetnator d t W R as
M X c , t h n ipgeR the MA rn4.tibhten them dsserlQ~dlg Ghaptw 1A or 1BI, wid the,
dternt+torIWEf 'w @wrtMd
R M t me tirnin3 bJt .qW b s d in Access will be'lmpmved by rrnmovi~gthe
Ghqter LC. On compl&iGn, mflll and >bigad
*!.WalinlJ w m =b8@w dA
29 .Un$C~r-W.mthree

3U ~n*&.-thQ Wqwoh
wmb i"CE;ihe
bqmb.
bo
wat~r:pymp:pullayW J R d n J .
In Chqp>hr6A.

p and tmpve the

wumqe water
h d a r blo&. .and removn the
(see ~ i k r a t t g nH~it. is stuck, strike lt
*mM;bfomatlm
1 The h a w and frmh air vmntila4on W
workg on the prlmlple of mlxing hot Wd &I
alr In tW proportions mteuted by means of
ihd ! v q l Qernpmtur@
C a a W f tow thbud~
kn&;
the H M ~ Fr&idr&#'a

shirply'with a ptastlc or hide ma0et. R m

27 blsconnect the batZlsrV n e d m lead, then
2 Alr 'difi&IMh'ls t r e W byJfhe M-hahU
wmw tmtml kn6b MdWr~al'mrttMI 'Is.pWMe24Y
wmd apbnlnQ, ela&ibqxlr d k d l n g InUlvWBI
a1 !witby r ~ l n the Q removal -op@ratiom, mcP1th@YabIa@hel.
qdng a new gasket. Rbfif the alterhator 3 A thrqe-spa& blow is oontrolbd &he
urwetsslS; m'd refill and ble6d tfia cooling rlght'ihandhab.
q&apqs:-b,wjbdin Chapter 1A w 18. 4 F?r &Mls pf the Jr canditionlng system
fitted ta @me b4&As, r&ab 11
r=h&
che& that dl the c o n W
6 ~erlodidall~

-
1 The awlrlimy water pump W to Tb-ual~g
n i a h'ddrlcally
~ &d. It fom-phnd
the 'antI-p&o'otk~tEoxl system, which T% 0 ~ f t h s - ~ d o e s n o t ~ a t
dasighed to reduce unW-bonnet Wmp- the fuse and the blowel rnuttj-plw befa@
twaturjjg when t h e m Is stopped aftera run cgndemnlng the m&.tf o m e-tw&pse&
This sysh'lsd d W inChapter:4G. donot w o r k , t h e f a u l t i $ a l ~ ~ b I n t h e
Rem,owal
2 Dlmnnect the kr* negatlver lead, W@n
dmln the cmlhg system &e h d b d 'in
Ch- 1A or7 B.
 - :

and air m-ndiiionlngc s i t y s +&?

Cuollng WQg
3 4 0 Cooling, hea€hgancfai~'mr&tionimgsystems

B If the mdor Is to he ranbpM, &ease the 12 Galn a a e l to W e b f b w'@mmbl~&3

%l@:mq+@ W h.*+en@>*&L5
yips (kwpfli~d , W I ~a . n w
n w dwpribed p~eviausly.ln.7tMs'S~~dIbn,--an$.
on d18~~ntrmt tho rnuttt+pttrgfibm- wt&w-,
t+mmFiiy. I Also dlsco.nn& 3he: mqltl-plug f rqpt'3b~
a :m*.oandlth df ttre E& sbsb*b>ha blower moterr .- afmmon),
Bjwg, P-H,kmn&qnbrsm 13 Ret?)oy.~'*e.two w q s , dww b e ctrps
and wrthdrinw the rmisfar ~ i I l ~ l o n s i .

!F!W@RWk - we.~l?lg
the m g v a l opWons.
w?am dmutbh
$0 f ~ ww
w met c~~rations:
RemQual
.. 18 RREimM B e aamplete faria & w W t b l Y as
~ . W i l - - :1. d d e d i l n @Ww11.
q.r fhis.r&&r is hated in tkdbhHiWd Q ~ ' htswr' aq&hly
16 R ~ ~ D V %e
.med+he blpwer d m . R Is .swlfdhepJinto 4a&bedbedprr!qu91y ln tb18-WEon
17 RemOve €h@
the circuit at low and I n r d f e s@BC&% If It Jngle retafnlng scr8w now
firEt9, BnB+W WWPW!!IW.b-,8~-'@9. from the w U l e (seai l ' ~ ~ ~
a- - . a

*I@ ~isqineutha thew w* 32.99 fhe duet b -

4
air dlstrjbutron unit
{amwad) Cmb acmwible after moVrng 8tbbulNtw4.H+ ruS of @'WM
UwbloWr so ;they cannot get mlxeup

I E m ~ o v e me n-r r;ao~awr
securing screw, if fitted

1 3 a ...release me cr~ps...
Removal
,22 Remove the air distribution unit as
dasyibed previously In this Section,
-28 Remove the foam seal and the closing
plate from the heater radiator stubs (see
IllustraDion).
24 Remove the two screws (if fitted), release
the clips and wlthdraw the heater radiator
(see Illustrations). Be careful not to damage
the fins.
26 Refit by reversing the removal operations.
ns. If the clips were damaged during removal,
secure the radlator using two screws in the
m renew the bulb, this can be done without
1A hdes provided.
14- Remove the sacuring screws.. . 3 Remove the two screws which secure the
Cooling, heating and air conditioning systems 3.1 I
...ana remove m e neater radiator 1 L l a Rumvva t h e screka r~woat thr
12-
bottom and one at the dde) ...
Removal
1 The facla side vents are each secured by
three Tom screws - one at the side, and two
at the bottom. Remove the screws and
withdraw the vent (see Illustrations).
2 The centre vent cannot be removed
independently af the facia
3TheremovalofthecentralductpanelIs l%~b.-.tofree~efacia~~v~
Included In the procedure for removing the air
distribution unit In Section 12.
Refiffing 4 If the reason for removing the panel is to
4 Refitting is a reversal of removal. further dlsrnantllng (see Illustrations). TO
- . remove the panel completely, disconnect the
14'H*
. 4
WI$WIS~-
~ ~
-
. :%
~
+ ,
\
multi-plugs and the cables.
~Refitting
1 4 .
5 Refrt by reversing the removal operations.
Check tkt the controls operate over thelr full
range befbre securing the panel.
Cofitml panel and bulb
Removal Control cables
1 Disconnect the battery negative lead, then .
remove the rad~o as descrlbed In Chapter 72.
2 Remove the radiolcassette player housing, 0 Remove the control panel as descrlbed
which is secured by four screws (see Chap- pmvious~.
ter 11, Sectlon 29). 7 Remove the two screws whlch secure the
heater control panel. Withdraw the control
duct panel to the alr dlstribution unit.
Withdraw the duct panel for access to the
panel (see Hlustrations). cabfes.
14.4a To renew the heater control p a d
bulb, free the bulbholdw by twlstlng It a
quarter of a turn with pliers ... holdar
1 2 Cooling, hedm Wd'.~a[r
3
. conditioning6ystems
A- > -
. -

rWpm rmwr T WWr,

~ ~ ~ ...l
e
W 8 L
r p the bvw W r s on the h-
~
dWbution unft when
~ ,W mblesn g
urlng clips. D I m - tern- ooWolm
fd6r by turd@ tljp 9 R3rgQ,x(d.+b&
tP$T$+ #M.tha? they @reQ? r Temperatuns 9 &drsrnt''
rrrut$w-, :% We hngw W -flap rn&
2 A / ~ B @ & u t i a v ~P Spbing
8 @d@l f$m twhmtqpreffap.
wwa
#-

1 1 the
B&+ $~$ng, &,on the levers 6h
aiilbwbrt unit in the "cp1Idm!&I
%*m' pmItI0~[BW u.@atIon): = f h
t h a h k l pnel,m,&UY multbw~w LBto
Uw @rmspnding.piUons.
1I Coni& @eB&lka and tne a m spdw
Flt the c&b mutmg dips, a d c t i d thk
b d i b n J & fthe,e0m1s.
$2 R d t the duct panet, and the cbiiT61
peand*
 Cooling, heating and air conditioning qysterns 3 c i 3

173 Afr mndi#odng system eketmnla

wrntrol unit
2 IF n w m r y , 'the cornptessrrr cw b
unbalted anti moved wide, wlthnut
diiwnfidng its flexble h o s e , after
remwtng the dWbslt.
Campmaser d d w b d i~ push thelsend i~~ its:@mrnst ~ + t
a Refer to ' ~ i ~ Pp W y t t & ~ k " . i nChap tha -1ng @mpoaemis.md WornWt
tw 1 A ~ i 8 , battery -v& had.
~lmmnic- onit .Wn$ fah and mdWw
t 3 A hvo-sped molhg fan W'fi&d to
q o h l s wm gir rndkimlng.T b fan-
4 D i m & the bai-hy nqatke W, thm at Ibw s p e d all the flme th& !he sXr
,rern& N e WIndsmByl 'wiW Wr& a8 condl!l~lng'gI& in inIf pmssumrlwe
described In Chapter 72, and the~~ In the hfrigerant clrwlt or tf the englrle
o o w l ~ l * ~ i n ~ - t l .o & a l thew 0-6 & h i W.
5 Remove the two s w s , dkannect the 12 The'two fan am obtained mlng
m>N-plugand wltthdw the contMl unft (SW two relays and a resistor of 0.28 ohms. For
-on). low-meed o w d o n , tRe resWr L s w k c M
in &s with the fan motor. For h~h-&peed
operatfon, tha W&'r Is bmsmd.
t3 TheTanmrlaysweIad$dhthe@ay~
on tlie left-had side bf the aftging bay. To
rwnov8 b b,
open f dlsconmct h e
multl-plu# and wfthddw WM rerm. Refit ,bY
7 MWnnMlhe battery nclgatlve>l&d!than mmsing the r e m d o p r d h n a .
remove tha windsereen wlpxrr a r m 'as 14 The rersls@riq'lQMqd 9tha IM Srf the
-d in !Bm@ter"l+and thp wlndscm &ator. Ib rcsldanca dm b checNed
cowl panel as ddesdribdIn Chapter 1I. wlthwt W y l n $ & mr blm~-,~:the
8 W t h d m t b ~ 1 W r P K w n hrnubplug
~ ~ .(gee J # m .
IWWIWI). Wa new m r l s b M W ,cut
the~appm1Bmateiy15crn~~~-

4 Pdtiotl h p ~ ~ & v
-rtrerrshrhlkW & p ~ b f & f f w i ~ i # t
8 I8 ~ ~ ~
17.14 -ling fan mlstor (A)
modwIs W h alr candlttoning
- 1

air gun w a halrotyw.

4A.2 Fuel and exhaust systems - carburettor models

On &type engims, the fuel sydern
consists of a f qJtabk m o y w under the mar
05 the car,a mmhan'rcal fuel pump, and a
s~~lg-b@l.powndraught carbutettar. The
&anl&l fuel wma Is omrated bv an
m p on the c&s<aft. end IS don
the forward skk of the wllnder Mock
k~,rnocieI=have a fuit ~IIWand a wptrur
s-r
t- w (dsfuming devi~e]fitted between
thqp !Wp.md'th@o q b w W ~ V
i s ' d ~ ~ ~ o f the
r o vapaur
m
. f w t ,qemmL%I
&par&@?t8'W 1 R@moyethq air cteqqr fflter element as
c~-mmmuIthrwrnsM
& #y W R
w r t h e f w e i ~ , m f w t o t h e ~ ~
givm In ffmtia at the m n i n g of
this manual, ahd W o w hem ImplWf&.
P e w Is a hQh&-dang.~m# and volatile
liquid, and the pmcautlons neeBway Removal
when handllng R m m d be--o I Remove the nut which secures the
acCehtor pcrlld PWbWt.
2 D b n n d U-I~woBlWw cable from the
pdsl &described In Zhe pWom Section.
a!h v e the pdalwd btkh
Remting
4 P@t k W n g tkp q ~ p v ael o n s .

TwdWtk: A or 1B.
h df cleaner contains a db~ossblswper dewlbddin Chaplet I
2 DIscqnM we air Irilet h o w and hot Jr
fnthv element, m n
idl n c o t p o a~ flap valve a7r how from the air chaner Inlet.
terinpemtwe ~ ~ n t r byatem.
ol TM6 system 3 Uwmw and qqow the mounting h d h
+lo\ivs& air fmy'tbsttbideofbcarmd notkg #IF -ggqp,mBntof* nrbmspmm,
warm sir fro& &e exhait& manl%]d to m14r .-@and Remwal
m@air cleaner In the mrreot pwpwtlfins 4 Witmaw sthe,alr t-.
cleaner body ffdm the 1 Okwnn&:the k d e y negathe b d .
$ccrrrdlhi tb ambient air t C I m p m t ~ wThe ~ englne. Rer~&xeShd ,4lr cl~anw,m d W W In
dap js ~on*Iid w b m d d l y by a -on Q, Q p r - ~ tthe o wbumthr,
& r & 5 4 ~ ~ h & W 8w h ~~psule, ReW - 3 Wng 'a p$sWrEcrw ,or,a pdr of pliers;.
A SQIW $2 BIB carbwettor is fitted. M~!uM 8 Refit& r d L W t q the iernoval opeWpns. -4 #e coiled end ofthe.&&, &b
eddhfinl W~lii'strlrtlng18 by a w u ~ l l y - from iha !wgw pn the carbur_etw (sm
qEmtd C h o k &litrol. I H ~ n ) .
The whaust s m rn Is In t h w sediona, 4 Prise out !he dip 8c)curSng the choke wW.
coarreEted by clamped or spring-low flange cabla to -the b ~ d m tbn h e side df tHe
jqlnp. The qy m is s t r s w thmghouf: its
~ l e n ~ b y ~ r n ~ , ~ BlwdUI-:
'6 W m W $ i@didathe am*Kirn~Yeti& sing&
wmhg: mt3y ofthe pmmJtw3
in W Chapter hwihj .3hn , R e m o d a whM&
~GJ@W ~eqm mraw ehde & n
the mntyOj, ~
~ O , Y B411 ~ Ihes~(gnd 4 TQ I r n p ~ a a m wm , o v e tb dr-oI,m~f aSmlol$i
w@.refqenea to SecZton 2, 's'dkkbnW.thk W ~ ~ I I IQht Q W, h d ttd
2 Wprkltp under the bonn$ turn W;thr.de tnnwand outer cable. Remove the mtro
quadrant by hand to release the cable wemBl$
Wtslm. Disconnect the Inner cable from the 7 Pdse .a@ the bulkm+d gmhm&, a$
q u m > wlthdmw the choke cable Into the englm
8 Pull the, pw wbl& and grmm& from the
W n g bra&&. . m w
4 Working Inside the car, dseunnwt ths
able from the d m m r p dJ b $ w w i n g
the Iws .oftheable.end flBtng.
3 Wtthdrawtho.cable lntp the gndm h y , and
mqve # On s o w fight-hand-drlve rnQMs,
the csbfe is rout& tWugh the q l n e mht-
hand rnountlng cover, In thls -, the cover
5.3 Dlsoonnectingthe choke cable inner muat b UnbbW harderr to -freethe &Fe.
from the carburettor
Remng
8 Refit by revershg tba rernwal operdW~s.
w t the d, if maessary =.#llows.

7 If n w , adjust the able as follows.

Wtth thi pedal fullr.rMw&, ~ h e b kthat 4here
zs a malimuntd.sla+ inthe cable with the
throtttr -or on'ltkWp, H w an a#Mnnt
fully depress the amdwdtar pdal, then
d e c k that the t
h "m ~uadnantL In it$fully-
open positton. If erdjustmwt Is mqulred,
fedoSf@t h s@ng~ Clip from tho .a4ustmW
ferrule, reposltlon the ferrule ;as nssBSSary, 5.0 WZth the choke conttol kilobin;tM5 4

5 4 R e l d n g thwoholce amr able tFi& Inart .te?ciidlp In rnm.b e g06m MI choke valve phte must be rir&
position (I),
securing dip .the remli: open
 ... .. 4&3
-scarburetbr,mod,&
Fuel.and 8 e x ~ g g t s p t m

7,5 ~ u epump
l m w s s w am
~ponem
7 ~ o T I ~ I I ' & ~13~7-&CB
S FWmbmIm-8 14 * w i n W
9 Vanthose #e chab vacuum aps@
10 V9pmrW r 15 vawum mi
I7 alp mewq
7 2 W w r n W 7GVBcsiwW8W1
~ ~
 44*4 Fuel and & ~ l s p ~ h -s
-- - - - -

l vfar & Chapter ZB or

theh aft and obP.~$ih~ ~ ~ r dips 18, thm ,disc~hmoVW
W ~ ~ M Y . coolant W~~gs-fyn .the@r,bWor.
a D ~ G o & the h- fmE4 tt)$ fud 3 Remove the a i r d w w r from the t6p , ~the
f
~i@pt..~.at w & ~ ~ i n ~ .
P H w 2 p l , ~ i $ t * ~ * e , @ e ltank.
~HB#IP$~~M$&&~I~MPW
b$ M k # R "ff~t;h'Yj+q*-&)#~~$pe
CI@S.
DkqiJmcJ &y rqrr@lrr$m43 0i:hM mt] t h ~ ~ b S . a t5~ppl35lly; Id
fdnove thp t@Bk' 5 D'ionmt tha~ainletm and
~ ptug L
8 W.trn)trs m c@d p M . If B li d m ~ b ,emf, \

R should 6 mtb&d,, P ~ P ~ w y ~ 4 & B d r 1Diseonnml any remaining d m Wti

w avaflabls, .v.+kthat WY mwm-hww.
tor L& dn $iQhfi&. ~ ~ k g & k n @7 M U m w ,.the tnrrunting nm or &b

-
exmi&*it it,d q q - a m i .tYr& washers, and withdraw the
~wburettorfi'lwn the inlet maifold. R W W i g
-ng ih~.ga@Ms"and, w k r e applicable, the he+
g R@fRby Wwing t h #wvd~ operatlons.
On oompletltrq~,adjust Mb h W b f a k ~W
\ dw$i&wh chapter TAWtg, Hemn$l
e 'R,IPW
I
W Fuel mrrw smfw'trtltcmWiWs d d4'rn*
mm

,(sender u m t and tha rfghkwy up) md.W

'?ullmp&UPn (sender up~kle~own). .M to
IHwimti~n10-6h PWb B ,$.thk $h@tBr ;fqt
W~ovalI4~mWation.The .following rmulte
.wm;obZatdwmWor)rshop;
B ! uw uFmn
4 A drain plug Is not provided on the fuel
14'- 8 1Pohrhs lnilnlty
(open-,Mi tank, md it Is ttlemforet prefwabla to carry out
A-C @FObW 0.7 ohrha the removal operation when the tank is nearly
8-C 300ohm InAnky empty. Before proceedlnd, diskonnet3 the
,i~rn-prrn hriateiy fiegaWve lead, then syphon m p m p
~ n W 2 m g & 6$ hrnJhingng
B Lf the readings o b b . do hrd h m the tank.
, ~ W i
&d if:eoWIe ammtl~naf th~,.fup! 2 Chock the Trent wheel, thga jack up the
gyp or WminglbM has b e a 2 e x p E a M rear-&@ =.and suppott i t ah gtands
?h~mW@rwlt'ghd'Id b@ m5wd' f&mg9pd Wjcfeep@~P).. R ~ o w
#B s p e *hael and the right-harid mar rnw&Wihg
wheel. W$ i3mv2b the mudflap: " f P i r d ~ s& a h as hIgh -fuel commptbn,
7 M t W reversing the removal operatha. Lq~senthe cirp diabnnw the f i ~ e t uneven I d t l ~and w ~ d ~ ~ p ' a
&kq,anew s d and tighten the rfng securely. *worn the filler R I P . W$'h& j:'e'k&adb 'du'a W T B U ~h r the
4 Remove the two sotem bchv~;lths. ~ b u & b r L Raphszad' tlnkTbg &th
brWwr @PB aswmSrb. &rbu&tbr'ifdju&m~ 18 unHW to do my
6 Me& the positions of the breathYv pjpea, goad. Check fir& lhdt th8 tb'itlein
then dl&mn'ect them from t h RUerplp~. Q Q i n ~ 66 h Ih QwUcondltfbn, thdt?h@
6 Open the fud fler flapand remove me mp. vAv& qlesmnms are Ebrkctly a w e d Wid
7 Unsem* $he c w - W d w@w@ Icmted W,'$$nQ;Il.~ h 2 3 h t pm I p1dPtIon ~ f *
.Nd& &&&' b the m ~ I n a R t t i w w # of Insider the flller flep 'm~esa,and r e m e the ,awgine Fs qwcj. P;leo ~ ~ l h a t - t l i e 'a&k r ~
' ~ r b e t w g ~ ~ , nrw ,-MY. aB'filk&~r6crw.
2 Fault& wSth 'the carbumtk~rare usUafl$
,Rk%okd Fbemw
e R& by rbvotskg the, removal apem[one
udng rrew h w cllpS w!mn neaesary.

3 M w . q d sqpbh #I& ear, Renioqe"the

.w%@i&;cqm a:m: 0 y e ~ W ~ W 5 h u t
* ~ dh~ e n ap~plloi4.51"
0 hb r d ~ hW any problm,
m a7 14. dt#mohl
4 Dlamnnmt the ImhdWgke &Wp@,B:ei ? 4 o k ~ . ~ w a a t o f g & & d I ~ & ~ ~ 1 M QweMauI,-Bhd
m aaQmtmmb
lwuali*r: Unctlp the eagle wid vay-y$$~mhWng.
OWof the w"w. S BI&mnect the batby negative had: &I
piwmn&fhrr -fuelflier p b s h m die'* ili~kiets~-wHh
arr mti-p23ml&c~, system,
Also d t s r o n d the Idrmthw hnd wiiz h-s. r $ m o ~ q l E ¶co*~ r ~duet.
If crimped how cllps have be6n 'used; cGt azbdn?& C O O ~ W ~ ~s'damed in manifold.'?art~ald a i h g can be W e @

after removal of the top cover, without
removing'the carbumltor itself. Thls is useful If
R Is slmpiy a questbn of clearing a b l W 4
jet, but be careful not to drop small pa* Into
he carburettor barrel.
4 If the carburettor is worn or damaged, If
should d b be mewed, or overtrapled bv a
speclallst who will be able to restore ihe
wbwttor to its origlnal calibration.
6 Before commencing work, OM& a Yepair
w overhaul klt for the carburettor, This will
wntaln the various gaskets, seals, etc, which
must be renewed once they have been
dMW.
6 If It is:- tp remow adjuster screws
u ~ lsuch
or r t u t s , ' d r ' 2 b ' ~ b ~ a d Jitems ~ as
an accelerator pump cam, make alignment
marks pr take notes go that the original setting
crtn be regained.
7 Remove the securlng screws arld lift: off the
carburettor cover, at the =me time dben-
gaging the choke valve opsmthkg IInCge.
8 The various jets are shown in the
acmpanyhg Illustration (seeIllustration).
Each jet should be m o v e d and Identlfled for
position, then the float chamber can be
cleanad of any sediment. Clean the main body
gnd the cover Mamughly wlth fuel, and blow
through the m e t t o r Internal channets and
lets using air Imrn an air line or foot pump.
8 No adjushent af float level Is possibb on
fhle carburettor, except by changing the
thlcknrass of the washer under the needle
valve. The thickness of washer required is
g l m In the Specifications.
30 Reetssembly is a r d of dismantling.
Fuel and exhaust s!{sterns - carburettor models 4A.5
Note: New manifold and carbumttwpkwts
will be required m raM n g .
1 Remov~ the carburettor ($&ion I I,).
2 Disconnect the brake w o vacuum hose
and the crankcase ventilation hosa from the
tnfet rnmanffold.
3 Unbolt and remove the starter motor
pratective shleld.
4 Remavs the hot air ducting, then unbok the
metal tube and a t cleartar support bracket.
6 Unscrew the nut, and wltl-fdraw the heat
shleld from the exhaust manifold.
6 Unscrew and remove the two nuts, then
remove the washers, tension springs and
sleeves securing ths exhaust front pipe to the
manifold. Sllde the flange plate off the
manlfold studs, and separate the joint.
7 Progressively unscrew the nuts securing
the manifold assembly to the cylinder head,
end remove the washers,
8 Wlthdraw Ute manffold assembly from the
studs on the cylinder head. then remove the
gasket.
9 Refitting Is a reversal of removal. Ensure
that thccylinder head md manifold mating
fa- .aie dm. U@ new ~as:keTs.on the
manlfold and carburettor.
2 Both $&$bwhplmand the rear W o n can
be rmoved IGvlng the remaining exhaust
sysrm .m p@rthn, To mnCove we
Intermdate &&tl&~, It 1s ~eewnmendedthert
the M v @pfl , ~ ~ ; D h ~i ~ then
, O Vthe~
Intarmedlatati W i a n a m be dlsmnnracted
from t b dawnpipe. In pragtlce, It Is often
easlei ta WQ- the',whda Wen?and Vi&
separate the sedon,s on the denck
3 Exhaust s v s t m clamps and connections
wlll often be-bund fo &.33etdty rusted. Apply
penetrating oil or rel&+ki7ngT~ftCIM.Wm $Mi&
W,or cut Zhem Bff # + t hw +
~to ranewed,
The use of a Mah-&mPemn anttrselre
earnpound on r&tbmb'ly will avoid M u w
problems. Exhaust l o i ~ n g ' 8 w h m dshould
be used on the joinis b e t k n s k ~ s .
4 TO rm,~ia ,the sym ~r pm QT ff~g
system, htjaEkupihekontwree~~ftheear
and support it on axie stands (see 'Jacking
and vehicle suppofl). Alternatively. position
the car over an lnspeefion pit or on car ramps.
5 If the whole system is removed, revit if wlth
the varlous clamps and connections loose.
Begin tlghtenlng at the exhaust manifold, and
work towards the tall pipe, ensuring that the
system hangs easily and without straln.
Now A new manifold-to-downpipe sealing
rfng will be requimd on reRtting.
6 To remove the downpipe, unsorew and
remove the twa nuts, then remove the
washers, tenslorn wrings md sleevas 4A
securing the ,downpipeta the m l f d d . Srde
the flange plate aff the manlfold studs, then
separate Uls Iolnt, mvering the d i n g ring.
Ralease 'We ~ l a r i l pwhhh s m u r ~ ithe
intmedate W o n b M.dawnplp.
7 Reflttim of the 'dbwnplpe Is a feversal of
removal. Use a new sealing rlng at the
exhaust m,@tWqld. I t e n the mifotd nuts
to compress tho sptfhgs untll tha nuts butt
agalfist the spacers on hshtds.
Rear section
Removal
8 To remove the rear swlon, retease the
~Iaingwhich secures k to the Inteimdlata
seetitlan. Slide the rubber m~unting8off the
barahand It n ~remove thsm
~ trwn.the
tln&body by turnitiq them through @%
Sepamte the w a n d htm- #&at&.
Refftting
O WIttlnqd the rear s d b n ls a rev& of
rernwaf, uslng a repait -Ion Wlth @n
4 ~ FWI
4 and -
m m s &urertt_~r mod&
- -
adttltland i01n.t. H n-m-ry, r j g ~ e nthe m e y e or dlseonned tttb se-cflgyr .= doyFrpfw,.#thenwithd-w W, l n t ~ W C t a
clamp[s) murely, Yp$l~,@~ew the rubbet dmribsa p~avlo~@!% R B $ ~@ ebmp
mounihgs If news@. mt&W G U ~ & @ ~ W I & " , :to* the"'

m e d t a b tg-n m
d ch p ~ w. -.As l i a i U W
,an4 ~ ~e
ww ~ .m
h.q@it
3 1 k d i g ISg'iewka! at'rmsyd;,.t@,hfp
f@g
o f f the
Fki-1 undetboa $y ,~tbMii@: %mu& 90%. !haL nut$..md,RW8 *b
10 70 lgmw mi$wm&ate s&mI W separate @temdkta:s&@n:a~m#@ ~ , q @ % d ttmmm,I
48.2 Fuel and exhaust syiiems - singlepoint Lel injection models

Torque wrench -@gs Ym

FUI gump Fkrg nut ....................;................... :,.. SO

Irtcmpomtes a W i r ; c o n m r , to reKhrw. n.,Rm~.w

thr~m~,whIck,
~ ~ ~ ~ s d alr cleaner f t f k d ce huHng.
~ l o €he ~ Uft off ~the ~
end other emission control crrmponmts are dr elm&, and r e c m @.@ q. 1 i ~ t i n &
--fn P&Dofthi$ChapW. ReFttfng +

Lfa@tiwMany of the -urn

Tha single-pdnt fuel lnjaG41an system Is . b w s c & p h w m w h m ~ 3u~~R dat by hvtirdltig , W e . i @ m IQW&tiW,
newswiq rl,q i f m r g .
!%tad tQ dl E-type w i n & , and'WAn F3P of li@sand wwetlo~s
erylkes, The,sy&m 7s & s c r i m in M I .In *-mayresurtsn~same~sp4%qe(*
$o w o n 7 anti deprezwurisa *he fuel HF,mgtna
Ssc;tlon 8.
TtPe W pump bdecMc;it i s l o W 4 n s i d e ~d -& b m~ ~L ,d Wh W& m~ wa r n f ya W nR W
~ ~
~ MFl
We fuel'3mk.. ~ W l ~ : ~ l f cantin~pusly
& ~ s
when ib pump Is sperttu'cg, fuel M & ,y*.Mw? h.K-*$ 4 Diaconne& the call H7 lead f r ~ m
th1M lbw?s&* &,@ilk b ~ M P ' Mthe W n n f n g pf
-. .dm@??!-
- Q'e e h d aptem la conmtlonalj and W .mawah ar7d W o w tbm
&ia is h high~dzutge~rrs and v6hdb
,& R d ~ t ~ ~ , arad
d I 4pm , M W t ) hot @
" ~ a r n d m ~ ~ s ~ w h e R
handMngRcmnottmo~

v ~ ~ ~ ~ valve
~ on m - E
the dr-lnt& h
- Wb.
7 RwtyweW two ,boM whioh secum-M&
. @&iiib
8
gie a
tm wl
tray m?r-@?,
tfff out the I r tteamr d y , f&3lhff k
fbrli th8:&Id 'air pkh-up hose f he 3 b
Removal
we I!l-w.
9 If It Is -n .t&rern~m,me ' i i p
1 Dlsknnnect the hat and cold air lrntake pick-tp hum, a?= is wined by W N n g
ducts from the air dkan& h5uslrlg. itiiisi'fro;rt1 W d f h e : w h A splash s h i i

25b ... then releasethe clip (arrowed) 2.7 Remove the two boks (arrowed) which 28 RellldIQ h . 8 1~~l l e a n e i a h w ~
and disconnect the outlei hose - secure the air cleaner to the battery tray - W&@t,& ,I .

F3P engines F3P engines

,'Tilid hase caf~ fin Re uncltppepl

W R&l b~w m h the m w v d o&atbrn

(a -
B
"
6@.t?by .rev@g
A+,

A d i u & ~ ~ c & lJfemc&W as follows,

A # u ~ A ~
C8ble g$menj is carried out by
the odsJti6,ir of~ha
hdJmin clld an the outer
-
$be removal o p d ~ r r s . peddw d e w b + h & ~ ~ i o.Sedom
a -R @ai,sm+.b'uai

4 RWby wewing the,r&&d-ms.

I I:-
w

thfQMe:?!iSrmY 'NhW the I'@lttionIS s w l t w All firel injedati models sold InHe URntw&
d& Th& b&'~t~o@ ~ bgl~tjle
~ h l In tW k only .ue file- peml. ~ g d fuel d muat
tadl~wmb ffrmqta'C~OSBp'ast thrgr mitlbh not ,b used, as It will damaw +he catdfiio
otdkiFW& a stable Idle speed wtll not ' be eonwer. ma fud fillw n a k [sdes[gned to
obfgned. a c w only unlaadsd pump n o d e n
B Qn automatle transmissiun models, the N rn+& mn use h,95 octane unleaded
WG&~QWI-I switch sb0~1qwly operate.when fuel aytapte thrglrghout the UK. Super
the$&& Is de-sed beyom3 t3-m wide-opeh bnl&&i ochikl cA% al& b usedi
tlyqtt!e wiaont Gonect.adjusunent of:f-wIs though t 9 q T3! no admgw8 In..dotng so.
W $ e h r a ~ i r a s$h-
. use of spehjal test Same W e l s can u s e ' % l C a ~unleadade
equt$pem,-&jtsfwt@Mk In.doubt; consult.^ fwl, #he@ @dTik; ~ ~ ; q I h M roetana n
~bnahE?&&M. rat~ngisw' n
i -&S
' *-.

3.5 On $0- models, the engine rim-

hand mountlha c m r must be remavedto
41 Removethenut bmw@J -
sewms the a w d e ~ o T ~ l . p hbush
bt
4B.4 Fhel and e ~ t a ~ B m ssingle-paint
-- fuel injadbn,models
Fuel supply
f3P wine m o w , Thla:.W@@Ml a , w a l l Y
I
the same undl-B d w dlW- are
3 The fuel supply & - m m .mnslsts of an
$ken k-th9s~&M~T~F - 4 . @ l a cfuel pump I m e : j n w W , rr fuel
n*+.q;e, -=*- a fuel pr-re r ~ ~ k 4d
h x a fud @*l
m%p'&mwW -6 +mr)mtional f&ed-fet fllt~r,
InjeUor. lpsgi Mhrcr hem&a@ I+ In 9 Tho InispWan ~ M r o laub-sywm
; gomi*
~la~bu@twr~ ~ ~ ~ ~ r n n thw
l tbrottlebi*.
~ l ~ ~ n ~ e d
muyU.wlnt fm lihm~fl, s m m (-
uf &a lnfmtsonmrnww-ernd.lhassaid+
&&mm wB,WusWkkAsmfi%W$ @1:+
K e .wq~p.utw mawel
coh%oIland lgn~tiqfi~ $ ~ W Hwih & I ~
~ ~ - ~
I'etqw i!$ qe Bmuhlm8"mm;~wY10' pi&1plj~@Ibtis In the:ChigYne
u m Z d - Q brrtte&. e ' W ts bay,'in me right-hand SWW4011 models
B y ~ ~ P v A h k h r e c s l r n ~ f p w n
f&uqtd ta G*. ,!?@I ;s#lmye &r chdltibnlhg, th* computer Es. lasz$@
v@.~~.mcamputer*~ts~ clrcutathg dall'@:timp #&@ pump Is running, insidethe c8t; below glovebqxd It d v 8 5
Idle speed, and manages the mlaslon cowrot wMch mum a & M supplty of cud T ud, signals from sensm whkh monitor the
and.ogmrmsystem and Welds pmbiwr# with m p - * ,f@IlpMn~ funwns:
8 Tho main advantaw of bingte-point 7 The fud Infector cmsls& d a n W t e valve, 4 C 0 o h tbBmpm)93.
Injectionover a carhmthr Is thd the inje4ion whikh kxiperred by an d$t?omagn& and bj mder air mpeMurer.
system allows much more precise cmltrol c k e d try a spdng. Ilia sl&omagn& is cl w n s speed W h Q dmw,
over the a$.fclJ ratio (mlxturey under all aontmlled by th9 Injectlm compupq- W b n 4 ~ ~ ~ c a b l r P m m
aparetlng cmdiffme, This mmol is the valve is open, fuel is $ w e d earn I ~ B mi 0n.dmadels.
nemsmq to keep exhaust emls$l~nsta a lpj&$tgr.grta' the,t hw1e plater, W s e W
rninlrnum, and for the mmct apemtlon and d @ w fuel'pmmra le eonstant, the qudhY
long tlfa of the &dyUo mnwrbr, Addtlonal ~ R vW
ofqh1 m b d m -rrg P Me
bend& from the driver's point ntT v t w are gPem w.
Improved fuel emnomy undw all conditions, 8 The4i1d&lc~Wrlb the fuel pump is v h a
and bmr drlVmbB@ whm ~ I r f . r q l # m t e d by Me i n j d o n oomputer, The
4 me 8 y W is best und~r&ood If ,pum+ Son@ensnepglaed whm the mglne Is
ccmmored In wb pasts; thefuel supply and mnm w .whmt i ~ SWW e rnotwb a d * .
the W s m . Soma p 7 M u r & In thk &apt& q W . t h e
 - and exhm#;$ms ->single-pantfuel injearon
4 ~ 6 Fuel . modeIs

h*tyqpjnp
N ~ I~.t. ~
Wn&>hmi, a at gw md'&

- , -.

1--:put a p m b M k k a$ -Yc hi
WpM-w618e!t&m.
;z B C S o r i ~fhi'%~l
i &turn pipe from Nk
m e horn. Canned a'@gth of fiexlb6
union, hther&e -$+t q$iw <*re
spmya_irt_ontq:h ~ m g i ~
muId
~
h&s f5tb d m don, mY pbc$Vik
.end i ~ ~ .
dUie kwJn a meq'iqg Iw (-1~
e' 2
;P ReMmthe&phFtWfUwwhBh b No 14 -I* &@,
'in ~t.pter.b~m& ( a @ i J h&q. S Make the f u l pump rup by bridging
3 to &&+he tahgp&.It,may mi briefly trkmlnalilp Fahd 5 bf%s fud:pump relay 6
and di&, w It my-nmt starkatall. Opefate it@ b r i b e d in ~ previousw b n .
st&i(mdor 'a'cwpb inkre Oh&, ensum 4 N d t e h a w W o b W d : e l l ~ h
thgtalrfuel p v t m m w e d . om minW& W m C t wluei am glvm In the
4 8~d+ck Q&i thrs lgnitiojt and refit-ma fuel ~ m ~ ~ ~ r l s .
1s W y n mp~ln$ the wtnghla, the 'q sped Pump fuse. 5?5 kmovre the bMge fefro;m the fuel purnlj
wnirol motor first closes the thfattle
mplqtely, than o b q It in readiness ml&y- .R~tm'tW pumped fuel to-the tank
7~

fur the next start. This means that with the put Hfn a s u W L ~ l & ~
eng!ne t h ~ - w ] Ube mom s@ck in the .sa Up~tywyb !v, qhe& h a t full bat-
-@rator caFh than ykh fher eAglne1dling. - voltage As ,@&ti at the pump retay'
f 0 WI le&r mod& are Wbd ~ l t ah%elIWa con@m.~tmdat'W pump W f .tThe pum@I
cuf-otiewlkh fseebctlan 141, wi?bt?,&& off ,* + f e ~ wirjtrg .w&a~r'b~cm$bIethrough te4
&Lthg. w w n q at the end oT !W& ,, =hatatrIn h f t w r . j A l VbR.
- ;..-.
the fuel supgJy h the event 'sf ~@~veihbd& *<,,

bdng invdvad In an Impact. The q g h e s m n f b&om ptaw3mg. A soitabM will mat in a dtop ot
mnoY be awJ,fl$h~lcswitch is acWa&d - plrrssuwgeuge and T-phm d l be reqdtd a p ~ x i m @ e ~ " f D ~ n ~ W ~ .
hr hi*'&. 7 H ~ ~ ~ ~ ' u D P I Y
the swWmust.bm&mdbb
1 D&ysurlae the fuel system as d e m b d is sf111low: ikre a@%o possble YO&.
>Fault&tdw In ~ & f l d h ' t ,remernbritq b refh he Efther there Ua-blockw$ s w w h e w In the
$7 In the e$mS#a fairk 'dev@la6hathe PW'@ m supply line (jmludhg itk meiEn fuel filtw and
amount of d i a g n @ l c . ~ o r k ~ d b if ei r the 2 Rentow the a11cleanet hausfnp or the air W pump fiW; OF the pump l6'
heme mwftantc islirnlted. Renauk ferchnlclans InmMgSln$,as - W e to Improw ab%!S h ~ - l H # i e ' ; p l a a p!$def&M, it mustbsc
ma .ddlwt@ test ~squj@mmt ~ ~ + ) p n " f i h d* o . h thmW h a W a ma:
a- %uFt.>@id4ydntl p d W y : I A ~ I B-fawlr- I 4 qn$w$ a Pfw8811re$au@ (ran@d to d' a.Il.:Qa-+pn remake the original WI
?indingcWks should moentrate.mwkmal Wawwudw p i p w h w i t ~ m 8~~ @ j m m m =
M o t i suoh as a blwW fuel T f h , W ~t thwttle 8hmkrg, 'usihg a P p l M ' t i
,wrraded ele&id mnndons wd h e or - n). -,

'dmag6dq N u m Roses. 8mjmhrdW-that 4 Make the Tuel pump run by brldgJfl&- ~ 4 ) l k rn w Pump p d wur be, mqIIW
C'

incorrect adjustment of the awemtor able temlnals 3 and 5 of the fuel pump re@ <on.**
:can affW nwptjpn QT 'Itbe WeJ tn5~c,tiofl (tcmtwi.Mi ? & m u t e r o w aJr h the relay '9, R e f i ~ ~the
3 Wl tank g9. dgscribqd :la
&wm'lj.
system, mspmMlyat idle. MX @ kgnlof tftei@-hwd s t @ H d n tuw ~ OMB ~ n q$9 , mU-
16 A 3t we&#$that tl93+uKiult:lsIn one of tQe ~ ~ . ~ l l 4 & h u om . purrmp.*.can
n l fuel be pluga @mm j q w W 1 h$91
the iop of he pum'p [ase
sensors dr in the oampmr, ,ewirl p r o w l y be
mom SEdlsfmory t~,&sqk;a R e n d 4% U-.lI
or spiafist than to drhbiu;&on&6p> y U ~ w ! h s x l n gu~s@, it001W s to
.rnd-mIBP P W ~ OW~ ~ F * & &s ,d!qms&ng w q~qdius@bMg

. P K ~ Paeflww! ! , dw'w1*"E&pn 9,W

see whether @ekglt is @>b,pugp.urthe
pieasurn regulator: If the k&dl& m hi&,
the fault c 6 o n l y be in Wp p w e e qylat&.
,I8Remove .the Ibrlda6,TTcm th$ fuel piimp
 -
3 -

Fwl and exhaust aye- -. v&@s

sMgjt+point fuel injeCt;i~b, dB?P

Rtlb U ~ ~ r e w l n g ibet pump rlng nut

th8
using an adjusbbEa peg spanner

0.1I d ...then withdraw the pump ... B.Ti ix ...

and recow t f ~ e
& O ~ ~ B C U ~ - D U ~
MI. V$6hd~e
(q
- ,
Td#g gauge or warning light:has h e n experSenoed,
unit: the float shwld be
.4:Invertvert;themndsr ffie'%hcbrunit should be rbneWMi+
M to w e . . mmng
C ~ ~ ~ ~ m & r n ~ ~m 1b~ la~~7 Refit
s t byh mverslng
e the removal opwdt~ns.
Wo.at,a.qrne,dmd, ob~erve~thw~changes In
rmI&nm-:beWeq .the "kmpfy* poslsgn
W W uprbht:wd the*M way UP) the
"full" pMtlbn 6mdet upsredawn), Mer to
the kmrnpanpimg ittlrstratron for @mrfnd
IdMmtim ( s t aUlWratbn). The W l d g
mttswemnbtalnd hthe wwkhop:
T e M Y Uw"'FrilF
A- B 10 ohms bhi$
(DrnWHI
A- C eao'f&q o.??@W
-
B C *;;tltifi,,
hpn-~ipwilt)
48.8 Fuel and &%@wi
- single-fiolnVSuel W j i i b i i modds

own-bar war @s, the mar sptbg of-the

exha&t:mhkbeb mml$clwmit
gqipmertt (test box ~ ~ 2w5h i)9 plugs
'the dlaanosttc7$ockettirubkie'd On'tlle mdn
w y l n ,the p-gy
cai;ipsltnim.-fhis iquiprirenf p M e S a
ram and ~omprehenslvedlap?sb:# t h
mmalefe swfem. If fs the onlv r n m B of

=ti11p o q
hfmr@i~n fo the~
following ~
m o m h a is d e n as a wide 20 the ~ w r l r
&, 14 Dk&nnept.rne autr&:Wa from Zhwf t
d bnq"&w ,mtpi+lhlhary
3 % & b h d s@@&t the b r . Kemovg the flw Ee prepared for spillage. a m'lt dsmIops+Mp.$jiv@r, It may be
&qpat system and, where applicable, the ? ~ q v e assMant support the fuel tank.
me~w @ &khM, b$g ~f e .ReWf:
.@'ntxe @$ion hwf.shkld 8s $ - ~ @in Remaw the flve rnamIing b k a h d loW@the d&kr -&r &ff& $pWb& for 'WtI~
&&on 17. Q n rnodels-wiflr ABS andor an tar&, ftwtng +R from Wo brake pipe cllps. d~@no$y.of gmlt;
d k o n n M m y rmalnlng w w cwhdses and A Wh~h & ofh~)W&ldJ muMimWSs
@tpove.aheiank (seellbtmtion): c#@d fpy, thls should b~ a ,madern d$lM
8 ;mrtWiamad8'QfplaellGG Iflt,kWrMF, %p.e*;with in linterria! reWmw ofat M B Y
Is sh$@'be mewed. Proprlehry repak Ms ~qyephnq. aa not use atwjogue i m d q
wz aVaIWlg, h g check-mtware s u w e polriLrj 'nek~cs, whfm may have $n
expedb.P
rn form on ~astic.+nk~.~ fwd leak fs.nnfjmI
imcceptab!plaw htmd resxhhm.
r ltbdan@mlls, 4 ,%a&an'fn$ul testing E a pcrsslW..on th#
Rnr.Wng M _ l a d ~ i m r t r 6rnptor~
1 ~ W N e potana-
B 8eat'by byve#hg the removal ope@i~tts. i o m , the rnm&Jd mma (MR. 7
Mlwt &d handbrake>+ dwdb* iq @aP- q@ w sped sqww @hen fltted),-W
ier I A or 1B. 'm*-W.
6 ,@&om.ieetbw% d j y i d d b ~ ~ o ~ * ~
ma ~ ~ r n QynW~nsw
~ ~ ~
den arid awm @nrlthat dl he!, dl:
wbuum" h m are In gobd ,endltIoa, &B
rernwq that, @leW with Idta
wlf [on mw s/m& 'bik W.to I n w m
 -
Fud and exhaust systems single-point fuel i n j e c t i a n ~ ~ ~ 4B.9
els

valve. Note the I ~ ~ sleeve

o n
(arrowedl on the hose nearest the breathcpr
Fuel pmsure regulator
17 TeHing gf Fe
he1 Rrmaure tautator t
ln~l~&& thew1~&SWd e c k M i o n 8).

11 With the ignition switched dl,disconnd

-
the speed sensor signal connecior (0) (see
Illustration 13.9). Check the resistance of the N aA
sensor bv connectho an ohmmeter across Wid
terminals and 5.Tho reading should be 200 for initial setting-up after renewat of some the throt
components described In this Section. Read will be mquired.
a 50 ohms. If the reading is Incorrect, renew
the sensor. through pmaeHUW cw&TUI& befom Rgm~val
12 Uslng a feeler blade, check that the startfig waiir; h S ~ W whaf IS hmhd. A h I Dfsconnect ~s negatiw lead,
clearance between the end of the sensor (P) refer IO' tm wmina nbte end of Deprmurtw the fuel Ijlnes aa dasciibqd 1i-1
*
and the flywheel (V)Is 1.0 0.5 mm. If the Section 1. Section 7.
clearance Is incorrect, renew the sensor. N r inlet housing 8 Remnve Ma-air'cleanprhsusWg or the aJr
Imp ensfhe or3lyl Inlet h o m g , 98 apptiibta, from the top d
the thmb ho@ng.
B Discennml the t h k rnultl-plugs Prom the
1 Disconnect the'brwthbr h o 3 8 , W tWd r t
h w m i w (m4Ww-b
Inl&.hw.slng (sac Illusbation). 10 Disconnect the fuel suppj3 and return
2 Dkcpne&thB vacuum twm from the air Ihm, m$lclng I d ~ t l o marks for Mar-
Intake temperahra contra1 valve. Mark the
hwe$ If tQep4lq;#ny~48~lWty of mlxln~them
snce whgr refititin$ = n
+bp&eB ~ ' 6 1
WlIaP. I
UP (61ae W*~on). 11 Discannw* m&mtOr C ~ ~ I I . 4B
3 Rpmovp #he three T Q screws ~ which m Remove4heiReuP.W x l a w w litt~~off~
m u r * the air inlet hawing-to the throttle rRe %r&l8 hhrl'Sl@. %Qs€tW. '

L,thi$ injmtor. W tfie reelstance Is sill1 housing (seelll~~~W@pn).

t%*inie&r~ddecthrs. 4 Release thw h m '@tloand .dlsaann& the
%l#@lb su&cted that dr! or gum in the air inlet trUnWng from the b u r i ~ g(ewe
79 The ~ a ~ ~ % ~ : ~ m~n 'b$R
a & ~ & * F ; .&,W&j&
~ ~ *&
"

h r b ImDaMna wrfomw. the um of a HIuslmUod.

' 60
addttlve in the .fg'tsltslnk6; Lii3 OH tlk alr lnlg h~psingand recover #p .b&ew: the bau@n& h a l u ~ w h
pliet. -hbJJw?

1
I

.
l4Qb. .and the th-0 potentramefw
multi-plug (C)
temperaturn -sot muftl-plug (A), the idle
speed motorfidle swHch multi-plug (W ...
i
m
46.1 0 Fuel and exhaust systems - single-point fuel injection models

expansion tank cap ta depr6ssurlse' S ~ B

~ m t . h 3 n hdg 9 the wenw w a WW
using a tyw @ m k e t ~ ( s e e ~ ~ o n ~ . h g to hand.
16 w thg lwer hdf of t h e . W b WU8Ihg h8s Dlsconne@ the multi-plug and umcr,w
the ai-nsor.
mmw
24 Apply + IlWe &ant t t ~#le senL-
thrimds, &d ~ m ttwlnttj posltbn. Rbmhr&
tftp mufiPJu9.
Rsmbrval a ~bp-upor retnl *the WIIW sHenr, wm Mb
,sm,ed-fmI motor
referanmb "Weekly checksqor Eha$t& ?A Rww.d
R e m w 8 k . t d m r w h e s t n g o r t h e ~ r w 16, > . .
1I-mhqumf, *gppU~Wb. ,@ R$~IVB,M ab p m r hWdnB w the ap
-IT mm6& the-nmr multl-piug. Fuel In&&r
p-iklhq single waqlng screw, and ,inlet howMgIawppfim4k
&I' R@movq the. $ K ~ Ih~psing
? gecurin@
vsr (Imelllumdml.
iqsoto' sdg lPill m e w q . brefuuy mtmW.thrMlr housing la
~ s e n wm rsp~M an W m -
We ~ n d ~ anctt wWdmw
u ~the mmv* ~*?VP?C.
, w w together with the cover, wiring and
Ramoval w Dmmnwk?heimbmuWug-
im* (seeIhrWd. 26 Remove the air elewer houalng or We air 88 Remwathe t h m rnsuntalpkl ym.d
inlet houslng,as applicable. wlthdrew the motw{sp Mlustratlon). '

&
-
m -

&&&*/ &a$&&m
~~~~ on dffrng.
22 Dmln the coulln~systemas d w d W In
Chapter 1A w 16.&&atlvdy, remove the
 -
Fuel and e e h w ~s@~m-
t ein~jle-pointfuel injection models 4B.11

- .
, € i h n e ~ t t t&tt-pdug
~e IA)and h e
vacuum hdrre PI , I -
-@ Refitting wW%m$MwWtW@mP df
tmsml&ii~on~ i r ~illustmtiun).
, ~ ~ e
&%<fMIby m m i l y l the removal a p m n s , 41 Mtby m M n g t h e . ~ v aopmt'ina
1
@ ~ , p s r f ~ ran
~ n,hitla1za&@ a&%& & Road speed sensor Refitking u 3:
50 RdRttmg IS* W@Q&.diWWd, PLR It IS
s8IIsor 1s an iwpafi Imp&& to mbw sm~~prm&
9pw[al
the W ~ O ~ a W h illudmtion).
b (met shoddeed bolts -&:fib to the
For cable renewal Procedum, bJ ~ M N J ~ ,as * ~ p ~ m w
the'am
few seconds, Msn switch U Bhapter 1Q. dtshce trom;tha'Wh&
Inlet manifold heater Gompufer
Now A new &-dl1 l b$Wm wit it^. Note: Th@following ~~h~ W bthe
Removal pmoedutk'rdrd d s wtmt dr M W @ .
43 Certain engines have an electric Inlet On npdels w# drmdibhg, the wmp-r
&$y$@d pmure, regulator IS m~ntegd manifold beatbr , t M ~ his fi%te,d to the fs !matad lrisdde t hw;h b w bere g/o%bx.*
krt of the upper half of the throttle housing. If undersidenf Ihe.jntetmmlfOld. Removal
1 Is defecpe, tho upper half af the housing 4 4 DWnmgt the b a b r wlring,plug, tben 51 Dl~onnectthe battery negative I$&
n Mh i rmove the mudw &dip, md wHhdravv the Open the hatch h the right-hand &&of the
haatst Worn the.manlfM. Rmw#res d . Windscrwn cowl pmel and removp the ,@ok
mtfI8pofentlometer
Refitting For hnpwd.am#, m o v e tha dpmd
f6 The throttle ~otentlometeris an Integral
*of the lower art of the throttle h9.vsipg. H 9 R@!ng is_a
r9ve1s~1 of removalj kllt ussa coi-hpliattdy, 85 desmibed' in Ghptor 1 1,

n a mal, and- ensure that the dmtlp is Section 8.

t b d e f d v e , tkle I w e r half of the hnudng 52 Re ve the nxruntlng bracket?,M l ~ Is
h
wed. The Idle speed contrd ,W@YI*&,lR
transferred from the old half' ~ngine
It? gfcaPM.
(speed,,(&d~@S ~ O F illmons1.
"%
sp~ured Y tpo nuW:.wd B single.b@4(-
new one.
wal, the Mql S M B 4f ifbp RemovaC,
mu&- be ve* using defiau* 48 The wnsw I8 I&bTdd at:the Yap af the
?mnsmisrsion b s l l m n g ,
nifold pmsmure W P )sensor 47 ~ i s c x 3 n h6t 6 l$hwnegaf:ke l&iI @en',
If n-w the air d@ane~ Or fM
lntet air tnrnking for access.
M Uncltp tho MAP s e w ~WTI bbmket an 48 Fallow thgwMng b a ~ k frpm,tha seaspl,
the bulkhead. Disconned the multi-plug ~d then d l s w n h~e s s n ~ ~ e q n ~ W . w 2 V, -
rCuum,hose from If: (see ill^^). , ~,bmwhd:ham@
m un9mw ?new0 s m w & ~ m b ~ j1 OP*&

I
I
-1 Ta remove the computer mounting 14&& ...and the n * w $ h B bnli ham Unhook the retaining strap t
I bracket, undo the single nut here. .. tamQW@ ~ ~ f k e > w t l l ~ -
I -
4~.12 Fuel and m h & H i . ~ r n s slhgle-paint fifere1 Jnjwtios,models

E y p e engllnm
Mete? A new @et will Ire m @ i M @
F3F ewIse &w.
N;qfs: & mdw g H wjfl he @quit@don
~ v 8 . l
mm:
1,UR&& and remove Xhe hub' n,&. thm
W & W R new gaskef MI! be requid an Removal wqve p e washem, tension springs ElOd
.&Wng. tt %#e.th'rhffle tiowing ~ ~ ' . d fs wl m~ psm'ng WWaW fmnt-plpetolW
hl &&dfl-i 4. rrwlfpld$~ueiliwtration). Sir& the flmgct
7 WIn t h m ~ l m g system as d e x d W in p M off the maoitbtd wtuds, and seplvzlte lbe
Ch'ap'tw 16 $r 1B, *t@ rfescannect the w - 6 +
may ?Mmmaved together with the throttle cc3oW~S~*%# inletnm. a Whew qpplMla, , t ~ %he m ctip aM,
housing,.but If this method is used,lt will MU 8 ~is6oonnsef,the brake mvacuum hoae, dswmw thwJsd@r&+or t hair dahi-i'err
bi3 w m to dbonnerct the amdmtor and &y ramdning breather and/or vtacwrf~ dkMb &i&i~bi?&titM14 h@8ir1shrgud
&k and ~wlm W frmm *e ,n-&b1d (sseUlusVati~n)~ Wlustmtkin).
2 nfatnthe ooolh~gsystem as d-rlW In 9 Unsdrewmid nn'tbvsWa twg nuts, thorn 8 Whw! a p $ ~ i l anscrew ~ l ~ tlre nuts and

-
Chapter 1A ar 't0, then disconnect thg rmove $he washers, tensfon sprlngs ahd YO i$& hot dCshmud Wrn fha mmiful8
cq&nt @es from the inlet manlM. sleeves w H n g Wie W&st Writ p l p to .fhe I - EllwmNW.
5 &mrtW the Ww s e ~ wwym o hose, manifotd. Slid@-the. dange plat@ off the
ar@ yy mahInq.S;r&her arrd/ot~vaa~m mmifo!d&s, md 'sepaab theS jolnt.
*,fm th@k&@P~f. 3,O W e r e appUca:ab@, unscrew the nuts
4~F?wgr&&ly wrsrrew fha nu% dkm ssc@%igfhs hot alr shrpud to thernml@@
idmr&)the lhM rmanffatdfrom T h l w e on a@ mow the stmud,
the Wndw ha$. Rmovetha gash&
(5 Un&lttmd wthove the manfakl supM
'rnbts,
re. Proge?%lvely u m t)l@ n@ md Isale
!SXhMPtin$la e reversal of rmovat. Evstrre secudllg ,tRe.Iolet a d exhaust tl-yiwckj,.wp
t&t the cylinder hwd and manifold m'aflrlg withdrkv thorn frqm tb& cylinder htmd
i k c ! s sam CIW, and we a new gasket, Alihaugh the manifolds &piatm, t h q a,
Where applbbh, reflt the IhMPtb houdlng > W n @ .by,qs same. bolt% shne the bob
wifh pW l o n 14. Mllthe c o o i ~ holes are spnt bqwewi thb:ma~ld flaxlgs.
qstm wWl mfefe'mceto GhaptBr lRor $B. R w w me pu?bld W&
11.1 Unsacrrew3~exhaw f m f l t p l ~ -
manbld nuts. Note the a m a n a m af th;e
U, fmri
4 ~mgresi~vely

manifold Q&&
&@@Pi-

'W@W am c
'WIrnp&e
<&.
&J'mwtW~$

&€mBm;-10n
unscrew the n.uts and bolte rmqv& w e in ten he did^ wtbh R L
seeurlna €be exhaust r m W d . then &fhfffirw ?bb~mrft@ed Wat th mar s W o n Is
the cylhder head.' Regp'vsf we' r?M9v*@t,
(we 1Uu-m).

W,
lw and e ~ h e u ~manifolds
bh
9d
t.
- dW
d ~ c r i hIn o
+w:q?

a r ~
n 35.

-iThe swem &rtdS:bboftliw d o n s .. ,alus

iheh tb%jktehn&d&-w o n
mn be d$&@bted frpm We oatalfl~
*@, In-pmbM, WIG &en
d&o-
i h ~ @ % n gIS a Te.~Mealof remgval. Ensure miw'@ Y
m & . ewhiile ~ s m
p
wm OM wyr& tb

2
md ~IIW
f riecqfons on ttie bench.
i t h M e Wllnder head and manifold m i q g 4 E x l t c l b s t w h clatnhs and cormactions
aqd w a new g*. &e'bm
3
---- -
~ E Wwj .
penetrating oil or releasing dud before &w@g

a &l$o converter (seeIllustration).

2 Onmodels wlth Mmdicor amerr-bar rear
.%the rear $&ion of the exhaust system
~ ~ 4 ~ r s intact,
m ~ but e must
d be cut.
$&r@jfely,, .the- rgar axle and,
'$@* ,hb uhbolW, and IW-P&.)
$e&oIls flaw an anaddl~onaljoint,fn;iiie
$@Y which passtls over We &I@, The
doMptp.and h e intermeObt8 seotior~can
b removed separately, I.st~vlwthe rear
sbdlua 'in place'tf wished.
.O)IQR dlQthYmodels9komWe dawnplpe and
the r@r &iam can be fmovkd leaving me
,rcrmJnhg axbust sygern In position. 70

i SHrd lhtshleld 9 C a t a ~ ~ n ~
P Sdlngrlng p int&md&te,Won, 1Q AB1vsWion @-
3 DomW mnt W o n ) (Wghf-h%ugh) 7 l Clamp
4 H&&Ud B In@h&ab w & n (lvlth 12 &bbwmw&g
5 Haef8frkid expnslon dalembj
 ~ U wygm semorrnulfl-plug
H when temov@l.r1sp a ngw seallnhl rlng at the Icifwmdf&sSW?&QP
g ~ m l -re&
e t~ Pact D dththls CWpW: wkuit,,m&ifdd, [see,1IUt~st+lm). Whetl
,p the wtmb qstm has been rern~vd, ap-le, &O use. a new f4alW.t ai the Mrnhal
mt n wfth the yariou. dsrn~q m d !@pic ~ A W ~ TW~ M
. f e tthe 4ymsn 11 To m v r the intmad~~p!,$@
ko)~firntrnIgase. Begin tighteniw at thb sp&re tlj?-n? @peif @fr,to tm~vft pr r f I & y W the rear &tien- 8g
exhaw manhid, and wwk fw,ar.ds#art J PW D thia.&apt@. T t ~ w tlw n manif+ w J b & pmbuw Remw-tha mtl
pip, mspri~ that the system hangs a l l y nuts XO a3pgrWs the sprinw lldlthe nu& %oh ~ M i W-Wi h 4 h ' e 5 . d a l p t i c C'W~
and witbut shin.
aoHltfp7m
b@ qainstkbs$acws on ther sWda.
we-
the>i m m m aecttbm. SlW
munufig pft the barn, *~ wbber
jf .Ilmpssw
famove mrn fmm the underbo* by turi$rlg
MS: 4 new menito/d-to-#ownpr~eSWIW R e m d l "w
t h b ~ &W , thq~~medf&
f l wr(l
~ WUM. and madel's.Wt.9 To fis hmswfotl, rdm f i e i&&ti#t"fYfih the &sI#~u aonWtW, -d"t$rB
' W W o cOnve*M a new downp'psXQ- ~ h a t S W d (SH
clampwj~h Smums to the )nmmea*& s#ms h h b ~ G I T I Q v ~ithe
mwm w'ibre90ked~ section.Aide the rubb@mountltgSQ% the jl1-m)-
RmnW8t W,anu A n ~ e c w a rmomthem%m
y, ih
7 TO rmover the d o m p l @unscpy
~~ and u n d e r W & ktmiiiq thm@ $0' [W
rein'o* me WD nuts, t k ~~ Q ~Y B the ' Illusmn). @parate the
pleem t g t e ~ d h t e $iamb, gutting the
and ja Rmg
Isra,rwed
mwl; aghten
Q~
whw, tension s p r t w fh+ ~ 3 Mts
4@ ~ k l y , a ; dW4j8
-.
c,@
'qb@,rIna be dawnpim to the mtfddw@ # I _ h k ~ d l q ts&bn
e if neC=ptry to dear thb m~ntrm:H
&$Ls&
the fmgWpMkl aTf w nwimld awrl$., than r&r:&Th [wp#agrwh 2).
s+r&Ke&e jrrhrt, rqqv&nQ zh%~mtlr@ %g: hg
~ a . t h e d u~i' ~t y b d t ~ w h t ~ h ~ , tua
h eRr e m g a f . t h ~ a e c t l m I s 8 ~ o f a?&@& g O h r n m P
'riampfP@ the satalfi'o convertarn &pvd, U$&J a repair section wjfh an 3y &$&$btP~D dtb@G
h w fofdddllr
&Et the h&t gum if necerrsary. >addWanaljaIH if n m w . Tighagn the Wghg to th& p l f i p
,W.,@@ufio'ris
-9 ckhpb) sdurely, md bnew the rubber &~&k&
lt !s ~~
Inthe W% same
I 8 &iY#tltq of * a downpipe Is 8 rav~rrialof rnouMngs*nwes~~y. *iJibpdbte don,
 Fuel and exhaust systems - multi-point fuel injection models 4 0 3

1.1 Location of major components of the multi-point injection system

I Idle speed control valve 5 Relay box 8 MAPsensor I I Cold start injector (when Wed)
2 Throttle potentiometer 6 CO (mixture)adjustment 9 Evaporative emlssion control 12 /gnltion module
3 Alr cleaner potentiometer (when fitted) solenoid valve (whan fitted) 13 Computer (under cowl pane()
4 Ifljectwdl and pmsure regulator 7 Coolant tempeature sensor 70 Air temperaturesensor
I

91 Disconnect the wlrlng plug from the

MAP sensor. .. 22 ...
then disconnect the MAP sensor
vacuum hose from the Inlet manifold -
2.h Removing the inlet alr tnmking ...
i 13-type engine

:24b ...and the air cleaner-to-inlet 2.5a Release the rubber siraps ... 2.5b ...then lWt the alr cleaner from the
- engine - D-type englne

d
manhld trunking D-type engine

' I
 -
multi-point be1 hjwtion models
4C*4 Fuel and e x h & t i & , ~ ~ m %

,B Mscmn&cl the temperature control r.ubbw.stran*.&h~b,the qk Wnec -In% the lug9 qf the- cable end fMhg I-
iy+uuml bfrom h e valve. on the drlnbke then wlihdRw.malr oleiikr.from under tha3 k&ibh4:4 in BBffMs-tM*
.busin$ 4 ~ ~ w ' t h g p bI$o4hthedna
l e bay,and
10 Remve the two b$ts which s m s Fe rehwe't dn'sqngilgbt-hand-drhre modelet
8% &leanerto the b a b w tray. the &I& is qdd through the engine dghh
I t L% out the@r d m ~ p ~ e m b l y , ~ f p e ifi n gw m ! ' hand mounfieg W r rIn khls .eass, the mW
?ram fhtt.coM air @it&-lap hose& thkt)a. must he ~ , h d w t o 2 f m f h e 4 &
dt eteqner elemant as
12 If It Is rmw@eq ?o remove t@&d. *it
,pfclcdp W,W e a s 1s. gained by ' ~ v l @
h ~ ~ W I A 1B.' W ,Bsfimng
<& t& nut w h ~ am
the frrrnt part &%w whaet arch s p h h shldd. dmec homing. Free the housln~
~ums the-air 9 RM#,ky reverglng the pernaval apemtlons.
from the Eltr ~dlust3B cable B TBBFPSW hi forlow&
The hDsa canf i t h e n bs uni:1%pea* I&tredu& ahd -raw i%
-hg RWng
A#ustmemt
13 Reftt by rwwelng the removal operaElona 22 Refit by revBEing ttle rermvd ~ ~ 7 Cable . 18 carried arlt by a l t d q
s adjudment
the posttim '&the hahin din en the uutef

Nate: Cam& ~ d l ~ s f m ed
n tthe m~etemtor klckd~wwnswkteh ?shouldonly operab when
w i d3 * w !Jwlsdq-d m@ f&*~rn
a ,&M Me mr@Ue-WW~n. UD>F!@~adjudrn.f!,JJW
lf the@ jg d t f i h W!rn d"m * fm
w@lpr@M.If lht!AWb>dou&.cmwIt4
~ieh&-,

a 7 T @ ~ n gin me engine compartmqt.

ii&w me screws and the hut securing the
l e a t InMe pipe.
& ~ p l ~ t t o - t h r r r t tbo&
dlsoonm fhe end.of the dlpa from ltw

~ a j d h e r ,'-
:+W W&hw under 'the front wing, @lea@the

.
&m-.,~hdWthmyv$h;air-r-
+&engine
 Fwj and exhaust Sflterns - mu&-point f ud injection 4G.5

qrR@ +@ ? m ~ , W m d if
- it wpperurs that fhe fault Fslo p $ * p
d j ~ m ~ @W-.
m m ~ W6m OF h the c o m p u R~ dl pbahbV@
JI :%rat% @m.@*:ptent%~eb@, mqe to mnsutt a Rmlkwyd@&
4% yf-BBWW&, w @tW slpMalish than to mtsM on s hlt*
hj @ ~ - ~ , d d p m ~ w i ' f d t ahd7tdsspragmma d uomposlent ran@,:
IW@F<~I*J. '
Qn the b--ly@emtl F3P enolnes, the
UrnpUt~&0 ~ o ; S i g t l & frQm
b S kn@f
se'rrsor hlch de t#s pr+$nttltlan @inking).
Thb belongs b 3 s ignRiM side a? thd
sysbm, and is coMrad fn Ghawr 5G. The
o g p n wsw,la properly p@ of the ernissipn Not?; @*G$p, wepnlng at the end of
contrd w&C, and Is cO'ver8d In detalt in Sedbn f & & l & @ ; ~ ~ m
3 FW~ :
iim -" -- -&&i ?* W&
dllntml the Wm 3Wh-- &fij#~p @ not runnlM.

The multi-ppInt fwl inje@lon sydem Is

fie@ io all D&p engines, and all Mype
W&q,-@We wfth mane aode QP-
Zl$ (!&I& ahe the single-jmiM fuel lnJ@ion
lo Part 8 af.m,Cha@tr).
'FMmderlng Is contralled ehdmnicaly Ijy in the under-Mn
a mmputer, whlh miv@ s
Ihformatl6n froxh
wrl- a-w: The computer: also wbls
the idle md rnrmpges theAemlssjon ~tstcrrfermwa m ~ w 'MIWW
m b l and @ihn systems. fromhe- ~ a u s ~ $ m m rtso,debmine the tfiatall herel @%&ura
hhs bem-&lEvh
A fuel InjeWon system allawB prscl$e 'wanWuFfWMii& mud & e;lrdwtdQb wit 4 Switch of#the Ignitfort wd @fIt:.thp.&J
m m l mrwr ttwdr-fuel mtia (mlrdure) m&r pumpfuse.
i$i+ a p w n g 'mn&t[~~$. Thls c 6 , h ~'iIS Fpr thjs pypuse, the ~oluk;d Ihlet alrAls
*$Tt h kwp Mibust emiaslons t o a, calmlabd fmrn,the engins speed m d thrMe
mh!murn, and fot'the aoRect opemuon ,pnd m 4 o n .dmalg, W b . a MmWdon W g md&
long life of tho catalytic converter. AddMona1 for Inl@-aIrtempmture. Btra mri&mernt is
hIKNp frm thd drlver"apaht pf yew m prW@xi M ttful~adand during w m - i r p
hpmW l u d eoonom)c under dl cdndltlons, Cfarn~m-go Is a h tmc.aeot the *daf
q@.bWWdd~Wtb wh* >old, Nuts: Rdfer 1 the Wmfng at the and OF
fie y t m Is best wndmtaod If pmeWMd ~ f
W s ' k b m V pW:We fuel supply and T + @ m d f l bW q u m
4h'ec-m
e ftrsrl mrn as d
~ e p r w w j s the m
Secti~n7i rememberingC rrgfk,the~fuJ
om,one per cyllndw, are
@jp.
734 dnf&tom m located In the lwei
*~ wq d yaI , the Mb m ~ .
n P IlWalu4 ~ $ i h ~.with $, a
~ l c 4 ~ n v e r b e8.rJ, k o l dstad Injmbr
&g when the starter
$ &d'lmlant temperature is factom Woh as mirre'wew. We svs&m>i%r '
$ha I n ~ G @ m - ~ t $ f war n a h ~~-~orr~ngh &angm m a i t ~ h .
11,: whkh also WIW Wulp fuel All later madekars fMM with ahfuel~~im
mrn w&W- fuel C Wmd ta ~Ut-offwwah mb15),wl1eh am &
Q h rtm the fuel suppl in tQe eventaf We v&T~te
being twaNedY in m Impaor. The ewna
canpot be m d athamit&LMmd
The injeotton control sub-system m s k $ a the switoh mwt be manually.
-
of the Inj@doncornputw and IC amQclated
~e wd~a*rbhF:& n l e r n t t ~ p @ ~ d ~ ~ h&

wmrk&wm#mMm-
a
L a m&~t@~ I I M I- & M , s the -&nisal~m In the event sf a daurt dmel , .ng~%e
8dtrol hwsk m u o t ot dlsgnast/0 W ~ ~ ~ C ~ " ~ " , E : ~ Z ~ ) W
homer n h r t h b IS &M..~&j@&&&nl&~
.. ~GafIWw ~ ~ ge-~ 9 w b.- c ~i w W ~ i a ! W~1-t WhMt;W-W
k@h't-mr!:,!.Pn mMs.@i!in-@ a failtt tf&ty and,,pr&mb, InMd' fault-
%
?@Fl' M-cig.hh.EOmpUter L l o c a q lqsm finding dwclrs ~ b u l ~~nmtrate~werctwtd
d
tha q r , Ijblpw the gtove?~.) lt rem'Kcc~li fe&omI U C ~18-1 blwked fuel h k , loosn or
&hals Tram sensow which monitor the m d d dWcal mnnwtiow end t w or
UmwFFd WJZuumROW,m m w also rn@
inw- djptment d W&Ww &b
can @flW omratipn of the fuel I n l d ~ n
 4C*6 Fuel and exhaust system&- multi-poiht fuel i n j d o n r n ~ d d s
-

, g e P ' f f iit.& mi,i~,fiont

of the I&-
~ . I ~ & @ & $ i I '

d@pp&*Sgmaamount.
g ltdh&&retehdlnw are )ow, check the
p@g.&hqy,.as dv-ibed in ~ c t bB;I i~
s % w H ' t h ~ f a i r ~[Bt In.t l s ~pump or lhtfie

ReWW W o n 10 In Part l &.this m.

_. '-

.mm mrno.vd
+-,-out a grqsme &Ck a+d & W jn 1 Qn mP fl6-vabJangina models, p m e d
as;folbWs. -- - - - --- --
rdwn pi~&tool ihs 4 -w#i~ fuelsystem desmlW
-&%@6ho~% h t & d & n ; r ; ~ n g t o ~ # t & w WM M h n
pkbthths&IePrQ 1S7 pump m,e. \. t mere a* twQ f ~ eiwia
i on RP (1-e)
d I*I@P'~CW @llf* b) Dkmnneat theJu~/Wpr'mfM mIty m.@& wmah tank rn! an aufllary
. i i i l i s l b @p w b fvd 8f3IWr W s l i t ~ W q W d ~7~f r~e j. W
. r y . mKls f
pump nm by brldgRlg
the f dei jwthp'P'iel@)
q r r ~ M + ?-antI5+~f
s
&sc@&hWm o w ~ m t b n .
#! p e the quantity of fuel delivered in w r l y
u,
-
C) c ) ~ n m u l mw n&Ee ttt@t
p
mefW@p%md#w th.ohwend
- -:tbehmaIn a s u W cmfabr.
b) A ~ Wme
mt~ a [awr b e 1b a n tha maln .W.Whein fillhg
with fu# the fuel fnws dowq tk filler plp
into t tw*ttary tank, Wen Ytlhugh 4
mhn'&ng pipe Into the mln-tmk A flap at
I&s w n c t s , C o m t vatu= am gjvm t* * p u ~ bys
t ad 5 on ms w m p n*Y Zhg* of +he ~ o n n m g pipe Wwn& -1
vrinnihg'iwck out dpwwdn tank
n

2 In ~ ~ p m t i s ~ f r t s t l i a ~ ~ a w n f r o m
W k 3sy the bd;pump. Wheh &I
Iml,in the rmh t a n W s to a mWn pdnk
thgadtWyTu1pu~4uns~.4J
~ ~ r f u e l f l i 0 m t h e W ~ t o ~
At $w Sma'tkh~,ftre' 7~ Welswming:l@kt
Ill~umimbs
for 5 s w T b o u r X [ i k y pwhp
MIanly owmkwhen Wevine isrumtirig, 6t
when thestarter rmtor Is cranhhlg.
S W bofh.tan& we atlqwad to run diy; lf &I
 Fuel and exhaust systems
x .. - multi-point fuel injectim
I .
w '.h 4F?7
8 .

8 Refit by-M.imV@ ~IItbVdoperations,

when necesaty.

use ddoated test

oathe W n
in thi r t g ~ h a h d&dofthe lntet rnane&4dl
Q Disconn& the inlet airtemreiture senior
ehwldqg the opptlon of the computer,
2 Lhited M h a M.indMduat w m n & s is
w ~ 9 & $ r m M g ~in t h 4 ; y g n g
L@ma%?,gui6to $hepwnar wtw spurmmT,,
~ , t o : ~ ' ~ @ p M m l nOW
, d M wm*it.wsUUban-=Wb
a y ifa fault
a fan heater to rake the
and checli tn& me wiaweii or the i
@1k$ kq.helprpf 5 m%u!t dealer or 0 t h
meckikt f o r . w n n s i s of a fault.
 referendd f?
or 13.
Fuel -I
B
y ~-WV& ' ~onnbztw~ Th%appropti* Renarflt.8pecKal
Note: Nm p will Ire requIr&d
bal (MoL 11M I-DB SIN% Qhrough the
OR
1,
=I
refitting. wnnedbr collar to tff *e a w i n g tus,
28 Deprer the bal w&tem ,? @ySlt+?same effW can @ acYiiW
descriw n 7,.mdiaopnect the shall Mat-bladed %r&y$fiver tv let-a %a e
battery nay- -. Ilrp,uMbthaf=me madH%have the R y d t
29 Sdprl& @ tWo halves of fie *&I sgwlal t b l built l n t ~lhe hoss conneaMn.

IpfueI dm prpfmn the fesd IwecmnmW seewing

Mi-Dtvpeenrpllff llq#!s.*.

1 15.m Release the injector securing
cllp ...
renew the O-rings at the top and bottom of
each injector (check on availability before
removing the old 0-rlngs), and ensure that the
fuel feed hose is securely reconnected (the
connector should cllck securely Into position).
F3Penglnes
I 45 Unscrew the two fuef rail securing nuts,
Note: New fuel i n k t o r 0-dngs end new fuel
rall-to-cylinder head seals wit/ be requireU on
dor reflttrng.
1 the 37 Depressurlse the fuel system as
described In Section 7, then disconnect the
Pd"' battery negatlve lead.
30 Slacken the hose cllps, and disconnect
the fuel feed and return hoses from the fuel
rall (see illustration). Mark the hoses to
ensure that they are reconnected correctly.
Plug w clamp the hoses to prevent dirt entry
and further fuel loss.
1 but ,. 39 Disconnect the vacuum pipe from the fuel
pressure regulator.
40 Disconnect the wiring plugs from the inlet
air temperature sensor, and the Idle speed
control valve.
41 Release the engine wiring harness
connector from the bracket next to the
expansion tank, then separate the two halves
of the connector (see iliustratton). Release
the wiring harness from the bracket(s) above
the fuel Injectors, and move the harness to
one slde.
42 Dlsconneci the fuel injector wiring plugs
(sac Illustration).
1 4 3 Release the breather hose and the wirlng
harness(es) from the clips on the fuel rall,
disconnecting the hose and/or wiring if
1 necessary, to allow the hose and hamess(es)
i 15.42 Dlsconneetthe fuel injector wlring
-
plugs M P engine
Fuel and exhaust systems - multi -point fuel injection models 4 0 1 1
15.35d ...and remove ma tuel Injector - 1538 Dhonneet the Irrel feed and return
D-type engine hoses (arrowed) from the fuel rail -
F3P engine
to be moved clear of the fuel rail.
44 Unscrew the two screws, and remove No
3 cylinder fuel injectar clamp plate, which
incorporates a hosdwlring harness bracket.
Where applicable, If not already done, release
the wiring harness from the bracket.
then wlthdraw the fuel rall and Injector
asmrnbly (see illustration). Recover the four
fuel rail-to-cylinder head seals from the base
of the fud rall.
46 To remove an injector from the fuel rall,
unscrew the two screws and remove the
injector clamp plate (No 3 injector clamp plate
15.41 Releasethe engine wiring harness
has already been removed), then pull the
connector from the brackef and separate
injector from the fuel rail.
47 Refitting is a reversal of removal, baring the two halves of the connector -
in mind the following polnts. F3P engrne
a) Renew the O-rings at the top and bottom
ofeach injector. from the Injector rall. Be prepared for fuel
spillage. Ptug or damp the hoses.
b) Use new fuel my-to-cylinderhead =Is. If
5? Remove the breather hoses and pipes
necessary, use a /Me si/icon-freegrease
whlch run from the engine valve cover across
to hold the &s in position during
the injector rail. Also disconnect the vacuum
refitting.
hose from the fuel pressure regulator.
c) Ensure that the fuel feed and return hoses
are comct(y reconnected as noted b e b ~ 62 Unplug the elecMcal connectors from ttta
Injectors (sse Illustration). (If preferred, this
~rnoval.
can be done as the i n w o r rail is withdrawn).
53 Remove the single nut which secures the
Now New Injector O-rings wlll be r e q u i d on Injector rail (see Illustration), Withdraw the
refitting. rail arid the InfWiors.
4 Depressurlse the fuel system as 54 The injectors can be separatecl from the
described in Sectton 7, then disconnect the rall after removingthqmtainlng cllps.
battery negative lead. 56 Refit by reversln~qheremoval operations.
Remove the cover from the top of the Inlet Use new inlector sealing rings H necessary.
manifold. Apply a little sllkone grease or a slmllar
50 Disconnect the fuel feed and return hoses lubricant to the seallng rings.
4 0 12 Fuel and e&ia~st-t:~erne -

.. -emrt(arrowerJ)-
F7P (1&vftlVe~engine

'iqiwt em-
e J f l p# m r B l & W 8
@ WmnndA%.b&4~&@d I d
& R ~ fieMbmri8t1n6h bonnet hinge
~ e r n ~
r ~ in~Chapter
d ~ 11. b d
@ fit Me&&of fomrds. Disconnect fhg
w a n k c m e wtltation hose from the Inlet

a Dlsaonnwt thwMWfy negathre I& w D l s m n w t the~vauwrnhnse fm tb

D k m n W €heoorttrd 4 v e wirihg pfug mwdt'.
(aee Ihstmth). 74 P r b bffthq <,@ sewring the pmw*
W U n w w the two -ring mrews, abd t%Wlatbi,ri4 he I* MI, "then PT$lp
withdraw the wlvd from tXlebinMm i f o l d mWQaukafevthe" ~ m s u m q u h t a r Wom-'i%
[wllmw. R e c o w the howIr@,'Ngte the pa$It@n QT the Qac<wry
67 ReWng isa revers107 removal, but USBd M s p WF#BC$IM
~ w W the rqidatof js
mA- rMqInwmrr& p@W. RemW'tw .. > I gc.
*P ( ~ ~ ~ v r y P n e s %fhiAg s re.vt
m e p bls m (-w$@= ' bp
61) admnnBZtmDtMy m mlead.
9 D v * @ m d - ~ l ~ h-odt-w 03 gnyle*t
~~w#w'FW, @$J-r
7'0 Remove the clamp whlch ~aeuresthe
w&&&@&ph@
p m
+mly:
uwte - u r n h@ an-n'
q
Wi*,-an&mi'~thai the dk$p,%
lew 'u
rerrp a
valve. DWgrin@f .tfre WWW and \yifhdraw f l e m ~ .
the udu&
? Rmby W d m t h e W r f i 0 ~ 1 ~mp
I ~ ~e. 6 , ~ b
P~e!pmpStJm WfUr-r M a blew 0-#w$will be rswW 'h'
M&hg.
D-@W mifis
~oae:Nmge wlllhvm/ibm'&W@, d
DepweurW 4he fuel $&M3
dWW Sn &won 9,+*m ~ d i ~ 4be
l m
:+
72 Depr;88surba the f ~ k l wetern a tM+wyf@iw I d4
&scribed In S d n 7 , then dlann&k thk 77 Rsmeve the' >iudraN and I n n- ~ t s
bHwpn&~IIrvrr*M tkdherd pml&dy hr "r W o n .

-
wdwwitbg ptug F3P JQIW
'

G
I

( -
Fuel and whaustsy&ems multi-point fud injection'md~Ilsr i W 3

the two ecmws wnlch se'wre ffie thrwe

pcltenttcrm@ierbee l l t ~ o n )Remow
. &I
pobntrwnww:
#l by M n g thcmpwat wperatbm
If a new paPentlmater hiis Men flit+, the
c o ~ r ' w ?heBRajemt'~~rnwr
! ~ wiper, #d initial s M o g af t&,,potenti~Wer must b?
emurethat the potenm& Is fitted d t h lhe witid using Rmauttt@tM $R%.
wiriw im t
o w the atr intet Winking, 11 a
hew potentlometer has b m f@d,
sing 07 the pp?wfWrwtwmust kuerwd
mh~al d8 nesler
-
F7P (#tvalmgJ englltgs
-
udhg ~mM&t.boxX&.
IW f8-Vimhr4 gtr@n&

hwhs b m 'the
-throttle.h o u d n ~Tor
,

F7P (le-vah) engine

-
~ ~ U r r r ~ U I ~ ~ C W U M

m w a 1mwedl- F7P flB-valve) engine

4 0 14 Fuel and ext~ggstQ ? @ -~multi-pdnt
P fuel inj&i@lm models

lLtU@b-g me d t h e mmputsr
mountM&pl-- nuts D - W p
wh-
-
of ththe s ~ ~ & ~ o M ~B&Pl @(9cle I#[m~n).
For aabtb lienrnal procedums, me EMp-
t~ r-e.
# w&g&m14
r jjippd ~ntbthe a l r ' h m i n e 8-d -el) sensor
my;* -* -
tw !+wd&&i&Ibd in PartB, 14
& @&3im 8 4 wltlng plug f?nl-'9B
m m +mdlsmnect the Ws8 vaculrh3 bt'iWChW6r.
6- M m the Inlet manifold bxi!p*r
X(1-ns1.
w blase fhe two seeudng c;@s, Q-w'n*
a d d d ~ ~ m at o b ~r d~r d d -
I
$Of Remove the battery as de$cribd In
mepter5A.

akrm-I.
$09 Carefully dW the ahield from the

a m CBMW
the
@
I$
*-%bo
-
-$t&&Hk&~n-Wt 3,w o n 14
 Fueland exhaust systms.- inubpoint fuel injection r n W G +ID15

.#ha&&-r bwatbr

Plugs, the. s~mtaltool CURdrtto the ttT . --

kd h a ~ l M h ~ r e ntasGhaptw
t B if
ce -
1A or a p p r n p r b * ~ l & q & t ~ ~ ~ ~ 9( ~ & ~

4 lJndip the~wppsraa~llon ofS#e HT Imd

~ho&g, 4~ m w t h e HT b&dmr of the can be auhkived
'Mid mmhld.

I
b&peeng!m 6 D i m W W ad V ~ W M hr-F noses
WY New.r
uw w s will be mqwfw8"m fmm tk&hmW misWs&naEd valve {aee
@rn@ iUWrathn).
8 Wsc~nneattha vabe rover b M W t hose
wow from the.lnbt t t l d (seeWustrablon).
!~ d the fWwY @ p85 d?m+-b@ 7 DIw~nnactthe brake w o vacuum hose.
fiiA$&tl$fl 7, .Hlgri d l s c a n m the lj,tkky spd the rnanifald prewura MAP) senmi
2.:&-.m..-< {.
vacuum t@mfrom Phe inlet m%nmtd (sea
I , a&d%&W dm. ,andh i v e YhI dr 1lhmWtion).
8 Dl%Qnn&t tm fcxgsl supply and . r q r h
lWes Wm-thelhl r$J. .BBprepared for fret
Plm pPBmpft&Yrds& t6 Wright
iad M h e r fuel @llagg;: TQ
a a m tbdl
 4C.16 Fuel and &taust q & m s - multi-pointfuel inject5011qmodels
I

b) ~ m t a n d l f ~t a Q Mark
h ~ the Wq
q to emsw that Bey we
~ i~ . ~ ~ : ' A . ~ R c ( P r. ~ w, ~lujl.~:k,wtti~w

17 Y@YI @w'manifqld,@r am--to the tviro

bob recurlmg mh
to fUel @I b the manifold,
t8 ~mmw&ek o W Pail ssurliTb mP.e*inm .8~nwrmkirirn h k I tKp fw! Y-
om& W ~$euumt @ ~ f f P mme fuel & h u ~ i wbwe, and$e . irndi!dIer
&*mw
rqula$ar+~#%nMthdraw the bsl
(aree W U ~ ) .
N%:,A paw rnankdd wet, and a new m:hmfk
mh~ust& w n p l & w t o - d gaskt ~k'il'h
7
e
fw-hand
%-s&&%&d mmlq
UIbwillngA plqs%n! *w-m
.rg umbbw fuel supply h o b fram %fuel muMm d w . femwratwe wnsor, the Idle speed CbnWl
~ ~ ~ m ~ B t e #withdmwthe e ~ M RdthUvtrI
& ~ and the th'ipMe~wtlmM%r-
ma+W(sse .)n-*
~~g
21 DqraysurIee the fuel system as 27' 9b
Wcjb+,ln SacSIcm 7, #en disconnstcr the @
u&,

i
t-
Thp h~-dip,,.md r d ~ thb
air ' n d q sonbWi$ the, aVr l e l w
e
bd~*tve bag, ww,
mw*hm+ihr@p
p &&
,heq
hoseldp*.mdd i ~ ad~hqllpa.&
~ mfl bW nd
~$id ~j,"$km3
b
fuel t& and r&rn hoses frSIrn fhe fuet MI. a % & $ & ~ d jn,~
~.prn16 ,

L .

37.16 Li the manifold from me

-
hose from the connector D-hlpe engine head. ..

-
wlthdraw the manifold D-type engine

I
 Fuel and exhaust systems- mdti-point fuel injection models 4 0 1 3

R m d 9 RMiov%f4h@smbrlng nuis and halts, and

wtbhdraw the mmbld ffom h e cylinder Fr.
43 Remove the radiator as descriW In
Chapter 3.
4 ~emovetite main fuel inlectors and the R a Q
Recovwmagase,
.
ykb
-.
wld start l"jBctor;as d m & In W b n 15. 10 Mil by &he momt operations,
Remove the a t cfeener as demrlbed In using a new mgjfo!d g a p and a new
section 2. . .,.->T
rnanhtd-t6d&vn~lbwasld: I

Remove the aItemator, #a desorikd in

Chaptar 5A, and the bolts which mura the
alternator bracket la tathe-manifold.
47 biamnnwt the remaining hoses and
electrical mnnwm f.yn the: manifold.
UnWt the maniPdW ~ ~ t n undo g t h~ ~ ~ ,
n&md,wlthdwtpe magi@d.
rnmraI hfarmdan
-. 1 ThB W n con&& of three &low, and
r
48 by the m@ omom, on all .except some early F7P (I 6-valve]
wing a new manhld;g&et. ercgifm 'models, a catalytic convemr [eee
n l ~ r n ~ .
2 Dn models with A3Sandar a open-bar rear
axle, the rear.-n ,& the exhaust system
cannot removed lnlaa, but must be cut.
(Alternatively, the rear -m!e and shack
gbsorbm pan be untxilbd and lowered.)
nuts securfmhrg the RepdrsWima haw@ dd'itional jdqi In the
h&Pe q f i m p i ~ ewwhh &ses over the axls. Ttm
eld to Yhe exhaust Mot&New mdfdd,qaskets, and use a new downpipe,nndthe Intenedlate section pan
d o w n p i p e - m W p s h t wlli be m i r e d be removed $apatatdy9 Imvtng rear
on Mmng. 58dlon In p l m H wish&
exhatist edown pipe-to- Removal 3 On all other models, b$k,fllledwnRipsEW
1 dpply.the handbmke, l h n jack up the f r a t the war smtbn can be r @ h o W I m ' n g thq
of the vehicle and support securely on mls remaining exhaust systW~,;.fn position. To:
stamls (see 'dad?@and vahhbsu-. remove the intermediate mctibn, It Is
2 Worklng underthe W d e , unscrew the two recornmemid t h q @he. war s e e n is
bolts (If neceasaq counterhold the nuts) removed flrst, then the Intermediate- =&Ion
-curing the exhaust downplpe to the can be d m n g c t e d from the catalytic
catdytt~conve*r. Suppml the exhaust mnw@r or dawnplpe. In praetlm, It Is often
under the vehicle wing wire a siring. easjlw ta remoue 'hedhole system and then
B Follow the wiring back from the oxygen semrkte theseeti6nsan the banch.
emor, and sepa&M$,two halves of the
wiring eonnectw. '. i
4 Unscrew the 'eXH"aust rnanlfald-to-
downpl~ nutsiaad disconnect the downpipe
from the manifold. Recover the gasket, and
nlet manlfald from'the wlthdraw tha exhaust dawnpipe from under
manipulate t b inlet the Wide:
5 Unscrew the seven bolts securing the
exhaust manlfold to the cylinder haad, than
withdraw the manlfo3d (see UIustratian).
R-m,@-. ,

ReWng :'il '

new p i f d d gaskets, and we a new locations (amwed)-D-type engine

dowp@-?wmnffotd gasket. viewed with engine removed
 Fuel and exhaust systems - mukl-point fuel injection models

mnW seajibg rlhs MWm0-t-

remove or disconnect the rew asdon as

CaiaWt sum-r
13 R& to Part D M.mC h w d w
of precautions rdating to the M e
converter. ~trs mimed rn the m e wyqs
11 Ta. tarnoh I h W M %~ c t I a n flm
, the hWrndate section.
 .- -
Notes
4C.20 ma ,.
control ownponents - W n g and renewal ....-. .,,... 2 General information and p r e c h n s ....................,,.. 1

orn&zbn contm!
1 The putpow ofm Qvsgemtfveemlsslon
ZQJIWI aysYbb@*i&tgmlnlmise emlsrrlons of
f&$~$;*Thi,@qltA*"Rller cap and hmms
form pa& @ft..&is -*ern. The rest of ffia

Ca&u-r engines
2 Wurmrmdels Brg BqUlmM Z1a
vapaur&epmb(wdehrt'iihg Mdfand d
fuel vilpgur m n r d r ,
3 Fpel v m ' r whim 'firm tn the c a W i m t l ~
mn;dir-khmMrWhen the ahehglm is'n@miming
is dored in the vapour.wmlt. ~ w p w
3 ~ ~ c w / c ~ I ?
A vent
~ ~ trap k ~ ~ c ewpm @ ~m ed b *& fuel
4 ResWctor R PipeMWimk s w b Ilne, and m w 8 the fudCant
4D*2 Emission contml syst~ms

9 When the engine Is Idllng, w unck partial

load condltlohs, the high depression In the
Inlet manifold draws tf~ocrankcase fumes
(diluted by air fmm the afr d m w dde of fha
W t t f e v a b ) through Ihe calibrated M c t w
and Into fha,&nbWn &hmbm.
10 The crankcase venttlaflan hoses md
restrlctors should be pePi6dimlly cleaned la
~.csorFm opmtiori Of the system.

m k r c s f emhsbl CmntroI
11 All fuel Inktion models ewepi early FirP
(I&-valve) englne modeis are fitted with an
oxygm sewor arrd a catalytic conv&w+
These components ensurer a verv low I& Qf
t a k em& In Weexhaust&s.
1&a Crank- mntlhtlonhosm and
~ ~ - C - t y p e e h ~
Crankcasev
- ~
~ hoses
o n
mhwars E-type engmms
.I2 The oxygen sensor (&Q known as
"lambdaasensor,from the symbol used to
IndiWe air/Suei &lo) is b t d in the exhaw
a

D-type fuel i n i d o n emgines F3P and F7P fl&vaWe) engines downplpe. R provides a signal ta the injection
4 Fuel vapour wbtch forms when the engino Is B The syaem is as described previously for computer whlch varies accarding to the
not runnlng is stored In a canister located E-type engines, but a slrnple rwtrictor (or oxygen c o n W of the exhaust gas. The
under the fight-hand hwdllght. With the reattlctors, depending on model) takes ihs computer uses the signal to mlcutate the
mgtnar ruml~,vapour is drawn into the inlet plam of the callbra.tect bleeding wiv@The amount df fml. whloh must ,be InjelpM O
m i f o l d , and fresh ak Is drawn hrte the salm~idvalve 1s located behind the dgbf- ensrum ~ ~ ~ & andrIW &mission
n b ~
canlstsr. A wlenoid v a b l-ed at the front hand headAgM. Iweh.
left-hand comer df the engine, controls the 13 T h b . c t x y p smWP conmlrps an aie~trk
rate at which M s happens. heater, whm Is en- when he Ignltronl&
E 4 y p W injedhn engim swir.tl& on. This metblers i? to reach fE8
6 Fud vapou~ which fohs when t f t e wph&is 7 Shla system ensures that them Is always a o p a t i n g temperature (jn excess 01: 25Q@)
not running is stored In a canism boated partial ,vacuum In ?he crankcase, and so mow quickly, so mducing Wmt~~t-efrlkbtfs
under the right-hand headliqht Wtb the &reusat R e s q r e whld could muss olt during the warm-up phase,
englne running, vapw is drawn into the inl& ~ ~ i n a ~ l fume o n ;armsion and 011 leakage 94 ThemWIytlc cPnverXer k located in 'he
manlfuld, and fmsh alr is drawn i n b the perst seals. exhaust system at the end af the dawnpipe
canlster. A solen~tdwkrs and a callbraW 8 The fayout of the crankaaw umtilatlan @$tbqst brsrml the rnenif01d. It c a ~ h i w - 9
s& b&e&on t h bulkhead, system mrlm a c c d n g to engine type (sw $ ~ ~ W K & I sflu*m d & lw l m l
W e a d f n ~valve, I
control the Mte at ,Whit31thk Happens; U m ) . @wiawsm a w m ~ ~ u n This d . wmpound
~ e - , W a & tIn the m 9 e W of
WPMWCQ) to carbon d i d e {GO&,md
unburnw hydrocarbans (HCJ to w a f q and
carhn dfoxide (Hi0and 602).
Gatam m & r - pmutions
15 For Iwtg l i i and satlsfaotuty operation of
the c&lytOc oonveW, certain precautlon8
must beahsew@. Them am as follows.
10 @ly use .unl@adadfue4. Leaded fuel wlll
p o h n fhemtaiyst and the oxygen sensw.
37 Do not ntn the engine fm long perleds If It
is rnlsflflring. UntxrrM fuel entertng t b &@@
converterr can -use It to overheat, m l t l n g h
p m r ~ a mdamas. FCTthe same mason, do
not try to start €he eR$he by pushing or
towfng the car, nor crank it rm the starter
motor Tor long peFiw.
$8 Do not s t r i b or drop the uatalfic
converbr. The ceramic honeycomb whl~b
f o r m pfi d ks I&md 8bucfur~1may ba
damgd.
19 Alway~ renaw d@ and gadrats
U~BWWI of the mtalytk -Wenever
theyaredisfudwd.
20 Rmamber that the eptaiytlc mnver€#r
gets h~ft@r then the rest of tha mtwM
k y s ~ m . Avoid parking in long grass^
undergrowth ox simik rndtdal whlch eorrItr
PaWi flre OF bedamapd.
 Emission control systems 4D.3

Evaporatavs elnkslan eonfa

lGatWmtbfmodels u-

the'&uWr evaporative emission control

compomnts. Check periodically that ikq
V d r i ~ u shQsss are in a ~ o d* n & h ghd
WCWQ connded. 212

Make sure that the hwes am connsctd g#d conaftfosl, the ,air demw dement must
rnrr&ly. be c&an; md .fhe eog1m:must be Tn p o d
Solenoid valve renbwal , rnscMWw%dh
22 Bdnq thw e@n~4Wmmal o w j n g
a5 bi%&p& th@,h- dwrn tha s ~ k n o l d ~m p ~ ~ ~ i % b n M - W ~ s t&%
~alv%-qg$qIym
f* m . f i b r
* ~ w ' ( w l W &
a n ~ l p r l%
m&#sjm~&a
n o F Q T ~ ~ ~ ~ '
..1 I ' J
.I
-
16 Dkcwrrejtk muM-plug from the v&e. M AHOW the mgfne ta
Release the valve from Its nwwnting bracket # Wd @eSjwiftdiis'h &rk &
1dT4 and &eck the
'(an D - t y p englm, unbolt the valve Worn the C ofUlls Gbpter, as applicabte).Rapad t
*: '
hi
!
b
q l m Uffln~bracket), and remove it dhecrraff~5mbwm.~~thq~
17 Refit by y e r s h g the m o v d operations. within the specified limits, the $@mIs
Makb surer that 'the hoses arb reconnwtBd o p a m g co&y.
oo~ly. 24 If the GO level Is higher than s p d M , try
Crafikcase emission contml the M& of UlsmnMcting the m e n q t w p r
wiring if the CO lev& h i s when the sensar IS
Testing dlswnnwtd, thls $ u g g m that t b QX@?
18 mqrp Is no spclfic tast procedure for the m B a r is OK and that the c1alyk c o n W
crankcase bm'idon mn&oi systm. If + faulty, I$ diisepnhwing the sensor h a no
pfit?IBmBBmB@,susmed (sumtimes fndimtd &a, tW s u ~ faulta In the m r .
by mil e6htamrn'aJlnn of the air cleaner 28 IfadMaIWtnwW IsawaiW,4ke ox@w
4fkm)sntJ, ,GI@ that the hoses are elem msor sMut XQW mn 'b.rrWure21
intehatly, hat h e restrlctors a r ~nnt (terminal E of tb sww rmrHi-plug, or
bl~c~F&-@ @Sng. tennM rn ofthe ~ m u l t c pv$mB- l ~ ~
$XIUW mate,mmbl4M.dW&
GgmwnmYt n~mwal mixme)andote r O o r n \ r ~ m k & t d .
19 nifi,!s sslfie~ldmL Mark ttte various 28 tf Z
bsea More ~&mmdng
hm is m y possibkiky
them, W4here Is hershmmc! h emr,Wrn-6-
h%+w fu$
a@ po~srC3J&~~~wYfu&n~on mssmbly* 'eompwment,.m the @r u+@SwW.Wmls
b % h a ~emkminn~t q : w m w>, lw?&M%rn%:*1fW
mMha&uw. <

20 Thsreertainderdf t k Q S m # morlb wpll89

t o fuel I n M ~ nm&Us
l equbped wRFr hn' ~ ~ - ~ -
oxygen s m r . a n d mtaly!A~m w t w . N ' o t q ? $ $ N@fi-mpmturesnli-seb
cocim% i3ilt"bh 6d7db when mina- the
Tmng m.d@aqr. I.

w bn exhaust @s ma
wi ICQ meter).Mll 27"Mmi under the car, d ~ s c o n n wtha
-M., m l g ~ W ~ n & m& n 4n
~ \ ~ rbe ~(tlyvi-plug(see illustration).

ctatha hoses from the caniste+

tltg we connected
(Ifprdemd, access to the h o w
4 by r m v i n g the rbht-hand
nf the old canW d y , bearing
It may cordah llquid fuel and&
2.15 DkonnecMg a v m m h ~ from~ e &27 the.,qam-r
-
the mlerwid v h D-type engine &own mum-plug
*.
...!. . .
$pf!mlip.t h ~heat shield. J J n m the
&lili&r Yrbm twe, ~LX!I~U@,do_y#@ipe,
and
,mmbh~ ~ ' i l l u s h t l e n s ) : .
the w s o r mW bb r@new@. No attg~~pt
houldbq made to .r@r them.
a i Apply highX&iipg- an&s&e c#m-
m& tb ~ . o b i m r ~ t f i r & d sbritw
S thg
'%&M Ir, Ry ,W,then It &Wy.
32 R e w i n e d the aankr mulbl-plug.
 -
t m M f h W o r W I # renewal .
. ........,. 8 ,Ef@MaJwM,fi~M@

...........,.... 2

hwit ~onoemWI.T M owner whom-4 Instruments when the engineis running.

&ends beyond mere rxrmponent mnawal
should mbMn a copy of Via "AutohobiIe
Electrl~d I& Ereotmnrc Systems MaRualm,
'avaliiblefrom the publishers of this manuel.
t i Do nut allow the engine to tvm the alter-
nator whea the alternator $ not mnnmkd.
$2 N ~ V # utsp for lakmtor output by
nutput lledsd l b m .
qlasfrlwWW

f the low maimnan~eor

 swltch on #Iheidlighbf~r30 .seconds, then
' a ~ ~ ~ f f .~, ," im # - l.7t-0f.m
wdtt four to five rruhtrredbefom PWtW m
'1 'A&&; ? , ~*.&
.
? n
4

1 tihe located at f& froM l m~d

&~PbH.chFItthe '@p~'BndWg@eate Tul4
W When m M q - t h e - k $ q-@$k3n&-wqBIpy.
i " D i 8 b b ~th$'l~l$d{~$ B tm nmgatfve
&~FWB
i t c h ) m d i15~m,wy,
I;~SVOI~S,
then the baby la df&r&, whlist a feaRh)Twntml kybfl'umming Ne*nitiinhg,
r$ading of 12.2 Po 12.4 wlb Indicates a nut and mmvlng the tesmliigt Qlarnp
partlalk,dlsch- emdMm, 3 DlBCmnW$) b q , @ $ i ~.mlM,!881d(8):ln
7 If Me b-rnew is to be charged, cemove It themme*. " I
1 lf ths've~cle covers a sm4l annual mlleage. .$UWCCpy *?.qstq,g'w -elamp bob, r@mm
R i t wolfhwhlle ch&Ins the smlfic aravltv from thadldlei@eqbn 3) and -it%%'
tatq Rl a@BacBon. the damp assembly, then R thb W e r y from
qP lha dwtmrrpe every three morPths 6 -1bd ns L~~rtIon (age Sllwtmib*& h a p $hi
d&& the ar &arge of the W r y . SmdaIpd and low malntenama battwin an u mhtpwhlon, C wold qMilqg
Use a Wrclmehr tp make t h check ~ and -4v * elemo&wprs*e ~0~
. ! p a r e .hmsults with the f d l o w i ~table.
~
Mote; The krllxrW!hq is Intended as 13 g(rJd~ Refittng
~,Wth=a
S ~gravlfy
G sendim assma
& e i d $ e %?npWuraOT MUG QWfi fax PIly. A W a p f@ to f i e rnanufecturerJs 5 Refittmp Ls a r,Wrsal of removal+Smar
4
?VW ra6c~ q g i W i W IVC WP) ~ k m mbornrnmd&#dil$ (oftenprSnked on labe/
4@7*. FW ew8 I@& [$Wl5) +amwe"l#eg
, .#&FBW N~f& g_@W be@ d w h (a~ pgtro@.@ jdly oh, the terminals wben
~padcl KUrn @ , '

m w ~ - * m * (77- . b sWim@p Me battery a$a r& of 3r5 b 4

dbOv&**d 'wm amps and wntlnue to bbl*ge ther b a R q at
FU -' .1-;zr~ m r . m' F . P @ w M, ~ UMII no fumer fise In $v&Ic graW
m 2 w r n 1 d 1 . 1 8 0 i43m Fm Is&zWJw&r
0 r n a t i v e l
a Tour hbur M.
y , .a %jtrjckde &qfftl ~haalrrgat t
m
- Td50f07.WO ?.iMte f,lBD
21 kf h b b&dV CQEIRdftl~rl 18 W p m ; frfgt the rate of 1.5 mnps can s.itf1y W us@
& W . t h e qpw10 gmu7iy of dedmlyte In oventight
each cell, A va~btbnof PA# or' mar* 9 0 eSp&#tally mpld '$m&" charges whbh'q? "fftgtj-4'
.b@twpnany -1s JndIcEdes low of electrolyte ~tafmed b r & ~ m M p 0 1 ~ ~
thed-
&
% ~~
. ""' &d &l nt a' si i%We ~p rr7et rdnWW m *
i ~W i n
ordskdordmof the internal plates, 1 to S hauwm not remmmdmd,. m 4 y M*w&
3 b the specific gravity variah 0.040 ar oan o w wiaue damage M t h m b e W t lfzRrj*t$nMbn'f&dWge) wmmg lhght%@
.an@ $ha ~wttery:shauldtre,re.eneL& I$ the plates through oyeheailng. tq IlurnMgh whwltw ig&bn Is s S & ' c S n ,
11 Whlle eharglng the battesy, note that the first cd3k the &mhi@&th~ attgn)aw4ir$133
9 1W i n . s ~ a c 4 p r but-%
y battery Is
t;empe&un a f ?he atectfoiyte shaW mnnw'@t.rs, If &factory, &heckthd.Ptxe
~e~diaqiA,tt ah~1uld be ~harged as ~ B J
w&ttd& l i ~ W b i l b h ' $ h t . ~ t ~W-thf! a~B
$&p%lbedM w In M iSestlun. ex
- 37.8"C (1W F ) .
bcrl bhokd* $ secu~eIn h lmtbn [n W
MalWm~nm-fw Xsrrt&ryn I m 8 l l t p e t . a th(9' l@h* 'atk @
-PbmIng Illumhah cb&k the mntfhu~ af* wsihfi
m.w fQUo~&i@W'lstadstad4S~~df7(~. rrgtnt PW rn wm~w ~ r n g t a r ta.
IN

' m r to ha maflufa- m- br~lbbfciw,~ If. dl dlsWdW& the dW%W

~ t b h s . f ~ p d n t m*,khIwbchad e d 1sat fault, and g h o u E d ' ~m" %~ $ 4~ b
ia*>hwJhw$&smg*&w< a t l t a - W ~ ) a nSElft-mCf t&Ik
% 7hls b - ~ ' wd -ml&r%hly a ~ r n i m m ~ ~ ~ i w m
jfinm ally M W ~ J W S .$h~~&fidWdthe mine 1s- mnnlq, :ebbfie W c i e anrd
jyp, Ure.ttme%km bhg;&p$M& on8W GM €hat h e ' m e W t 1 9 ; r n ~ ~
extent of discharge, but It can I H R w m s@treqrhr 1A sxr:@%dtd W r n o -ablaWr
uptt ~hm days. mhn-n's wqe&m.Jf&il CddwOfw,s@8*
>laA pnnsrant VPB* jype chcharge~ Is faday, w h m p d t ~ ; ~ M & r t h b&ern*
l
wutWd,-kbe&wbn mnrwhd, to .la3 brush= and sllp.dn@ &k+xWxti~n~ 6)*RW
14DWt~ & - G W W .RumRt @low 25 .Fault pmkts,. .the d t i m i i t o ~~ o u l d2M
svr)m Mjng W-method, the ba#ery should r m W , or Wm t ~ m : ~
&:WableubJ.thk'$hw h o r n givinga voltage M n g and Wr.
 s li the &ernear uuiur ^le susijet @efitting,l
-jla Ref&lr@ \iO@WeW @V ff;dualI.&@$@r$
.~ mind the fallowing points;
@ ~ e f ref(mkg
o ~ the aitemrrtaw,tp@~
and adjwfer bolts, ensum W tM
a&rnetorshidd is in piace.
) Ensure that any washem an
:q '
.IC)kr~afw'asnotedpefomrem
:
~&hdtension the d t f W t as
M p J in Chap& I A or 7s.

seeWngJnUt

7 If hW u W voltage Is not as stated, the bWe@lne Removal

faultmay Lw dueto w o k brushas, weak brush
damaged dip rings. On s o w alternators, the
h h m and rings may be ctaecked (sm
,&Won, bvt If the l u l t peeiats, the
@WnaQorehouldbe r@newdw taken .to )an
W e I G M e i a n for tasting $nd W r .
G m enme
Removar
9 Open the bonnet and dtacrrnnsct the
Wtwy leacls (negative Wd fir&).
P.Umava the altematoi ditvebett, PIS
alternator drlmMt, and sllde It t r m the
alf&&or pJl@ as described in Chapter 1A
or Ia.
11 Dlsmnnwt Me witing plug, andfor
d k n p W the urlm Mrn theit terminals on
the mar of the alt&nafor, as applkable (8-
illustration). Note the locations of the wlres
for referencewhen refitting,
3 2 Working at the front of the ahmator,
unscrew the upper altemm, mountJngbolt
(sae illustration].^
13 Working at We w of the alternator,
unscrew, t b -1dwW alternator rnaumng
througkklt, then lift the aiternaturfrom the
engine compartment [see iltwrtratlon).
Refming
14 ~ e f i i i nis~a reversal ofremoval. Reflt and
tension the drivebelt@)as dwcrlbed In Chap
ter I A or dB.
20 P m m d ge:dqtgiM In pawrapha IfEa 3
Inclusive.
21 Unscrew qnd remove the bolt securing
the alternator to -the:&djustw-.Strut.Nate t h ~
&matar rrrwrlting nut NOt.e-~,!@an$@
any WWIWan@sww.
B Wlbd&'tf% % h u g h - M kWb' dW&@
IN? f t w altemgttorfrom the eng7ne.
Remng
nbt& bfom reh?val. 'ktr! and -tenston the
c i t i v w as d&bd In Chpbr l A of fB,
FaP ~ l # € M
*
m d s w h powersteerlng and
-but *-m',

w,B s i t l o ~ ~Ww
bfw b for -cet W n f 0 ubWwywand m o v e the a h r n h r
'ms; t-iPnrs[ nut [loE$te$l.at the tap of The
"3y y m m and r e v 9 tha a w w $ a r -w,,m&:MI*w~sM. wheel -4 unscre#
'&h&ti&r nut '(lamled at thi Yip bi +he I f ~ k f f thro~@h;the
s
and rem6va the &ernator mdmtZnrr rluf
~ @ ! & W @ z - ~ d * , m~ ~ ~ ~
maqmas.
.'5 y & q v * g ten$- m.
~s:srthfhHy, linsti*> and MDV~ the MY~%h&jjd
m m r mounfkts:nut end balt $ o e W at f 8 Wlthdraa .th than ItftTtha
aternator, apm
thebottom of the,abmfpr), hen carefully lfft through shield, out
ttle &emator eon ifm mglna
f h s top d ma angins mrnparMl@nt.
:&&,J
Lr% F l & I % l % ~me&
~~~ Df m o * :
E #i
m
'#at any washers and spacers are l'ocatbd g
oted beftfor~, ram~vpl.Rpfit and t.engjp_n tkfp
. ! a v e i p & ~ t $ ' d $ihhQhaptw@wil$:
~~~
,&type engine
~emovail
3 ~ i s W w , h t -1W bmW?W
bt).
bonnb descrl
m,
r r d@m.+ fmp~~w remove the
fn CKapter 14.
90 Where applkablq remove the power an&* laweaWtmugh~hkbbn
&%rt'ig p m p drive6alt, thdn s8)&kb the remove IhthsLttmmW- D-typa ;enghre
 6Am4 Starting a d c q 6 + $ & W s
-

-
-maI"d-bmu
(mviewed throah k d M r grille ~um-~~~.the.ln~mantbpW
-
pnmh3Cperhve FTP ( l & v a h r # ) ~ ~ mP (?bvllldq l h W

mi -9
S!Q Refftbfns Is a wuerml 'of rmwal, ensuring
33 Dis~Pnneat the slrIng phg, and/or
dfmonmut fhe w b s fmM tkelr tmdnab on
40 R~leesethe -&curing dips and lifi tfre
WiIm shroud. vppnr flap for improved
the w i r V : ,a ~appllcabla.N&
~~, -.
4he I M m of the Wires for r d when ~ 44 ~ ~~
tRtr~&rdrhrabeR and' slWa
m w " rt Mnl thb att#tMm pdlw bs d&~lbN in
t deacrlbed In Chapter 1A or I&
d r b b ~ las
34 Remove the two nuts and b o b mwrlmg Chapter 1A bl IS.
P9P tangiires -
m W s ,wi@aIr condi#aning
the air crrndPtbnlng cmprmsor +a the 4.2 blwnwct the Mdng plug, aWQr
samg~rIaHemtorm m bra&& and q m y t the wlrw frqm thdr iermlnals on
the single belt s&uiWg WaimaZor lotke the 'mw .of th6 z i l f ~ V i @ ~n<@+r&>
t~ 'thelr
bracket; wan wmovw the brzket, l a w f i n ,agp@@bb b= m r i ) .
W t f l o M the bqlts as the nnuts are & ; % $ & ~ IMAT ~w WBbrT'Wm h W
unscrewed,, dm, recov&r-my Washe~s.'aha wornm&@,trihtmmkd ChaW I-
spwra,pletirrgWr.b&ions. ~ilueta&).
86 U n s W the attmator l o w rnwn€!nB 44 Slwken!the abrrratw Inwar mauntlng
nut, wple count-mdding the bolt, then nut.
te&& mi,Wt, ,thk I W ~ S of my 46 U n s m the bott mcurhrg the aHe8na&
wshrs,atld SpEmm. rnnrrmQQl, pH@to W$ p o w r &&ng
%' bfefully *raw the altmatQrthrough pum~?i@r#)lw kk@Gbet appil&kl, tt
~%~he&ltgMaperture. to,ca~qr$#mld the nut at $18
Ram
q , . mks wWl @.pwd. Re@ and
tq@m h . d & e M as &mlbd&Ck&eir 3~
q !l'S@, .and retlt, the 4onfl;st +s de@cr!btrb h3..
TI.
WP If & m k Jengines
Removal
M Disoqnnh the battery I'Qads (hM~iU&
I&fiP.t,. ' mmtmtcmj.
SB Remove the radiator grlllw p#lelmLa#d
&8 4 R p b W the
nub*,and with- 3
a b f r~borlower mount1
the thm~-bolt_from

A;.

~ s#+ 5.w .
w m dr e m o m W e . m r . q m

-
Ed47 ~ l
-l g t
plate FTP (16-dm)q i h a
k i e
,
~ m w unwcew tk-wl't
lamwa) .
D

m w d i n ~b,v k e t S7b (ltfE.wW1engM


5.4% Remove the alternator lower
mounting nut. ..
a '
nsar d the alternator. Nde the location of the
lockplate under the through-bolt head (see
Ilkrshtions].
50 Carefully manipulate the alternator out
'through the headlight aperture (see
'1' L-on).
61 Rdrtting Is a reversal of removal, bearing
h mind the fotlowing points.
a) Make sure that the iockplete under the
Read of the alternator mounting through-
bolt engages mrrectly with the rear ofVre
alt8mator.
b) LWn refitting t b alternatormounting
plate, it may Be helpful to secure the nut
for the rnounthg plateto-steerln$pulnp
(oridler pulley} bmcket bolt over its hole
in the piate, uslng tape. This wNI hold the
nut in podtion as the bolt is refitted. The
-
&4a Disconnectingtha alternator wit3ng
plug F3P engine
Starting and charging systems 5A.5
F7P (15vahre) engine
tape mn be m o v e d once the bolt has
been fitted and tightened.
cJ Refit and tension the drivebelt as
described In Chepter ?A or 18.
dl Relit the bonnet as dewdhd in Chapter I 1.
Note. Check on the avdtability of spare parts
before attempting to renew the alternator
brushes.
1 Open the bonnet and dlsconnect the
battery leads (negauve lead first).
2 On E-type and F7P (16-valve) englnes,
m o v e the atmator as described In M i o n 5.
6.4b Remove h e m b m cover. ..
6.6 Removlngthe plastic cover from the
-
rear of the aartafnator F3P enghe
the head@Mapertum
I7&4 cr: (F7P)engine
-
3 Qn C-type and F3P engines, the brush
holder/ regulator amembly can be removed
with the alternator in place - but access Is
limited,
4 If the alkrnator is in place, disconnect the
wiring plug, and/or disconnect the Wires from
their terminals on the rear of the ahmator, as
applicable, notlng their locarions (see
il1uSbations).
5Note the location of the brush
hbldedregulator assembly wire on the
alternator B+ terminal. Unscrew the nut and
dlsconnect the wire (we Illustration).
6 Unclip the plastic cover from the duds on
the rear of the alternator, and remove the
cover (see nlustrauon).
7 Unscrew the two screws securing the brush
holder/regulator assembly to the rear of the
alternator (see Illustration).
6.4~ ...then disconnectthe aWrnator
-
main fmd wIre F3P engine
6.7 Unscrewing a brush holderhgulator
-
agsernbly securing screw F3P angine
 dl,Wnnactlog the w l p from .the ple??id
blade WPal,. WnneCt 'a voltmeM or test

~ ~ g ' ~ P rmur l d
s Wn~ m r 6s . M i m n W & & ~bkwh
-bly - F3F e m -n p~wot'l, t h && ~ a d iBBdlm 01 1bW
bulb, 4ts dpptkdde. If t W Is no W i n g or
8 ~lmonnwtthe rernainfhq wire *om the m e h q e (seeSeotlon 2) or renevv the bMW. I l W bgb, the 9oIenoidh fawkyanld shauld
'@M&alsn the resf of dhe,alternator, ZYm
l [Iff If #e hadIi$hts glow Wghtty, ~p&qH@ turn bp-?"owd.
.$&W$hh o f d w ~ u ~ tasmbty
or from t h ~ the $nition switch W the W posifl~n,tand 6 If the errcuY and solenoid am p q J
a&We1; (see IIhtmtbn) otSsew& th@ IMte. If they d h , then thls mq$ f i e ,Wtt pust,rke In rhe,qmr rn*?
4 Mmw the promidon of each brushfrom Indid88 f i t m n f is W h l n g the darter In .this went, It may be possdbb to haw thi
rh$ .brush hold& (see Illustmlon). No motor, WsMot#the m l t rnWfiein m'etaller 1raitw motor ovwhauted tyr a g@d.& kyt
mi Imm dlmqslon @ qmllied by the motor, If the I$hh continue to glow brhhtly
& ~CIFS<Was a to* !&I&, d mm (and no #eWng svynd can be heard from the
tarter m & denold),
~
check On the mst of spw& bd0&
ag it m y prove mow m n b m i d
&!#* [$be wgardsd as a mlnlmum. A el*w this indfoates that
I& 'Wrh below this dim$nslnn, the ~!J&IW a @ult h the dr- M sohold see
~ W ~ h holdwdmgulat&
s h membty tariawlhp paf~1~lglph. K t h e WrLer -mDtor
- to o w n a mew or mhmg8mgtlir.

wt b? mmW& Ifth8 bru&es me stlll t ~ m ~ b w When 1 y ,opera€&, but the htbq t s

q m~Beaathem wlth a h l r r n o ~ e d In g a d msrrdihn, then thl6 I n d i m that
i
&&I. qaYhW s h 'S;priwZBRsian IS meP,thegtartermmr h faully, or thew Is
qhdd~rablemsk&n~%SorheWBre In W
$lmiit
8 If a fault h the clr~uitis smpWd,
dlSQ~nnectthe battery leads (Including the
earth qnnddloii to totbe Wrl, the
&&erI&IJpold wldng and the
&$jlfrffinsml&&n earth strap. Thoroudhly
lean 'tha cortfieutlons, .and r a c o n n e the
rhdsAaibd Ut@nw$d a v d w ar W
h t b i far1 bmty . t m g g c
p t01,aa
@&&c at tm ~mepy w+Wve I+
r;OfiR'h&ion b the-mMdI&and that the ewkh
Jr agqd. Bmea~~plfSr~lwm ]ally a p e d t
b
battm'f&li?& to arevent mrrbSl~n;.

f&l$ Ys turned to the wpQprIate

pm&&evSira, paislbb marm may

h&. If they dim atter a few sao~lds, W.~Jmatw-semkln o b fl aml

bg
bates that -
the battery 18 d H a @ e d IfmthQ-1 m-c4ypemngw
 Qrting and chargtng systems ma7

L~W L iRbm6Vttigthe hW
r metot reat mamm wet
'

18 Ungb W, $&jq'*@vk e c..,9 y m h Is

secured in front of bn*, df t e starter rncltor

14 Apply the hndb&, then Jack up the b e htetd [swUlustrrHiW&

frpnt df the car and support R securely on axle
en* i ~ * * and vehm s4pport").
13' Dkonnect the wiring from the terminals
m@as w p n t rnlei*
~
3~ Unscrek lha bolt serruring the starter
m%ltbrrear suppart bra&& f o t h gyIIn@r
~ end of the wlhg is positioned c W of the
blmk ndhgl the Mt ale0 & b s
~Mmgh q a s support bracket
Garefully wtthdraC, the starter motor
dkfpwayg from under the &ht+hand side ~f
.$t3 dar. Nate We locating dowel in the
32 Apply me hahdb&ke, thrnmj*tr:~p:+@
fwnt of the car md 8 ~ p p fitisewdyan axle
w u&hg and wrlae wp@n
startE1B C
- - - - . . -
35 Remove the exhaust hwnplpe as
bj Wheo r&imrig the wMng to fhe In 'the reldvaiw~m m ~ w d
motor. make sure that the t m ' n a l on the 54 ,Urncrew the two sewring bolts and
fernqur?, the @xsxh@dsl heat shlW ,W
& t a rmotor bgdy and surrounding
ill&on}.
85 Unscrew the F o seewng MI&. and
r~movethe exhaust manifold-to-cyllnder
bl&k braclng bmkw.

* ,b$-h*.
$8 Diwnnect i h wltlng
~ from the terminals
on the &rter moior wlenoirt

-
d7 Working ~ndwthaesr; m mw ththe thw
B.MItUng Is a 8 , W m lof removal,Ensure bolts securing the M e r motor rear mountlng
tha+the loGm doW is cwr- positbred back& fb the cylinder blpdc, nat[ng that the
fri'3he belbuehg bolt hole, as noted during bolts also secure the fuel h w shield.
F?P (f&mh) 'engine WlfMraw the W e r mmr frbm the engm.
,Note tbiocrrb'ngdewd in the Wlhwgtn~bolt
Removal haye.
Bmoval 28 Remove the baFery a5 -bad' i~
16 , ~ p mthe bDmet and dls'connect me seaton,$, R & P ~ 3s- ~ v of movd,
d m n g
@@-$negatbEl b d .
,@:$h@G@u:w$ 8-, $Nd m D P B
Leeair orleaner bunking ta Improve a~ces8. . .pW&qdTn tfhbtlbellhodng b;olt hole, as
tbtt m wwin rpddds, R may b6 'nH&dutf@ mhovd.
&&my-io moveifieoomplet~alr cleaner
mbb.
ZI U n s w the khrw>bolts aecurlng -the
qQW m?tQr to the geaeox Mllhuusing.
& h a e ~ l f c a b l e , noie the IomtIBn d
d h g b&kets secured hy thsbolts.
22 h u k m the front of the car and su~part'it
p y t p ~ yGn we stands ,~sm"~amnganu
& & $ b r h .
aS R3,W8 -the .exham downplw' as
$%rlbMIn the rehvanl Part of Chaptw 4.
E$ . U n m w the,bolts sequrtna mthn whaust
~~ahltpldtrear mountlng h~mketassertnbly
tstw :ql?fi&tblock end the starter metor -

bracMii and wlkhdraw the assembly (see &$4 Exhaust hsatshbld s6awlng-h @)
u1,- - F7P (16-wb)engine
5A*8 Starting and. & t ~ ~ , ~ ~ e m s

mw:
5 E n 3 ~ 1 , %e &Rat& thmds am e l m
fht
&dq, . t h e n d t fhe:wwb ta fh~.haltslng
aod b - w
6 FManmt-met W g plug, !beg [whm

h
9'
$59gfarter motor is thought t0.be s w ,
4uld be refpoved from the veNecl?and
to an avto-e!actrfclan fok tw~nj~;
e&-electrlclans wlll be able to w@pIy@nd
bfu+w at a m s m a M i cost. m r r w k
@st
f3t
IStqc~~d-ql the front left-hand siqe of the
cylindw'blbck. On D-type erwln@;'the 8Wch
applhblej r&t the engih&hsmiwloh
undetwfildd6
7 L-wer Oh& yehide to the ground then
hc&%tbe baby fi&Wl h d ,
op the cost of repira'before procqAitQ asit 8 On~campl+on, d y k and, If ngcerssaty,
-W prwe mSwe econornl~altb sbtaln a'ngw top up t h i engine oil level aa described In
- t m t ignition system (G-type engines)
5892 T r a n s k t o r ~ a ~ g W ~ nbreaker
--
v
whim carrtes the full ~timry.w'ent. .
11 On mme mddb; the unnlt ha8 -%o

*4cf &W &~!QYM

-
inthe connector ses 8
~ p e ~ ~ e , - f a I . I fpkwdto
t ~ i s be h thia
trart$islw asslshncg unit. If the fault readns,

2 Thsfe ari3 two rna1fr$ympt6rns L n d i ~ t ~

faults in the @nftrbrisystem. W r the'englne
bepn~rnege4ivedue to 'tile voltaga drop
poht (A)h h d mrrent-thenfl~hs Wudwghthe
War mlletor (0). The rdmm A1
md.R&t@h cWPto W d K a Im

m m .Re csntact poine Br6 used to switch

d&ev#?ehi@-
m*8opSudde$Y$ll
- emion
m t
m
B r e iHtW
at *I, n*
a tmnsMor an and off, and R Is the transistor H
W~ ~ ~ % w ,@jn
%s!w** m!$
bas.of po&F h d ~ ~ @ ~ ~ g ,
f
a 4119 q@uption sertunp, we nof@y'du
tdi .6ii'@'h%
ignitionthhg.
3le
UWnb&af, or fO incwr
-1
a
Prtginns farls to s i a ~
3 If the eq@e to $tart and the erlpln6
'WKS ~ ~ f ~ h p ~K W
~ S &~ l US&
p e n
rrpst uh&?kt there is el h the %iir$&t If
ztra&jfb@tUrns imm#fty on thwstam mow
q n d i k ~ k Y ~ l l y c h a r ~ , ~
maly'b6-ln ewer the high- w twv-tm.ies
cimIf&Fat chmk i h e f $ ~ - t e n s hc $ ~ @ ~ &
4t$$&#tPv mqortums slowly or not at ah ttrls
brrotan l m ~ O n s y e t t e m S a u h . ~Fa&&
B~~

WUne ri w g q ww~96?ykpI.ug I.@

&@htq. R?thpyq ,the,-dlWfburqr;,G N , - If
m A * m , . C d&$ rndh dry tlle,w
wlthafa&andalsqwipowthe~~~~ds.RBfit
?he w3aw~$ly, UIptq 7, *a-
P* &,&,*:-*IQ ?3wma &
wane,
6 t)&e ~ ' s t l l l m w m ; ~ hthat*@
current Is reaet.iing the plugs, @
dlmrinectlnrweh plug 4-4 imiurn'd tha
lwrk p ! q md, h~ldtnQt h @ . ~.Of
d
W@ & a t 15rnms away from We' @In&
blook Hold Rhe laad wtth ~ r u b b t - ~
phi%. to gvoXd,:~teC&b
engin&# tbm
a b c b . $pk8
t motor+
*
S S m b w m W @ * d l h &b&
the b l W - h ~hd m g
rag~1a~ bIue.apwk.lf c b m I s w h i n g *
plugs, then mnoue W m . m8 chwh WIF
g@b. Men the ptugg awrsfl&& W m&i
sh6ufd~M-lfnoR, @#'@ft
7 16 therets no+spa&atthe plW kds, thW
# tha m- laad ham -Be m e ef We
dWla~tw, cap, iand Ihold It b fhe bl=kW
 # 4 contact breaker ignition system (C-type engines) 5B.3
T~mistor+assist~d

I k$ore. Spln the emlne on the s m e r anm frdm the block. Rmtart the erk&e. I+the
niorer. A rapld sucwsslon af bhdq spy& sparking is fairly I r w r $ and regular, fhs tault
between t h wid d the lead andrfhe'.bYqck mu4 liefn tha spark gtug.
fndlcate#sthqt the eat1 Is In order, -md W a 16 The plug may be lapse, the bsirl&n m'ay
dthq+lwd&dbutwcap k m b d , tha met b e q c ~ or, the
f&Ulty, 'of- fRe CWhbh b ~ hh tll8 aww, ' W g faa we'a' g-6 ?qt%q&&
~$&Ibutm cap is not making gaud w n t x t jump. Worge d;me of-thgd&gd&, m B
the rotor am.
q@hjhereare no sparks fram the e g a
rnw h p humt

have bTo#Bnm.'&WW the,s@tk pll;r@lnYMs

7 the c*.
an electrode and some other part ~f the
dIsMktor. Thm8 lines we paths rvhM now
m -
Lt run t o e&,
dl&ibutQI-c&Q*
Ib'
~ ~ l thus
~ wig r
Ttra only answer is &:'Tfmw
m th* ignltJan ~tl@r@ hdlQ
Irrcrmiw@,-Pther caus~spf rnhfirlnpnh&
EdmIdg keb deM wlth under the seolon
~

~mmthg mtt3~6~t ~ m m n e 1 ~ 1a8 17 If;there is no sp& at ttb - ~ j 'of d the pl*

@wPe(lend ofthe I d . If tt is in &r, start lead, or if It Is weak end IntemWeht*&gk
j?h$drr$ we low-tension drcuh., the Ignrtin lead fram the dlstrg$ttr Xb the
9 Either i r d w the ,cnnnactw to the I 0 . w ~ ptitg. H the insulation is crankd
'SO.* on the transistor-assistance unit, or klblh$lead. Chiselc mCQtlWbn3st tw c m & I ! ~ * ~ # 7 - drcfult. ~ n
move'theconnector and interconnect plm I dlMbd6r cap. cj The c k 9 n m m y be s h a r t c i m ~ .
p? Q in papne@or, as shwn (ma 18 If there Is HIII no spark, emmine the
IluWaWn). The 6 amp fuse In the figure distributor r3arefully for b&khg. Tbb cart
4TRerf,~~a~@~nW~uIt-k,tfte
dktti&g (prsdoiilt.@n$l spi& or
pMWZlxY:RenauR'dlhgnmtbc equipnknt, be recagnW by &very thin black line mrrrring
'Wiihe not n d to be flM& If dl-nosyo W w n WQor mom electrode% ar between
mw.wr.*-
a r m6 hiim $ 1 ~ .6-Mmtatkd, it shMlld
;esqwmp9baing us&. & a p-om
&ha dtskWr,
@aii'st'sl.~uky~ondeirk~f
h m &md condenser shoulB ba cohnmd
towthas shown.
IJ F, a 12-volt wbeter, or a 12-vM bulb
&d"twa h @ h s of wire. With the tgrrHloR
+tied an ahd tm paints o~r8hi
betwwn the low-tenslon wire to the 'mll
$@tlqe, (t)rerrnlal and earth. No reading
!Fidktes. a brmk In the supply from the
~ ~ m : sW& h . the emf [OR a the
$WhhtpseeifanyarelaosqrefttM,md
4&m$w~hald run-
t i if a reading Ls indi~atadbut the engine
d b e ~mt nm, this shows a faulty 041-w,
m d ~ m or, a broken lead W e e n tha maIE
@d the dlstrtbutor. fake the cordmwr Mre
ofi the points membly, and wlth the pojnd
wen, &st betwmn the mayjng pdnt and
ti them is now a mdlnd. then the fault
'(If is In the oondmser. Pit a new one, as
,...
W b d ttt Chd* 1A, SeEflm 9,~Wdth&
W should dear.
12 'With no W n g from the movlng paint to
bad earth, take a rwdlng between earth .and We
bd @I:nb#lw {-) +wqlndhA reading herb
b if &ow s bmken wire betwwn the mil and
P $WM&. Mur M m C0Mm-m 4fmt the mil
ha$ Miledand rmrst he r e n d , after whkh
Ei thh &ne should run. R $ M b r to Hit tha
mndmeer wlre to the poinbs assembly. For
b.
'by
tnbB8 tests, If @ suiTfdlPnt tp %parate the
p7nb with a place d p a p while -In$ wlth
The pohk Open.
ttho
me BtgIne rnkfims

E 4q ,H4he wn$m r n ~ w mgularly, mitt at a

dest idles p e d . Pull offt f h lof the dug caps
, llsten ta flre Kota 6f w hogme.
k i h ~ l tand
W d me piup cap in a dry cloth or with a
K
bhs
~U@&Te w aa BTddMonal p r o W V o n W W
a % h kfmm he HT supply.
4Y8Nb dHeWnee in' ~nginemrmltq wlll be

E
Ca~r n & W w h ~ hthe lead from the Mectlve
V@Tt irS removed. Removing the lead fram
he b h e good cylinders win ~ a c c e M w t 8the
ra1sflm. -
l as
58.4 fransis@+assistd met breaker ignition system '(C-type engines)

rafrW the vmwmduwnw plpa rnuldsewratha

suit the aclwnqe. ~ u m ,of-t

b englna by
arfjwmw $f, th2 m t 5 d ern on the
WF#~.& ~ B & K &d&
b @ 1 a f 6 .thltT~
';
~r-awqrn&u~@i%&~!p:
o 'wn tdkkkJi@$b~0~ tp3 &n r3'fiod&?J m-mw/
&mmd $ e r v b + m d h & & ~ M 3 ~ 4 d j e Y @~ . ~ m , ~ ~ r n t h ~ ~ i r1 o
mechanism
Wm, % j~,~%!k&hto qfiwQQN. [3'wnna,tmHf
lead *p i
hri. 1
u s t REtw,the di8trtbutor m p rqdninp
a wqmy the L-T ~ g d r !h r pqslyion, kt*
dleumnect them from the tarmirnals m the
,
!ips, & p w ma 4 i i n d k d s b ~e em 10 To mmawmq, Rwt,&* that *e ecll,
P W O W FEn ! plyg .(nwest the still a t b ~ P F I ~ Qwlth-bk
~ 1 g m , t mm ~ u w , n u t.and&&
, wdl 1
rAmsl-mdofths-atigifie]. ~ykifdrron r;gmprmbn. H #W8eng1ne h& d, bM<m thar wm
9.maw,a Rnger ovar the plbg hole, and turn been turned whlls the dlstribubr was
the q l n e bihe n~rrnddiredon of W oo (emWed, letm It to the correct pwfffon as Refittr?
(cl&kw$J3, vt&

Ihd-
from the crankshaft p u l b
@rid)Wlfil h b t sfglt tn No 1 ql(nd!.Th$
that the pkton Is commencing
bmhprhslon stroke. Th@ englne cqn ,W
\+
P M ~ *deedbed.
$@I Is h p~sNonm the base of the
dmWr.
11 Wth-thG'mtwarm polntlng directly away
, -_
~~~ fhe 4 Reflnlng, tg sa .reyeml of retnpval, but If '
wipe dew the i c q ~f ths mil XD 1
SZLtr8~dnQar the HT m t .
turned with a s d e t orlopayer on the from the angina and the v a u m unPt
cmbhaft dullcay b l L appWm8rdlj the 5 olcIack pdtlon, dlde the
4 Continue hwnthg the engine until the mark dtsidht~ lnt~wemlnder block, and turn the
on mfhaflywtwl k aligned wlth 4i-m TDC n@Ch rotor arm Jlghtly Untll the d k e 5 peg on the I
1
on tha dutch MIbusIng. dlalnbutot drivwd$ poditlvdy engages with
6,irsmgaFIabofp@qqta~Ulflkmeah c k l v e m .
& m m mark bmqystb&W&
~,mQ.FylMdBi$$@$
-. . base 132 Np ?ha pm~iatisIy-rnEtdier refence
: mark$ on the ripr4butor b a end ~ cylinder fie wjring plug ~ t t f,h , ~
i
0 Bet&& the &u$ ddvame pip+*'a% . hick. I f a new diWlbuXor Is being 'Rthd, alIsl:an~erutle 1waW on th"B
rnem~nept #a LT Imd qt the piring ; '@milidnthdlst$butor M y w that the rofw
E o n w r . R M s e t~'@klng'lmm
~~PW~P~~**QTW.
-
from t@ - $nn galnts w r d tfrs No 1 sp&tRplug HT
. q m t i y t in the wp. Wlih the distributor
7 U w e w thb dktdhtor e t a &inhQ nu& fk ths pas~tltin,refit the &lamp and smurq
and IRoff fie clamp ~tthcimwthe &triiw with 'Wmtaiping nut, B ~ w
Prom fhe'mgtne,and h r p e r tfYe &. 43 Rbconna the LT letad at thb cwmebto~; ,3:RgkUng @ a m ~ m of1 net~Wq1.
fi Ehapter 5 Part C:
mr q m ~ ' m
(all ~ Y D W - Q ~~ngin-1:-
J~
.....................
r f l ~ , wt..y&:md
.odd@-,Mng;
....:.... : . . A a ,$".h.&&
.a>..
.-.+.f~.r+~;.&-;.li.i.i
..,
-WC!@.@ .4
....... NO......:2
..iia : i..i.:.

ofdifficulty
D>~grees

Specifications

?gnitfon coil (all except D-type enaine)

5 ~... . .'.'! .......'..!' ,."'
. -
!, + "". ...,-.......,.......,... R W ~m
' !. ' ,, , r
. n@ o$lgnroim moc!ule
. .,........... ....
P r h i y ~l&n*[bYplmJ) - <, ,; ...... pp*~<paofjmfj
;;;V.,,-u; ;i
. . ..
. . ...............F,A
;,;

i . , . . , g5pa:otrm
, 4
nri',tsnot-+ i&b. For 4 :a;i,~T
mm, and 'thence h tha appmprlata'wrk

- &,m1$chaptw6- d d 8 wth ihq %Uy-

slectronlc lgnfilon sstm TIP& @ mqst Cllo
models. ,@ all fuel jvj@i~n. flg-e,
an

I
engine 8rj!mggmmntc ~ m g w hw,:co$tr4
over troth the Injection and the ignmon me mmputer I&shared wlth ttle luet
-s & is-bed h defailR
An engine speed sensor (seeChapter 46 or
dp),bolfd to the flywhwl houblng, proad&
d ~ a l s lndimtlng engine speed and >M@QA~@w~
brankshaft angular posltlon. A ~ I Y G , @ me dolloiln$ pmxmttms muat be
pksmre WAP) sensor (see Chapter &,&&I
pmvidss s slgnd varylng wlth inlet ma%$
vacuum, whlch Is an indication of load. 3
slgnals ar& Rmcessed by a computer, and aupplled to one cyllndq during the! igrliir'on
u s d to detmlne fhe moment when i g a h cyqls;' hut-mh a m mYii-Iw& This w.
must occur. The computer - - - qg
c,ontrpls~
z l m p l a ~whi~hd r the~ignltior?Wil.'
~
All engines, except the 1171 cc @type
englne, &so have a knock sensor, which
ptpvidera a >s@nal# pr*tgnition [Nnktngl pass- $om- -ths aGt'to the dl~trllo~utor
rotor
5 0 2 Electronic ignltion syatem

I!

4,Oa not eannect a s u rnndwsr

~ Engbs
~ turns mma& but fails rnwiehen$lria www fw-~o%e
3ar.tesrllghfto the &n@w@I RE$@M m:siM spark plug I d a
g ,,On . F W $n$lnes with hyM-wlflt @I
Injecti?n, proceed a6 f61IoWs [W
r u ~ . ~ 1 .
3 Fiimo~$:weonnears from the Ignition
a) ~ n c l @ % k m l t ~hbddp~h
Mined theglrlnletiUktjheh&mqve~smy
arnpllRqr :at stsatlr: lg,nition mdule, as s 5 c u r i n r p ~ ~ ~ p . &&
b ~th-poflffe
tu~
el W n d t ~ W a n # T ~ i a s / ? o d ~ ~ taw~ @ i @ i ,-and check the #smina!s for
spark.@nSt the m p u # wmniroI unit disMntWc@'~.
Bo~crslon.if necewary, rbrnove ma refit t
M
WYJ pme&e ~ral~ m 10 tD the
In Mdm bJ S & k M h securfng the air inkt
hnm$to the W inlet tube* t h y move

a-
Q QoMteadh thecotlprimergrsr- ~nnih&ls.f thev are v m dim, scrim the
n g p ylth a suitable instrur6mt.
rn tubtoonesi*daavdm
IgmIn#: The mhges produced. T 4 C h W th'6enrrloe s o d Wlvwheell sensor as m&wmc$A,
by the dmtmnt ignition w&ml
am. c p n s m b l Y hmw *# $@+i 'fn:~K&l~ 4 3 , w 4 ~as
, +plicable.
5' On E-,iyqe and f-typ56nili%s4rnconnsd
those m u d by w w t i o n e l gy5tem13. ths $ql Wp~ltral'sand kh&lf?e r m . o f
cJ ~ m ~ ' h b r e a l t rthe
m n m w m>GIrw<avn&qil
undip#e M w h I m m h
m
e r ~ ~

E & b p m e .rnW,be-
~ Wheh W Pthe ~wlnbh$$ using ah ohmmeter, Typical mw*
PimutQrw
m,@@ fiw)PgnWnn swftched ws~y~~q~.gi~w m ~e s m c a t i q n s ; 3 On an khadsle, uhmk that the'* plu
@?. F w m m 3urgfrn@-jmp&n@d lead?,gim diaributor .sp qn marked !a ai!
Engim.rnid%s refitilhg 0,4 mark the leads and tRe
6:@heek4he MT teads, distributor cap -( d l q Wp@$! Qn the: %w*
ra
.4PRJ!!9$Fd,
GPWRpiWl* refeiw-mto qp$_rbpti&e -tyllnder rthbsr@.
'$hgpt@ 1A off W<@Uq~'bt diYbUtW'wJ
7 m,W*,@gkl$ s p e d (flywhWmnsor asMhed. U d tfie'rdaMgscrew, and
as dewrikd In C b p M 4E1 at #C, as
appllwle,
a If no fmptolremmt is 'produced,.wnsuRB'
Rerl@uItdyk~,or
other s m i s t .
Qmmi
I $s, tbsrrtibned In ChaMr 4B or 4C,,them is
I~e.4Qst can be rlpne by way of t a n g the
'ElirrtPoJclr5gnT)I an fuel lnjectiori rn&@18
with$$ ,pecll ft9ulPmnt. The f o l l W
'&@npljg provide au$gWon$ foi
p&l&.atU; check whT& m be made Removal
Wj'WYmh eSb@mW. 1 Oh m o w s with the VP (t&valve],g~gim,
8 Ch~@:thgmov,n.tof play befwaen the &4d Remwlng t f r e d Worn tt@ baste d
dIsWht6t dhaft and body. this should not be the dlstrfbutot
me@lVeunles3The engine h a cawred a
h~gttrnlfeage. H H IS ewmsive, the complete e m @
~ W ~ . uMlw-d,d 10 RedWhg Is a m v d of mnwd. Do nq
D Gsdk the condlb d Oh& d w u t w her a%ih@t-to
&nd a Mbr A r m ?& ~i.~'ohnkfmft
&:W. ~ : ~ H n m = @ + ' designedto w p t a m~amwith a MW?.
scad ~ ] ~ ~ ~ ~ : : ~ g ~ t i O ~ ~ s ~

, ~,&-&==m:&Bi
' - -, w:-(Dl#*q-
D*,mW
.,
I,
Chapter 6
Clutch
Contents
;$;*-,
p. --
:.
. .,;::,. ,. .,,., .
,.,.
-.mm~val,inspMOn and d t r i n ~ : ,:;::,
...... ;SWSh.@WlA or IB
.. . ,
p&d.-tern&i1 arid msmg ;.
W(
E h <
.,;.: ;
1 .;..,..,; .. 3
.
,;,
;,,

, 14 c I u W . ~h g, h~g - m ~ . ; i k ~..;. n a $.................

.,

' m f R & g., . .:6

~1~ *$.- mg4ua,..and ,&
.... m< ,.....
,: l I-.......,.................
!
H W W O ~............
g *&@&I I ,ii ..i-Yid.a
,:, ?.. -.?
1
..i-+-.:-

Degrees of difficulty

Specifications

Clutch disc

Torque-w m c h m n g s . '.His
Clutch coverbdts:
7 mrn diameter ;-..
.<.;-. &... ; .;. ............ :..A. .. ..
.... ..,..............; ..-,....
;,: .i i.;; 26
8 m m d i ..+..... ,+ 30
6.2 Clutch

pr~srrp,plate -snd the %wheel, thus alWlnaw or ,a&

1 All mwtpal gearboll models are equlpped tknsmntlng mglns paw to me.-g
wfth , a cable-operated clutch. The unlt 6 W w of #q M&m material
@@isioP a steel mver which i s ~ & w ~ I l e d disc is, a u t d r n ~ *ompen-
,andibol1;edfa+Wjm
~~y ~ o4
,Mwof.tt?esrlwhsal, q@H-@Jt4sthgrn&t~s!sm, attwjwi te the-
M d --Pahe
f i e o l u t ~ 9~'%-#@?%h~ &bl@W
t a Bwb.&~nwlfhd~w#19,wt~~
*-
duahg, w-rdl~g to
V v ! 9FtrtofcCh33
-19 fm ae

pnh , w a ~ ww QM, plate and clukh p&d. TheLmwhw&mA~~_n&@$f @

* m ~ * * ~ ~ ; i U u ~ n l ~ a@rr&pd@adrani, a, pakhed mm ;a?d a
I r n e c)M&.d~kc'ls fme'to dlde abng tbs bnalm @g. One e&'d afe dwh &a C
fjjWti6k'spllWinptvt mat The dl& kbeld fn attachedb the quadrant, whlch ls*m pivot
'p.@fjog b d w w the flywheel %andthe on the pkU but Is W in te&m by a-g.
br&Mm pI@ by the prassura. rrf the When the @a1 iB % r e d , Wmtchad.&&n
 Clutch 6 4

2.13 Checking the dutch I m cable &ek

-,.dbereleasefork end
11 Depreas the clutch pedal to draw the
outer cable Into Its locating hole In the
2Ab h e r -1s location on the bulkhead, ensuring that it locates properly.,&
gelf-~14-9 quadrant the same time, the Inner a b l e gulde will be
1
I - r !gut@@ amim
automatically pulld onto the top of the pedal
to hold the Inner caMe in poshition.
12 Depress the clutch pedal several times in
order to allow ths self-adjusting rnechanlemto
set the corm9 free play.
Intfae bulkhad. 13 Whan the self-adjusting mechanism m
the d M padd L ftyletionihg corrwy* WWe
should be minimum of 20 mm sla& in the
cable; To cheekthis dimension, pull ouf the
lnmr cabla mar the mtmm fork ,an thGi
e x -8hWI (s8rtrn-w+ i~
!&'than the rnirdrnum slack In tha cable,the
e e l f ~ ; s d ~ n g - q u 9 dbe~ ~e lkdk d for
mkum OF pmslbbrestricted movenmt, Rrsmowal
74 lhpmsa-the,duteh pdd fully, and ch.edr
that the ta&l rnevmmt at #m:Xop of the i O l m n n w t h e baWy n-lve lead.
2 Wed as describd for cable removal in
rBtr3~s,forkIs between 17 and I & m m (see the prqvloua Section, hut wlthout aclw!ly
tlon freely under the tenaion af the fllllsmum).fhlsmwmnt~nsumthat the
m d n g the cable from the bulkhead.
k ~ ~ b m If&not. make
aluteh , p M l ~ l r o Is
sure.#& tha quadrant a d w w r t am8 am
3 W m t the retainingdlps from bath ends d
fwIt0.mo w i t m l r . m v a pivots, and that tha clutc~brake pedal cross-shaft, and
recow fke washers. M e that lha dip ends
e compartment, slip the *FIR@ hm mi lost Its tension. If
Cable through th8 t ' h m $ & Wt h e m Mgth of the spring
angqgs with h k k pedal bracket (see
d wnmct the Inner Ww3kkmm).
a
- a,new o p a shmk W,,W>,hnqc
Refit t b mble ro the e a a fs,mt$&l~dn'the~wtera b b 4
t6 F m M by w f I t t i n g , ~ , l ~ w w m & W .

pit-hd_rawths c l u p&al~ ~
'h %8 v@h-fiwd ddb; mid

.
t 3 b Remove the pedal c r o s t d..w.t
minim olip (amwedl fi,
6*4 Clutch

- w -m~&rsl;laftr~-h~
support braole4(rsgWhanddrtve shown)
rmW together 4 t h the self- I2 Wt the sprirtgmqthir and s
um
adjusting- ~8~ and bushw (sea hartel',endof tlw ahaft. $brew on
jlhl$qtq@..Nop~Wtfre,'thl&wbush Is on
*&*Mhd w e B
B!'Wi'thh~tCle*at removed, unhusk wid
remove the sel%cUutlnp quadrant return
%pi$@, w@?ethe 3iHd p~sitionof the &If-
adjphtitig bmponentsfm @m&ct rdMna.
? emow the bush= and withdraw self-
,mllirsrin$ sup'psrt arm8 ml suacfmt (8-
1 4 1 J ~ Q b lJ1n8pW
+ these wmponsnts.sthd
m a h e m ff worn. t h g ma has not already been dona
UrdraCn).
ht P w~&iJusting
MWng 14 Remove the @dampandfully tIgh6en
mdanism from the pedal 8 Apply riama multbpctrpse gr- support bracket muntrnq nuts. NQiB W
,to the
bu$hps..8nd to the baring elrrfamsof the & s lo~klrtdh f ~ h
support b ~ a ~ k has
suppork a m quad& and p&al sfi~ft. p * h t ttl~awm r&atln$I.
9 Locate the pfastle b w b In the Clutch 16 Recgnn;e\st e i e , and
-1, malcRtlg sure Wt tho latgest bwh ISM . o ~ ~ @ f r . t MmW 4 ~ ~
*ra b W w W side:,and ensudng that iM d&lnS&rcnr%,
lugs on ttw bush& beate h the out-outa b
the ,pedallser Hlustmtbns). ReoanneEt ttth
Mkd@tlfig quwrmt Mum sprlnp.
Sb facZ(Motheceftttlngpmcedure,
DM t h b~ u m arld.$uEgxrrt-arms 'ta&tlr, it
t helpful So assemble the pedal m"adttmmy
ell&. If a sultabte shaft is not available. 3 h ~
pedal m M I be reftttd but Et will/ k
nsoWai$ tg hold the lmsbrn tpgetharrurrtlt
the &hhg elips are In plm.
I 1 t o m e the q ~ m b l Iyn thq bra-
and push the pedal shaft through fPwn the
right-l@nd,si@ [see IllustraUon). M t the
tight-hand retainind spring clip wP1 wjwhar.
rn- *rn that the 'dip engages c w W y in
the bna&ap&w:
 &.Uemoving the dutch cover and disc
from Dhe flywheel
remwdjust n k d b one side
elm.fib I@ b@ dme 4 M d s or h a well-
VdM1[hW@-$W:WfW tQ the ~anfing& fhs
kglmrrltig ddM$mmh.
f ~ ~ ~W ‘clutch disc tor
5 ' . ~ a r n l fIinirtgs
wear W I S d u e , <atid&a dim rlm far
dWbFUbfi.WH& hokm t-n springs a i d
w6M epfirit&C i i I ~ l m iThe
~ surf'am~of
.
&@frtddn IlA&Fmay bhtghllf d m , But

sign OR cmtamina~on.lndlcated by
black dk&hMon, the disc must Ue renegy6d
and tb:source opthe conternination traced
and mdfted. TMs'wII be a IaRln~'craTlksh& 1-the dirtch,dkcIlnings-(q,.
cjlr g,p&ox Input dt +a\ or bib. sprtngs (B] and splines (C)
The medp h h r e for the f m t given
In*rrrlmt P i i ~ d ~ ~ p t h6 rm2 ~o f msernbly. Renewing the d+ alone Is not
thegearbox Inputsshaft dl seal shollld be always satisfactoyy. A dutch mplr kil can be
e h t m e d 0 a Rensult gardge, as W Involve$ obtain~.d. conwhlng the ~ e .my mppnentB.
.enqlne; G h w and remove the clutch cover dismantling tS ~ r h and x th& mew4 a f 9 knault clutch kits for the E-me enaines
mblnha*Jts. Work In a,dlwnal sequence ~ . B W61eibbmt~withww clslma m t a i n a specid dummy bush $I& m$be
and skken the bltsanly i f m turns ~t a p p y . @ disc pwt & -be w&,B the f l t € d h l f h e ~ k $ h a f t b ~ k 2 ( 1 ~ ~ t b
C&n ' H,dd the'- f i y ~ k d~tatlonaw & h%@s'M~b:~tn Z~OW 10, Wlusta W,the of the dutch. d n g M I d-wsupp,M in the
~ p ~ i t l w i n g - a . ~ d r j l y w ~dowel
v ~ ~ on 1wd.dthe rivet hdsi
~the
kU. To fit4h1sbush. first~cfeanthe W . b the
,&c.~Ylfnderblock and enga&i#g~ ~ the, w ~ 6 ~ k ~ t machined
h e faces of the flywheel
M e t ring om {maf l l ~ o n s ) . and pressure pkb. If elther Is gwovd. Gr
h&~ily & ~ r k dM ~ hWd dB DatSSMv. n e
pmsum pMtgrmu&sdw b r a e w d ifarty
cR&B &B +BP= .Qr If W ~ I W W W
sprlng b dqmagfld or It&:p-urb-swep@c$
stration). Ir~eelMMwrl.
7 ~ a k teh e o & ~ ) r b hmrdWn&
the release wncl:as dwmed in&don 5.
4 WHh t h i ~ , ~~ T b m h k yr m u @ d ,clmn 8 kia q ~ g d d & : ~ 8 ~ w ~ t h ~
p a l l fraw of.&estos dust ualng a dry pressure plate and Weam bar(mg,-man

-
'aeb n .,andthe,diaph~affl sprhrg, &Q 4,Q Fit the dummy bush In the cranicshafl
pwtieutar attention to&e tips (arrow4 bore with the open end facing outwards
616 Clutch

hub lo p l @ t ~to
n the bore In end of the
cr&Wt.WhMthe,txwe8piwra~in
the Gem pfi$.edutch &.hub, all is correct.
t7 it a m b e c~utoh.is ~ ~k i n~g fitted, an
altsrnertlve, and mom accurate method of
cmtdwHon is to u% a comrnerc!dly-
alhdm totool W p d e from
a@ita@~~@utch
mwt~.-pw*b+uww*
tfl,<:qn$h $re clutqh is mntrgd,
UMwm r n 6 a W bqka In a
propssivkly h j ~ ~ the
m ,Before $dmt$wiq the r@&rblg wa# sew- to h t o r q u e ~ n h
gfoqdbn, apply$ ' l h , hlgh;mM@-HdM la h .Qpebln@ons 4-
g
i1111~~m~.
s&p:@ fbhi PI^ ??ahe gwkm Jntwt ~m~ th~ d~l'es,
~m-ng
dl@. (A mchd of wtWle m y ba IB Tha $$&ox csln now Ile retottad to the
supphd wrtn the clutch kit,)' Distribute the engbe, r & h s p Chapter 7A ?F 4rr, (;he
&a 'funcflorjing d the- dutch p M .as
#qlbed In 2.

1 Am@% Ta We c l M ~ htease MIQ W,

be galned Ih' one of h~ whys. 'EIMei;tl?+
(servsHustratrom). gwrWX may b ' m o v s d I n d e p ~ as ~ ;
13 Place B e alutch cover river the dowels. desctlbed in Chapter 7A, of '3hB
Fpflf the ~etaininghot& and ttghten, them mgln&Fhlpr&ax unit may be pmorrd ia\s"
$now-tight so that the clutch dim is gripped, demflbrxl k C h e e p 2E. and fhcg*b.p!
but mn still bemoved. s&~at@fiTHfi Wxa$lneonW$snah,~lftke
34 The W e h d l s ~must now be centrallsed gmmx is.Wng ~raniaverdindepbhdwdym
$0 Qhal.when the engine and paarbox are t t Ftp'mgirw#l, ~ ~ It ,need0hk.Mmwred to
f t slde-far ammstb the d m .
~ , b r e ~ ! p s o f t h e s m r b X i n ~ ~ l t * eoas
~~~-~~ the%&@&ln the mnw d P Wlth the gmbcw removed ftorndhemglm
thw ',a'itd$ && hub, ~ftfis ISna ddne tilt fie reme Mt$''qnU d@el:hp bearlpg
a&&i'$%'$411~~ IrnppFlbEa to refit the assembly ofl t@ geatb'Px In@&r%hM auld6
@ww-
I B ~ ~ B ~ ~ w I-91 ~ o;arr~ed
~ P ~out ~ ~quite
tube.
Q W3 TQm w e the rel- m.-' q~sj
wsily by in~&&g c
hole A ER ~ A B ~
the end d ~ , m V ~ & ~
b 6 4 h the ~ b t k c o w m d t h e n p u ltheWoff~@
r p ~ dl=,
h scthat baU stud.,
; end
In WQ t , o ~
l PW

of the amnt@ht:N%, W :a Qtaatl~

centtlllblng,tuM is @hd@l@ I WR ~a ~ ~ l f
clutch klw, maWng W u w df bar
u n v w1 - ith~&&~H1.
18 H s h r b-&ng,used, m& h - d
up and dawn until tbs. clutch 4lsG Is
cenWi&. Cenitalie~ncan be .judgedrby
Chapter 7 Part A:

... .
..

....rl......"....'..... t," ................................

;.................
...........!.........-.....................-.
,;a,,
!.... 39:4
......... ,4:2:1 r...
dOlO) .........,.......
:..,*,., ....." ..........;................ L b : l
i.......mh.i.j+..;.r;*,...-;>
. . . . .
.. ...................... .* ..
.+ w-.. a.... ... ....... 42.:I
.;I,.., i.;.. i .Y..'.i

'Nm
? A 4 Manual gearbox
 Manual gearbox 7A*3

L-&
the gdtMxiiv6rM

11. 23b Q e w , ~ t l tor*.gem

s iever

1 APpJy t f i & h W h k , .then jack up th@<*uIllt

*
orthe emd support ft.m a t e stan& (se&
uJeeking&d,KshMampp/P).
Ramltal
I ~ & r t g Inslde the car, pdae the 4 9 lever
2 Unbstt a@ ~ D V the S s p l e guard f r ~ m gaW from the hntr6 mn~(ltB.

--
undekf he,$&hox 2 Apply the handbrake, t l y jack up thefroht
~ the gearbox by moving of thb s@dnd 8uaapk lk.~ n , ~ & i W s
3 B e k t 1 ' s t . g on.
thd I&W@ hk &bfi&t pooitlm. RenauN
technidans use g.speWtool tc+hold the tweva
In @shnnmid ,$aim any fr0e o h : a

*cieamke
Using a -~+BJ& Ma*
bet%&
. e b k -that the
the m v ~ ~ ~ h n - r i n d t ~ o n
the gear lever and the Indined p~$e.~<t-@
rlght-hand side of the aetar bvsr"hhustnsr i6
b k n 45 and ~6 mG,(saeI t h i ~ o d
6 W adjhsfmiii ts n&&&ap;y, unhbcik "the
~sprlng.ftrrm# I B ' ~ Wretler'mdd
llnk rod,,then b s e n the damp bolt at the
g e m x end dths @ .y@zbg IT$ @.@n
be moved on*W j b@$ l.
~6 Mave the p e a r - l s y r * ~ , . $ +mvwe
.
stop-ttng Is &dnsf w~~l@Jf&@ R ~ I & o
housing, them ni ma ult&&bf&q .btMe
,w- ih?g w,&e'1+~7~h
Hold ihe {wltl th@&t@$ mqighten the
ofampGk,
7 Rern+w..fllpbidhg tool agd pM tf~uMum
+ping..
Flew$ the clw- m k giwn in
mripti4.
0 GhWk Qhgt.gjlgem be sHWed, *en
r4ftt the,sgla&@&l and tighten the bob. ZB Adj-the wPl&Wm5&&sin
Lower hscarfoW ground, with a Mer blade
 -

?A@4 Manual gearbx

19 Adjust the gmahrngs mwhmism as Weg&f.shafr. M W swe that4 e n g q

deswlhed,lnWtiOn 2- b g W ~ D C & O rdchlsa
tvith t ~ b g c t l y (m
iuwtqlon).
10 RMt the spmdwneter -18, and seGw
with the g$.
TT ,Ir&4&theBifJmqrgmw&dJthmr@
h : @ ~ @ e andr ddp.
12 Rekonmct the I~Tt-hkndU r k , h a f i wg
Note an ib&;s f@r ma;@, smd r6fer~mwt.aChapter 8,
orneteddw i.@Wfiwn the Hgno-Inmd side
of @e-*~@'1se
n&*r, tg mnwa Sk-dh~
,$@-& -9
wt ihk3
q&wF
*"
t?@ ~WvtilshrlhIf isS

mbbwrn~dn '%%heg@hkgmS:&a#ofthe
clip om 8 e a & c ~ & j s $ -
X=IOtoI2pm iIEu-I.
Unhook the rflurn spring €mmthe lnhrpd, R ~ ~ ~ o v B I

-
5 Pull backthem ~ . b a & f m m*@.fnoht.enq d @p$?nm,*.deft-hand drjqghaft B .thB
of fhfa llhk rod. RetriOWa the $glt and g W b x M d &&t - €0 Chap* 8.%W 1n6
disconnect the rod from the gearbx+Iavbtt @ fg disturktha hub 41 of the drhkh&
R w e r the-byph wd ateeya?Ntiteitipt the th~'d~d'rlu&~iwlWlhub cl&brt7b& can b& prn8.
CIWCat the f r q t k i d $f the rod IS'oMh3d mmP& together, as .de+ribed for angim 9 Prppty,theh a , then la& up tho front
must be &:aorr&q* I r n p b e r PE). of *e car md qtpprsrt It on axle Sands (84b
s Remawe We nine sewring the, casing 2 EWact the uirallp snd Ehruatwasher, thsn s@MLRemwtj&t
m m bI#YQ fhq under$ody+ tower the wftYi%lruw left-hand sun wheel from the
aaemhly, d the sariie tlme puBing tllb &lfWm4al.The sun wheel E d s ~ads as the 2 p~sitbna sulhble contalno'r beneath
&q&t sy&m ta one aide. dilv&harffsplki&ho$'k-g. gearbug, then unscrew the dmln plu
7 Me&tha$hk ~d and am Wer cleyh In allow & allto drain. (Oh m d mad&,
3 Tm ttp dp@al mtI1 the planet wheb
relIap to w h QW:
UOM mqpzbbott &To a'5Mkgd p l d I @ ? p m q p q ~ q @b~ mcl3sw
~ to a epksh guard
&. ~~~
8@ipm~lew
w-dm@..GI$* ,*, d&ep1$&31bIe ~ n i u ~ o m ) .
ivviUe,.t.l$fm @t:@Wfe 4$ufl tw $ 1 1 ~ lpM akbqm~~a
khe Wain oTWeQ&n$WW) When I??&@
the the all has drained, ,cl&n and rerftt €he drafn'
M @ B m m e
iV k &it* l t * i @ ~ qmdpqmtar ~ & l e from th&odtd& 'bfthe
~ ~ l ~ , a r r d r n a y 6 ~6 x~ . ~ ~ ~ .
@ %a the d~db,
fi.$$ th? @-Uelnq long-lw%d pliers, extract the
par I-? wd dthh fhs ~p&meter dtirctrgw shm verti~ajlyfrom
fWni WW4. ttm wktde af W w p m .
B~ilslng WB' sam plfem, mtwf ?he
RMmhg speedmeter drivqear 8?om Inside fhrP
90 RefHhg is a mwd of m m s ~ ~Wing l, huslng, hlng very cerrefwl nal to
cflffe^r~ntial
me palm In thefolfowIw ~ ~ l r s . drop it.
I q Urlcati the pivot pdnts with grease. 7 &@Mrra the dcvegear teeth for wear a d
and use a suK#a d h 4 v e ta b o d the knobdamage. Renew if If n a e a s w . Hbte W H
b"i h iher. the d & e e e a r ~M the dlffe&jal m w w n
I2 Make sure that t b clevis
~ on the -front end
or damaged, % wlll be mcemaw to dlsmanUe
.aP the lM rot4 is f i e d with tfmoffset t o . W s
tfrag&-~s work&ould LentrnsWto
*e gerttb~x(see3UtWation). If the devkhas a Rmaultd d 8 ~ .
baen WQV& w If a new clevls T$ being fied,
meet t b thk rod tothe c b l s leavlng 10 ta
)~rnrqpfthe k p u aiaa ~ *Lping. 7 h h ~ 10 Using. bng-nosed plkrs, 'ins& :be,
d@e thegear tewF in Its con'& loox#udhal ~ W ~ m e t d eMrtvgW Inb I@W O ~- ,
+&@5. g From outsib the gearbox, F H E the
 Manual gearbox 7A.5

5.9 Tap the dd dmergntial output oil sml 5.lW ,...d . d rm&al
l v e . f in with a s w h t or
wlth 8 -11 drift to ~e it tube
wrth m q tb Ohapaw3.
l a Clean &dmkkwd en'8tWIljbtilt tapdrfind
the stmrlng arm, t b Mtt the ballgolnt lo the
rw~qephbelow the casing Age. This ia arm t l g h the hut to ,thb specified
&&,- b Wermlne 'the eohect fitted
@bitW! bf the new 011 seal If the speck11 2R"%!%is3ah thr mpct Wntiw
ahd'.gmde.ddl, m~ d e m o t 3o Ctmptm 1A
w t'Bi Ref& t h i splash guard where
n v -
2.1 RHtt -thd ibadwheel,and iower the c a to~
!ha gwnd.

Manualg-x
[c-!
D:-M~E**~):~J
N W ~ new:W'tchW e t wnlbe rewkdon
removal wd ri@i$&
reffttq Note: JhiS SWoh d e w . . Re tqhpW B f
Rbmiival the qw-boxj I b M g the ~ g i r P ein posltIon In
I , Apply W M h k e , thefi Jack up ths tha car. ~ f m b q ~ m % n g g eLa gW-
r #
of the,cq,&nd. suppa~tit on axle @mds(see will @Mo& -'n& b fQ.rn~~~B..f
'l&clQ'n# md W C l a sugpMh).

~ ~ bJ w
3 ~ ~ e j ~ q n & s l l i t ~G@Ql eM ~ t h the
gsarbwa then ~ S & W Wthe drdn plug 8nd
allow the dl ta,Wn, When dl of the all hae
drained, c h md- miit 'tha' d a n plus
tSgMen1q W ~ u r d y *
4 The s w K F h , $ . W on me m-handside ,
Rw.~QII ,-- -
. ~ & ~ j & " q & - @ f i W & $ ~ me
af' the gsarbav~next>.tothe dr-fb&ee
Illushatton 8251. [3isconr)~_tha w l f i g fmm engine comparkmsnt, $ter disoannecting It
the swktch, from tbs -he. Due $&e weight of the unit,
5 U n m the witch from the g w b m , and it MI,e , @ m m r y tq have suitable Ilttlng
remuwe the wmhw. equi~enf:@mh.asan enghlb crane or hoist)
-.- -
2 Ap&thls-mtlm,pen IaQk up mh n t
qf.tQe,.dqand wpptf Won axle 8tBnds (sea

*w- and rPeH@e swppbft"). WnaW4w$h

g. "0% me 'baptew wim rMwm w

%Rw%-
mfhdwle the banna ,wltk MWm
aapt-w 11.
a ,~@mbv~ tt~e~ W ~ O - W ~@:B@ip
UW~
D T , - ~ ~ ~ D X . sbskt3am a.8.Wle r-
Ii-;sxlWA&.&w.W Wm,v,"&b
plug W$ &,e .err .to. &in( I'M
Ulu&&6n). W& 6jl hWd&#,
7.5 ~ n s c n a w l t r g +ge3rtrmr
h dl drain plug clean and r d t tRe draln plug, ehtening A
ser;urely.
7 A 6 Manual gearbox

,,A
I ; '
;

WWFB noonmitor T + Mf~ ~ i

b w s l n $ ~ $ h te& prr the 4earbo)r~wlQ.
C-iypweigin-
6 - U n w w the nut securing the, left-hard 'the Mpod components m a i n in posttion on 28 Unbmmd m w
t e h-t-m
%dw mck-rdd and to the S W ~mm Q, 'the-InwnrJnf the dThrOhaFt, atherwisethey ttwrcsdi
&&I U& a balll~intWJ-IQYELI tool ta.se&ati ,maMl:im&e Q e a r b o X k E-Qp e q h a
the:WjoM WT- .l2 ,Worldr~&#te.rigHt-tlan&sk& . d M a f t r
S"W&ing in the englm cornpmmt, wher&~sppliqgtrlema a 5 mrn .dim'Ww Pin Lpqm @+ nnotlemve) baZt 4%
unscrewthe thriaeriaebolts the left-hand punch to drive nut ths roil plns. H e On ynscw djj63 m m ~ t sb$ltk.[B] from the re@
Aw?ins Jnk[seeW *
PdMhetff&ner tvbbef baat to the ~ m b ~ a . @rng,,kter-madsls, the roll-pin at th# Inner
8 to .Gha@er9 W unbolt the I ~ f e ; h d end of thii dHvsstfaft Is &IeW; s r d the
~hapt11A.qrlb.
*
26' DWn fHe'$wlngsygtstern dyalbed h
btah caliper from t b . m i v e i hub* Po n a ~p1M~m.d of h rlnveshaRjaM is qaWg #Q
clk.mnn!sct rh$ hydraulic hose from the r6Mfiif In I n # d M w n wheel & b ~ M 28 b~&',th dlpe and .move the raplator
dm. lhthe caliper ta fha sus-bn wn -. /@ere the ref~fencasto h m @ Wwb' z q hp.A@ r e m e thetherrtt*
sprlwWtlwut 8Winlnp ;the hydmulbJose, mWng tb tW-W When uybang an one of 2'7 Remove the dWbutor car? with *en&
g i . u n w Etnd W d v g thd pMcb-b~lt ~ , W I c Y % to cn&tw6B or BZ, as apptr&ble.
w~irrg tke fmnt Ie.$ lower balljoint to the i : S : ' ~ , @ 99 u inpt m w e j ~ i d w 6 bplt
r 23 Wired klrpfmbk, rghlove the en@e
s w d ~ ~the g rlghfhab'd swlvd hub to the sp@ (flywheel) sEartmr, W QnWon
ReQend &dm &the ~ m s l o n ~ s hUt .m w gtnd m~M~lcr'wlthr@&enceta Chapter 48 or 46,
nmovwthe upper k d t i tRen %It, me sWd hub as @ppikaHe.
and alscgnmqt t b drlveshaff from tha % Lodgen (but.'& not m o v e ) the boR
se~qrlhq{he rmi ,mhnMtig bec;ket l~%W
q e ~ b aun x wheel shaft+
~ w # - m d
t 4 ,Cut. tme phsYlr: tie and pull back the mr*
marmtlna M-
& ~ e s
C t gearhangs
rubber bod, &en d l 8 ~ b 1 3 ~ the
td .rrQm tha b r UB the gearwx '@ .80 Refw.tothe accompanyingtlluetrationand
unwhw1ri.g t k n l m d temovlng the bdt remque.&ud (A) {aee Ihfustratlon). We anJ.
(w,fllustr4ti~nsJ.'Racsvar the bush Yr6m
i&de .the kave'i. 'C)a nat sewate tho
g&chanQe rod at W e damp, athQ*wr&eit Wll
be ne~&w
to adjusf the gear lever position
ql,rrflt$ng,
tfi Unbk fhe' frpflt left-had fnnw M~Q'
prabdlvs c.ouw @bra necass.w, drdn but
thenWnins fiW).
18 On @?ipe sngines, tinb~ltand F ~ W B
t h s dr5t'ikh ~aver.ffom:the bottom of €fit3
gearhx bsllhSIM.
17 On E-Wps mglns, unscrew thWng1W

7.in ....a d wine

E-type
ttm &hd-
at
. --
 Manual geat#m%7Am7

9-t9m.engines sfarter motor Is correct&IItied. R& to

@! "&ve dha air clmnew haumg memhly
Chap&% Mneoessar)a,
+.
dl@-w .&w~r
b:UD-S* .thanut smqrtng the +X
e) Wet8q ~we new m/l
mmnhedti& the HgM-Md ddvWaft,
~ plns when,
p i s e Q a l w ~ 6 u s i n gsuitsbblesedmt
s
;j@%f
i$b&$Y!ti&@$@ wbfiamk Unbplt fSte n M t m d Uahm &rlbMe WIw
rnb@ng.Wn h?
gearbox,
$ Unbolt and fbmbve We rear mauntlng
,@QI %.rear of the gearbo~ g) Whw dlpp&able, c W the e n g h
g6 W fouthg df the englns >wIRrg
it and remMe h
m o u n ~ @ ~ s i mdnl tm b s , as
gmn In* rdevant Parf of Cha@w-2.
h) R&l/ the W r b o x kikh dl. Zvrd'check the
91e m s
M ~ m - and m r v e the partmtto-
'kkgrnk nuts. and bbm froin around fha
and from the darter motor. There is
n# to maGe 9m e r motor. S. M o i i $ ihe rn.:&wr WI.$hqlm
Support t k welght of the gearbox. 6i *e:gapbcrq ~ps~$iqn:~:&M& a~dr!w
&&iti+@t h g & ~ xF rn the *n,e, M e @ ! h L ~ @ ~ ~ ! & ~ : & @ & !~ ?Y~! , @ @ '
&Inp the gearbox end houslng between the and kllw plugs and 7 0 w the oi! Pa d d n .[see
en'gm* subframe and the front wing slrfe Il-). W h q ~dl6;Php oil h*,$Pdjned,
panel. GwNl use of a wide-bladed '&sn:qd reut-.mg.ck$in.,piugi:.wpmmg#
gsrewd+M ,my b ~n. & p w $ to. fr* the
behausing fpm lm&n dowel. Oo not
dlow the we@r%,@the.~@&bpx to h q g o n t b We pa@x, *&@g M%engine in the car. /f
Input shaft adei&Wf&@s,$epr ts e v a i ~ a ~~t
e ,may tw
Pivot the gearbox forwards to release the d e b b.pm$e the en s and g@~&m
fin% $Iyp section. Lm the~earboxupwards
frbfi fhi,e@glne cognP&Wf~pt~ bellli~yjng
t d r , . a j . des-2riiw In b€wa5
z ,and &I

bow isbin@W i , & r ; h A f P

rnOuf!$iKg h#rbhalw.
be r&md on refitting, and sdtable
will be q u j i y d ta s p t @wds of -@ df
pins.
Removal
eng?'ne, position a length of wood or a 1 Th& aeafbax Is m o v e d upwsrds from ths

2 &pG fhe & n i f b ~ ; t h e n @k.up,$qi?r?nt

of"tha.car and sumorb if an itxk sIantf8 h
uIlaIla&q l&-m
f@ scrpp&). qw9.w:ljgtqr
front rondwtieehs.
9 mm$y,*,e dth *rvce
bhpiw 5d *'la &~lea%eT ~ b k w l t h
mfermmto Chapter 4 8 QF 4G.
I ~ ~ ~ n d k c . 4 Remove the bmmf wEh rekrence to ad Unbolt-theme
m xw r &the swwl
'
4 Make sure Met W dff #ng bush for* Chapter 11. hub
7A.8 Manual gearbox
8.7 Bolts securing the left-hand drlveshaft
h e r rubber boot to the gearbox
Illustmlion). Do not disconnect the hydraulic
hose from the callper. Tie the caliper t o the
suspension coil spring wlthout strajnlng the
hydraulic hose.
0 Unscrew and remove the phch-bdt
WOa Unscrewing the boltssecuring the
swivdl hub to-- bottom otme -pension
sfrut
LtOb Disconnecting the swivel hub fmm
ihe lower balljolnt
8.8 Left-hand brake callper retaining bolts
- (amwed)
securing the front left lower ballfolnt to the
bottom of the swivel hub (sw illustration).
10 Support the weight of me swivel hub and
driveshaft on a trolley jack. Unscrew the two
bolts, and separate the swlvel hub from the
bottom of the suspension strut and from the
lower balljolni(see illustratlans}.
11 Wlthdraw the left-hand driveshaft and
swlvel hub from the gearbox. Make sure that
the tripod components remaln in position on
the Inner end of the driveshaft, d h m i s e they
may fall Into the gearbox.
12 Working on the right-hand side drivdaft,
where applicable, use a 5 rnm diameter pln
punch to drive out the roll plm. Note: On some
later models. the roll-pin at VIE inner end of the
driveshaft is deleted, and the splined end of
the driyeshaffjoint is sprung to mfaln it In the
diffemtial sun whew1 stub shaft - ignote the
referarrces to removing and refitting the m/I-
plns when working on one of these vehicles.
halaw law me merr!
&=
I k h g ' p m cover
~ WE,@mWdl
I
8.9 Removing the pinch-bott searing the
lower halljoint to the swivel hub
13 Loosen (but do not remove) the lower bolt
securing the right-hand swivel hub to the
bottom of the suspension strut. Unscrew and
remove the uppar bolt, then tllt the swivel hub
and diwmnect the driwhaft from the gearbox.
14 Cut the plastlc tie and pull back the fubtser
boot, then disconneCt the gearchange rod
from the lever on the gearbox by unscrewing
tho nut and removing the bolt. Recover the
bush from Inside the lever (see il!u~W8thS].
Do not separate the gearchange rod at the
clamp, otherwise it wlll be necessary ta adjust
the gear lever posttion on tefitting.
I 5 Unbolt the front left-hand inner whg
protective cover (where necessary, drill atii
the retaining rivets) (me Illusttations).
16 On F3P snglnes, unscrew the englne-to-
gearbax tie-rod bracket mounting halts, arld
remove the bracket (- Illustraijon). No tie-
rod bracket Is fltted to the F7P (16-valve)
engine.
-9
I
8.m win@ =<-
.
I
3 un&>$e- angl~+~o-gearbxrnpudy
nut IocW?h e 4 ths dght-hmd Makbbx
ouq~u)sh@(@e Ul~matbn).
18 W m - t o g e t h e f ha $lmlc clip, and
dkconrlW the speedometer cable kmi the
7A.10 Manual gearbox
&&a ABS unit bracket bott (1) and
geartmx mounting nut (2)
30 h s e n (but do not remove) the bolt
securing the rear mounting bracket to the
~eadmx,and swivel the mounting down.
31 Connect a sult&le holst to the enghe,
and I* It slightly. Alternatively, the engine may
be supported on a trolley Jackso that the hoist
om be used to remove the gearbx.
52 Disconnect and remove .the bottom hose
from the coolant pipe on the cylinder block.
33 On models with ABS, unbolt the ABS unit
bracket from the rlpht-hand innw wing panel.
Unscrew the uppermost nut securing the
geartmx mounting to the left-hand suspension
turret. Tle the ABS unR to one side, being
careful not to stmln the hydraulic pipes [see
ifiustrations).
94 Support the weight of the gearbox. -
35 Remove the remaining nuts and bolts
whlch +cure the gearbox rnountlng/bsttery
tray to the bodywork. Removethe bolts which
836 Short bmm (arrowed)on the left-
hand side of the subframe
d Removing the gearbox-to-angine
mounting bolts (amwed). ..
8.33b Ualng a cable Ole (arwweq to hold 833 Removlng the g-ox moumng
the ABS unit away from the g-ox assembly
secure the mountlnp bracket to the gearbox. engine subkame an.d the front Wlng side
and lift out the mounting assembly (see panel. Careful use of a wldbbladed
Ilru-06. screwdrllier may he neeoeasary to free the
38 Unhott the short brace from the left-hand bellhauslng from the location dowels. Do not
side of the engine subframe (see iilustratlan). dlow the weigM ofthe gearbox to hang on the
37 Remove the air inlef duct from the left- Input SM.
hand fmnt mrner of the engine oornpHment. 42 With the g m o x moved as far to the l a -
38 Loosen (but do not remove] the front hand alde of the engine compartment as
bumper lower mounting bolt on the left-hand posslbl~,refer to Chapter 6 and remove the
stde. clutch. This is nacessary in order to give
39 h e n (but do not remove) the two I&- edditlbnal room to manoeuvre the gearmx
hand subfrerrne nuts, and lower t h subframe
~ from the engine compartment.
to the extent perrnltted by the length of the 43 Plvot the gearbox forwads to release the
bolts (see illustdon). This will give the extra final drive sectlon Lift the gearbox upwards
room necessatyto manoeuvre the gearbox. from the englne compamfient, bellhousing
40 Unscrew and remove all of the gearbox- end first. If the hoist Is belng used, attach L to
to-engine bolts and nuts, noting the locatlon the bellhousing mounting bolt hdes [see
of the washers (see illuatratIons). Illustretsan).
41 Dkconnect the gearbox from the engine,
slidina the aearbox end housing between the
44 Rsfitting is a reversal of removal, noting
the follminp addWanal pairrts.
a) Be- @smklIng the geadmx io the
engine, position a lmgth oP wood w
similar dlsstancepiem between the md of
the dutch rela* fork B@ the outer &b@
* bmcbt on the p & h x casiw, In wder to
h o k l t h b M I n ( f s ~ p 0 s i b b n77?h
.
WII prevent the reteese bearing fmm
bemmIng dtsChed from the end of the
rdease fark during fhe mdttlng p r ~ e e d m ,
bj Make sum that the locatioon dowels rn
cmmfly positioned in the gmbox.
8.39 Subframe lowered to the extent of the
C) Apply 8 little high-meltlng-pbInt gmse to
mounting b o b (exposed thrsad armwed) the sphes of the gwbox Input &a& Da
8.43 Uttingthe gearbox out c.
Eompmrtmem
..-,.,.. a
 rwf Epply too much, O h J w i E 8 them ism prsvidedm~ld~~an3a~dXtlr
paadblltty of ih% gms9 wntarmha&$ me - ~@aJJ~$?weh
adeWmte @epby&q maww
d t c h fd~tiondisc, mthatnddn~bwerlmkd,
4 Mekstl~~tkifwmQFmfar,m
&riwmqtork~fltte$Wta I --
CbpterSA Ifnece&Yq -1 -ullng a manual g&rhox Is a diffhtlk
e) '$'ptllpvb~redjob for the DIY home m j c . In
&tUon to diiwna and reassembllna m v

mtwwp
tl
mmbq!hw
fer 8.
t <m&@lpM
mftwmetocliqb- '

and many i n s ~ i . e x b m d expmive.

y
Beceurseofdthlfme s&tm W o r n afault
rnahnd~anfnpCircaln pWlams *an be
c l a ~ l yrBW@ D sp?imiflc a- k the
side
add
e nghwEllln~and4rIr~~~ gearlaox* w h M c@n make crrmponervt
. m W exarnlwdn aM whqment WW- Rerfer to
the the " k u k hdingu &on at Ybe end of Wls
a not
Q RetWI%~I@~rnrn~h
G%apW1A dSb. manual Por m m .EnfbtTt@m.
htM

k;
a the'
glv9
"by
B the
lards
sing
( It to

I 10 11 #I a Q

L '
I I

I LIP ~ r b o xm lm ~m t s
I :t ~ k m e 8
a
%mhr0-aagI
3d/ilffim h 0 b
76 y&speed>$sar
15 TsVhd gstv hub
&~fi+k. m m h m
23*N m. 84 m m d p
I j3>, 1.04th d W 37Input&& ~ # s m s p e & g w w @%tsiS~ddbddn
I $ +lM@. 11 Washsr m ~ w g 25 5th e s p d f l g "uf+qpk?
I 8 WIP nstftmm ISWWC~ 26 5th spmd q~ hub 68 S O U W W ~ W
'B Q M W h l e a r 13 Washer 20 ardR 275& V d m r t 67 Whe,@.?Vd
7 M t p d g ~ 74 5th speed ddlp 21 Washer 32&vw&h&andgsar &3&
7 W l 2 Manual g e o *
7Bv2 Automatic transmission

turn open or chm dude Witl?hthe hydmullc

control olttlt. mi$muses tW dutch& and
brakes tp b l d :by r & m the various
wpm af% w + g m n ,and W e .fhd
n a m wb ~ r r n - ~ - g ~ , ~ , r v 3 1 m
Iqad, 7 % ~Infam$an from t k ~.9mputer
modulB can Be avedd#en by use of the
s@Wrtwar, and e padqular gear can be
hptd Ifmqulmd, w d w d e ~ g l n ape&.e
5 Pie e u t o ~ f i ctramnisdan duld is mk
ed
by v t n g kthrou[ah a GQD!? l o w on the
top of the trans!'nissIon, Coolant from the
~U~ system thrpu@.the aqol8r.
9 &$'$t h q # auW%c.
bwrnmsfan, any d t 453 @Miaul w.&
rrjwst, $8. refi toz@Vpenault dWer with p
s#@?\= @ylPw,t- *r , wit
npeZ3
dt86li' mand'rnpa3r:hi r i e&:a
~ ~rtarflt
develMg, LPq~inby MwrirPlg the fluid level
(Ehtlptgr 1A ot 1 and fhe adlustthehi ofAe
4 & o r mmhanlarn (Smion2).
Note 6 - qf tM fallowing &&ne tagul*
tz IuII-th?bfW &/&$on gttfri~ #mrBd#k
utim &a(Rei@q1t tesf e g u i ~ &here
~ f
this I t h ~ Ttre Miif $&ould not b
-pt& uni@@he n e m s q eqWrn&jlis
d I ~ b t %6&d%8$
, Y
i h i&&W&bn. WW
cham% m-at ' wmct smWs. '-1vkh
We
- S ' % & : # t & d l d ~ ~ i npravidestheforward
w pbrr-+S&dea, dwnainq m which of
I@o~rnpohentpart? are held statlanary or
ellawd 50 turn. The compmenk of the
gea+&ahan held or tekased by haw and.
.IThe t r a I M n i ~ ~ bcongists
n of a bqw chrt@haswhleh am aetlvatdd by a hy,dr4ulf~'
4 - ''WnW?jl-uhR. An '&l pump wiiWn 'the
%verter, an epieydlc g e a r t ~ , ' ~ y d r p @
o p n a d clutches and brakesiw kd&$ If-bkq~ p m v i d ~ % ih Vyw~ lfc
cdn@I unit 4s- IlLwtr+~). L! ) % I >r - ~ : ~ r W u r $ j o : i 6 mtth
a e m , w dclu@bes.
2 $tx& torque ~oovwterp@$tc%%a nuw ...lo tW[$e$ from & M W efid ' swsars
. . N i n db W ~ m englw and tqsrnbsrsio~, ~cdn@@ t~ q? Tph,mfmign~R&Ba d
h i ~ wl-
whioh acts as an r l ~ t Q m a f k : e l u t ~~IBQ t l n k q e s am dlrwAtad to s q o m w
p V I f % a<degree of torqua multl)Mcation mpdub, which &ermirles the ratio 'b be
Whlml9&lhg. s d ~ t e dfrom the informatton MeNed. T ~ B
 Automatic tmmissim JB?3

MwnaW the cablexend Wing %om the

w.
4. QKeW that the k v pn~the ~ trtmsmi&ian. Is 6 U m MTmr nmswmflmfhe sefeotor
I? ha 9"positbn, and If nec- movb3hs t&w W&@YI~&ta W,un$rbady, Wen IQWV
~C~GOfdiw~Y, t b ~ @ @ , ~ n m Ws c tlFlIW fi-run the
6 G h e that the dimension beW&t'~ %4 idwlorWM~ s e m h t y ~
&lqyQ ftXtW ai'd the auTw @1a lwqon 7 &.ryg $&$and wlftidraw the cable
Wk$tL akshirwn (wtImhalion).4f thb Is horn hsrel-r. INw ammh!y y d from h
qpf the wsb, 1~-n thavbra~btmunt4ting trandlmiorl,
n'ut:[~).and move the bracket as n&=ary
3#!@e dlmWplm is qrwnt. Tighbn the R e m a q
8 kdhWis,a revamat of mavd, but adjust
~ ~ ear, r,rneve l from thed thk &Ism
~ ttte gaiter ~ d M b ~d in W o n ~ 2,
lev^"^ with refwen~sto Ch- 11,
a. L m n the f w r adlustment
~~ sdctirlflg. the .mntImI mrqg tp the
Iwer assembly (see illrrsfratlon). Aign fie
dW+rti&wM k the "D" p#lfl$i% fim Plgttten
,the-" ad the g&er..
p.bpm$qrthe qlhtgr able wver B~OPPY gate: d new &Hng Seal will be WuIW on The kiddown swltch Is an i m W pW d
mlng It through a qudar-tm. Gheck that reffttifllg.
the aceeleratar NIpr. Rder ta !h~ !~@@
d@.caMe slldf& part of Chapter 4 f~~.d&ilsof a~odmtor
&q~opw&&a eabte to fhe bottom of ib Removibl &,k W d I - ~ l T d ' m .
&&t&, the qwer W p by
lever, and t r g h t ~ Whqe g.ms3qy, pmwe the @P clean$
m h g itthrougha qua~ter-turn. hou$jg &embly iarlth referanize to the
$.R$tW&tpWet$it~ cover rs thw spleWr 4:fisw
kl&WW$df$
k@r*mi* 2 pl$"arln~ctbasjmdohider cable from
30 thq -the a d e r lww' moves
U&p,,and that"the m e r ~W d11 only
* p " ~ P & ~tP*&=Q2&
h~~
$w-Mth 'POT u N p d l W ~ dCU$B
, 8ehW
MI#-* Park $untilnn o ~ ~ r & G
tw@~WY.
.$bnfll adjgslmenka may be made by turning ~efitftng Removal.
the wtPa4iable cover stop through a auarter- -_I L .

.t&, @eq pulling or pushhy. the cable as 4 Refitting ih a r&id.Fkd, me fe!nb\~d .i The SF@ Is l-onh'e top h-
I ~ g ~.b@mtlglMinQ
r 4 the &p,.&n; prowwe, using a nw.Odng&. hmd
. . side
..",, . of the trahsmission
- 4 -
(see Illu-~rJ.
J$ k w e r the- met gmrud.

8 Apply-,W mdbraks, Wk up th&fr'mt

@fI@Wmd d , w M~Wle,W.n&.(F
~ t @ a r n d ~ ~ ~ ~
q.iy#@
the w3rnaue'aa&Wac IPVH to
' @ d m 'Dm;
& ~ , t b ~ lby pulkg ~ r tt hard
Q ~
-.
& ; { i ~ ' n g under .the car, remove the
, '&$$&~vB,xxIw~ from under% sshcbrl-r.
ipmmw the end fittings fmthe I I
&mm a a aetwtor leverand frw the 7.T Speed sensor (amwed) loc*~
Imnn@iatetewr on the tranemiedon.
7B.4 Automatic transmission

2 To m o v e the sensw, flrst dlscamect the
wiring lead from the computer, on the left-
W e i d e of the engine compartment.
3 Remove the bamy and battery mounting,
with rehtmce 'to Chapter 5A
4. UnsG#WIhe mounting bolt and remove the
clamp plate, then pull the switch out d the
bansmission.
Mfittfng
5 ReWlrg, is a revanal of the removal
pmcedur6,. but before using the car on th.8
maPl~eioompmrfu1I-throttle posltlan should
Rs v d l d a M using Rsnault test equipment
from the fuel Injection system throttfe
potentiometer. Refer to Chapter 48 or 4C, as
appucable, for -1s.
2 Flt hose clamps, s available, to the coolant
hoses each aide of the fluid cooler. The
alternative method Is to drain the cooling
system completely, with mfemce to Chapter
IAorIB.
3 hasm the cllps and discannb the h w
fm the fluid cooler.
4 Unscrew the smclal rneuntlrtg b~ltir,~arld
remove the fluid'&oaler from the top?&the
fransrnis&on,There wl bet some fosa of duld,
so gorne dean rags should Be placed. w n d
the cooler to absorb It, W e sure.that dM la
prevented from'enteringthe hydraub system.
9.1 Automak Xrrlnsmldon ~ P u W 5 Rlrnow tho apmlal bob, and emmlne th'e I
location (arrow@ O-ring d s for damage. If nsrcesw, obtain I
4 Dlseannect the appropriate' wiring plug a"d fit newO*rtng
from the computer, en the left-hand side of RefiftCng
the BngIne oonlpartment,
6 Refitting is a reversal of the remov?
Unscrew the mounting
the Bensor from the hnsmtssion.
procedure, but check t h tmsrn~ss~on
~ mid
level wlth reMceto Chapter 1A or 1B.
~~m~
6 Rdfiwng Is a reversal of the removal pro-
cedure, but bdore using the car m the road,
ths computer full-thmttb position should be
validat4 using Renautt test equipment. I

The automatic .transmissbn must be

N o k B&m ptaheding, mad the note Given removed t u g t t i i r wlth the engine, Bnd then
in a t f mI . a e p a W an 4 h ben& Refwm Chapter 2E
R~~OWI Access to h e frffemdal output 011 -1s 1s for the rsmowlma mfittElrg Procedures.
1 The oomputer Is,mounted on the IeRMnd gained by removing the output flanges. This Before*t~tbcarwlw~rwrxrmp*
side of the engine compartment (see work should be cawled out 4y a Renault fUbmMe @Mn wtd Qca
~h&man)),If thsrwmp~terlssuspect& of garage, as speclal toollng Is required to Rwault-
hauipg a kit,the car-should be taken,ta-a overcome the tension of a large spdng
lhduKd&r €oha* m e sy$teqn 6 ~lclcafed
. behind each of th6 flanges. Also, It is
2 To remaw,the computer, disconnect: the necessary to vatldate the full-throttle position
wlrlng plugs, ndting their positions. Release using sR;%ialFlenaulttest equipment.
Ihe s t p and withdraw the computer fmm Its
bra&&. Take care not to allow any dirt or
fomlgn matier to drop Into the wlrlng sockets,
ReflWng
3 Refitting Is a reversal of the removal pro-
c d m , but Wore uslng the car on the road,
the computer 'full-thrattls wMon should be occurring, it Is flrst necessary to determine
validated using Renault test equipment. i The fluid ~ w i w
is located on the top of whether It is of an electrical, mechanical or
automatlc transmission. For better access, hydraulic nature, and to do this, special t&
remove the b m and mounting bracket with equipment Is'reqLjmd. It48 tkw mntlal
reference to Chaptw 514. to have the wark carried out 'by a Renault
dealer If a transmiion fauR'ls auspaed, or#
the transmission warning tight an the
lmtrument panel IlluminatesconQnuously.
- @ ~ q ' l E ; $ w ~ , wad hnO& ~ I w
in Smh'r. -
>, - , J..,-' than -20aG, the au.ufamaUc trammission Pluld
Removal temperature Is tao tow. Continue d&lw unttl
I tine p m m senwr is mounted on the the light goes out. w iiffa~hesunder my
lower front df *he transmission (me circurnstanws, the fluid temperature M o o
l~stPatT0n). high; drive at a bwer 8- until the Itghtgow
2 To remove the line pressure sensor, flrst out,
apply the handbra@, fhen jack up theTrht of Do not remove Re transrntsslan from the
the car and support on axle stands (see car for possible repair before professional
nJaclo'ngand vehicle supporp). fault diagnosis has Hwn oWmd out, slnm
3 Remove the splash guard from Under the 103 Automdcfransmblm Pressure most tests rqulre the tmnamfssion to be in
automatic transmission. m s o r location (amwe@ the vehicle.
Chapter 8
Driveshafts
Contents
CV jdnt gaiter renewal (a~rtornatlotransmlssian mod&) - general
information ...........................................
-
Orbeshaft removal and refitting ...........................2
Drlveshaff overhaul - general Information ..................... 7
Driveshaftgaker and constant velmrty (CV) joint
check ............................... .See Chapter ?Aor 1B
Gmeral information ...................................... I
6 -
Left-hand drlveshaft Inner gdter (manual gmbox models) renewal . 5
Outer constant velocity jolnt gaiter {manual gearbox models) -
..............................................
renewal 3
-
Right-hand driveshaft Inner gatter (manual gearbox models)
renewal ..............................................
4

Degrees of difficulty

Specifications
General
Drhreshaft type ............................................
Equal-length solid steel shafts, splined to inner and outer constant
velocity joints, vibration damper fitted on some shafts
Lubricant type/specMcatlon .................................. Special grease supplied in sachets with gaiter kits -joints are
otherwise pm-packed wlth g r e m and =led
Torque wrench settings Nm
Drlveshaft retaining nut (renew every time):
Myloctypenut .................................... 250
Self-locking nut with Integral washer .........................280
Left-hand driveshaft gaiter retainlng plate boRs - manual gearbox .... 25
.....
Driveshaft to transmissionflange bolts - automatic tmnsmls~ion 35
Roadwhwj b o k ........................................... 90

lenm, open ,drlv#hafts. thread&= that it can be Wend to the hub

2 Both driveshafts are fitted with a constant by a large nut. The jolnt contains either a
: velocity (CV) joint at their outer ends, which spring-loaded plunger or sjx balls withln a
may be of the spider-and-yoke type or d the +cage,whlch engage with the lnner member.
ball-and-cage type (sgeillustratlona). Each The complete assembly Is protected by a
1 Drive Is transmitted from the differwtlalto Jointhas an outer member, whloh is splined at flexlble gaiter secured to the driveshaft and
the front wheels by means of two, equal- its outer end to accept the wheel hub and Is Jolntouter member.

'1&1 Sedlonal view of the splder-and-yoke type outer constant 1.2b SmcHonal view djhe ball-and-mge type outer constant
vefoclty Joint velocity joint
1 Mer member 4 Dniaft (3 Gaiter I Outermember 4 Ball 6 BaNcage
2 Thrust plunger 5 Outer mfalnlng 7 Inner retaining 2 Driveshaft 5 Inner 7 Clm!Ip
3 Driveshaft spider clip clip 3 Gaiter member

'I-
 roll-pin is d e W I and tho spKd dbf Wte with a m m a f f ~~af!smlssle~,,
MolykpP* BIB
g m e vlll l @ ~ 9 u W ' - @
&b@@ thig!I&
~ ~ ~m ~ r
-
ffe&#$ml;' ' :. .I;I -; >
A

wi€hia tripod joid,,,bW~hai$okeIn which tho

4 M y 2be &&k;thm
of the whiole anb cuppott
(m@
*&Mrrg end wh& p
w~~~
iaek.ugthe-
;
;
drlpddm$k - ~ ~ ~ P#~ f i d of thQ ~ madwb&.
ka p~ p yJ o ~ e ~
the &mkid.l s' Wheat. Qfihi&s16i&e 2 RWlaplwJiwa mdwhwd bolts to.the
g h t Is secw~;&e IranamlmJon casing front hub, wd tljhtentbm wrir@YhMW*m
wkh a retasirlh~&a, an6 to a MI-bgarfng on assistent-firmly deprewf ha*bmW @id@f6
we
,wh
W
driy@d'."
I Whlch;do* s
G
M
i
f k
a 8r@dningdip. -fie
t
,t@ tuin~lfhlrnttw
prsw&W W 4 fMnf hub, .Wm . m q ,
$,Ibrrmrn*,-bh a:w1fO w iub 'Ud&
whwl bB,
and hrw $9 pol tu prmWt4w
*,
4 On vshicles Srpuippd wlth aukmatic byP fram m@@g aa W ?ti%?,@
99-
of9 rtght+md.tnner
r$:-~onalkh
-
d o c l t y joint Rea90 type t@nsm!+@8nJ kpth f he;l&- and rlght-hand
Inner Writs: &a fki sWa Each lolnt .Is
&ik4t grr&nbl (we
-P?W
T @ I : ' ~ ~an s-
and .ajsna %xt&&q ha,~ B C M . dm&&
4
setup$to ,$? Wsnl'IsSrm;ddv? Aanae by six the g m ~ 5 W n f n p .en ;~ I y 4 I p
r#ainRg &Its. wlth the out& lolnt, the i a j 'This .nut d ef
@ i$
d , t* .
cqmpktei-bly I6 protect+ by a flexible $tie mpnlrt; a newone &odd
.wlter'whioh' is secured Yo the driveshaft and b~ud~on-dwng.

any atrain on thfhahydm1.kbPaki,tie,' .

4 Slqdmn and remora the nut %e&flngthe
Mi@& g mpoht sspami.w tool wjil be ateehg dear 3rwk7"6d end k4ljpIrot.w tke
f@@f@d*hfifii% w m . A A8w ddv@8?#flswlkel hub, Release the. bal!jalnt mpmd
nbt wIlI 4 e rdquI+ DR mflmng, and when shank ualno a,.mpqW,gIJi~in! ERWF~
workhg on theRdMt-hand ddve&atY pn Esee 1-M):
",ud& llp!th a mma/ gewboxi a new sun 5 S&hw&&'rmwpq th* two nu?s and
w M s15"r 04ng sod, @me WWL new w a s h d ~ m 4 b b& s&wrfw lh&dVel
Udw!i&-*sun y h d rail pins s u h e hub t~'fhkiquefiWdlonstrut, n&ng that the
&t ~ i l l&bd~ M- s ~ a m&& nuts m8:&$ltfoh'ed ofi the mar side'bf-Nt*

SIrgi$&tlp$i Nsw - p w d as *Abed

u @ & % a m Mhd Whg.
McrcrWm- I

bf&4wiM ftwW.gearborr
% Pa&ittn a_bul@Me;e&t&ir$ beneyW&;
g
* @a!n NUQ,4g m e the dqi@
QTuO,ati @liswthb fq df@y fpR)
qew%o&'Owthe 011 has drk'&, flpe &3
pm
tf.li&&~2rf the drain mug elsetm, rMt It tz,
dghw #'=rely.
2.2 b m ~ t t r e d r i v e a h * ~ * n & ,
and w a s b th&side Of$tyfi..@s@@[sree BlWtpWn),

,- -
'23 .w!qn&aljrdljQM*pwwwmb- I
lhtraakr md m l ldja4ni frurm:I's"-
hub
 I ,metop aftha swivel huh until
.We d w h a f t tripod joint Is dm& fmm (CB
,#q be prspamd far some bib spllWe.asm@
&int Is withdrawn (3- JllyWMan). -Be
1- ' that fhe mllefsm the end &thb Mpud
!*not fall off.
$~~
0.. the lomu bolt sacurt~ W@BWM
hyb to the,auspmirnn strut. ~ m care-not
n ~
40 @maw,$he drlv&Wt ?elmi& the
&city lobtfrm -hub arrd
W&iv&M, WBR$ iTW lwkjw flqld
\*ml~i.ta*8 outk -ant velmlty ~ohlt
~ @ l l briurjng ci&smbw, @$k is Ilkdy?bt
they will h a tightfi~inthe hubsptlnm W a
:K&nmer and a @t rnw drift to 'tap W'jolnt the ~ I s s i a l
out of the hub, or use an &tacim to p u d tb Left-hand dWeHmfi
&ive&aB ~ uoft the hub (sef3l l l ~ 0 n ) . models whh rnandWmWx
-
~ 7 h w I ~U ~ . -
;IT W w i d ~ ~ % s ~ e l & ~ ' tbn fm~ ~ ~ $
~ w i # m m u dgearbox ttm tripod jglnt into th~lasun whwi yak,
ksspw ~p#f$g&#,r n ' r l # @?"&I fii: & j
- ,
pmdlele,
l a AI$n;!M.tWnlnQ~ W K irshWt
hoka defg'the r&inlng bolfs, and tlgwn
kheril to the splflutorque. Ensure thanhe
ge&w lsn NW.
18 Ch&k:C~'w.$plines on t M drlvesm
o u t e r m n j a~l h t~- a hub
and dryA8 '8 &mN $ @ ~ t p p d f l v 8nut 8 ~ts
t o . b e T W , apapFily..amat bf IocWng fiukf.tb the ~ @ : q @ & ) t e r l the madwheel b ~ b & * ,
s@lm ~ ~ ~ ~ ~ q u e .
20 Movethe bp.dthe s W & hub inwsrds, at g7 R @ ! ! ; W , , m with dl cies~ribd
the aame timamgagim the drtv&& with ' Chapt& l A of 1B.
we hub.
u d 6drivdwk-
21 Side rfi& hub fulby ohto fhe driveshaft Righbhaqd b '
splines, then ins& -mew0 auspenslon strut f&w@;
mounting-bob fmm thefront sided the strut-
R& fhiwm- and nutsto the wardthe s@jnd
/ i l ~ ~ i dda~whj~b~i&@M,ta
g n d 9 f ~ @& jh?
i i ~ ~
balb,md>aamthem the sp%Ked torque
(CbpW 1O ~ ~ ~ n s ) . awn.~ h - &&@WJT& $&'w
&cib s
@
SZ .Slide on W washer (Nylcc-type drbehaft - i-m ih% :~ ; - '&.i&
n u b onlv - ,t&r -If-lucking ;$lvwaftnut3
haus an iintagml,w3sher),'th'en fIt fhe irew
&iW&htalnii.lg;h& .mtitentng It by hand
only at this B&F
H R ~ n n e ' t h @ m g l ~ rod c kbdjlljolnt
to the swivel hub, md-tfghthits t pb4&lQ.-a
to the spMfm t o r n , @barn$ -10
ewc-Q
24 Slwe the brab caliRy a?mbiy Into
pdtion ov& the bake dl&. mf
thb d l p r
mounting b~!t,~,.@vlf@f Ip3 .w~Nd
.s,h w

tiie roll pins zzg Tighten thm eQi*'retabline nutip

pin punch the specW4 torque
229; -Pit-she O-ring dtwh & & W l m..-A-
shaft... l=r H
enslrrhrg : ~ r o i ~ pMI ~
*.-wM
. -
roll pin bobs are In aimen4 (see paraffin, or. a m b l e s~lvent,and dry It
). SUdg th8 drlueshW onto-theBun 4ho~~ughIy,~rf$ out4 kigual tnspdon of
weldrlb, .
90 D m In hmv roll plns wlth their slots gQ" 6 Move the dnner spljnd driving member
apa<fi,then seal the en& of the ptns with fRIm slde to slde, to exgrow each ball In tqm
&ng cornpourad (Rmaub W Tt11W d fhe tqp 4f IA tmck Examine the balk for
or q m ) (me-illwmana). ara& Plat+p&-or signsot8urfacephtIng,
descxlbdd "In 7 Itppsr* t& baH,iracb:cn the Inner and
wtermembersi d! the bwkhave widmad,
t h a w l & W l l l ; r p m bB+ ~ tuht fit. A? 1h8
s#lla.tinW,.&k@&the M l w e windows W
we,@? mw
Ef2 Erwm the ,inner conslant velbetty jolt14 P Ifan.ins-on
bpw@n~thswidows.
my of4h~1mnstmt velwity
m d - ~ l ' k d b tW i Bflange m a t I h ~ - s w j0lnt
~ components are found to be worn or
are dleran and dry. Pack MB dlive flmye amgad, It S(vlll k,m#smy to renew the
mW& mlyk6fb Bm @tWb& (in'dkble c o m drIv.wW ~ @smbly, sinoe no
from p u r Remu# dealer). mrnpcmenb arre wdable sewatsly, If the g a b 8 a a l m e & o ~ t k P o n p i m w ~ h a
m E m @ ttw dksrihM .InW-GPmtant lolnt ~16.ID mtlaW0i-y mnditinn, obtain g
vWc& j,o;l.~$+wit41thp *nmWm ,drNe rSpalr.klt fromvyowR e m k dealer conmng ~GEed*cEamfwnd
f l a w , &en r& UI@ sh relnlw Pglk @f8 new @t@r,~mWr oalh?Wlnlng wing, ~ r s & ~ 9 + l w ~ ~ t h m ~ k t k e j o
~ a r e i mbn
y the d > y A gk&bg, d .wbe ~~themrr& We and quantiW4 ma=. wlth the gmae supglid. Work the QtwW
off: srj~Iw:,@a&. T w , m @t h ~ - q & m on We end of the M I Into the I s d tmks, and flM thewkerwfth
84 C y out 'the,pmadures deacribsd:,!b UrIdwhTk, -then Gs F
itLB tJx*'rubYIRIr 4 1 8 t anti am WESS-
paragraphsl.g?6>2B, ~
e . ~ o m h ahaft. Lpmb the Inner end +gf $2 l d e tka outer Itp of hihe,pdtec in the
th,gra~* onLq!mvwi&, and swre It In s a p.on the Blot QWrytrytm"tbwm , W h tM
@i@l with hrubbw as#. mpllng alignd with the Weshaft, lift the Up
l a egmovw ure-~w~ tm $li.dame m- .bYYlte g#te"ltb aQoallee the $r pwWr$,
wlo~fiyp n t mpllng o m the drtvmhaft un@ S~cu$e the g@i@ In posWon with the ldk
the' lntemgl ettwSllp lemte+in the drIv@shM W : ~ @@ha I ~ I . U S ~ Wt w lehgtha
~ of ~ol&$
$oDve. m & l ' ~ ?to~e a s ~the spring into p6sMh
I Remav~the drluwahdt as dsscrb'ed in 11 Ch& that the drdlp ha3ds We Jatrrt &pa-n).
%@on Zm t3 t3HecK that the &netant velacffy Ioffl
Pat thmugh ths gait& m h l n g cHp() ar mfoves'Mefy In all Qreetfphs, then !Sffit %a!
,@@& the E@Iningia~flh-s-and inner colw drtvflshd to the mPde as d w d b M -36
[w q$&U&e), lhm slide the flafter down the W o n 2.
Wft tQ wpose the ouQr mnstant wta~lty
!Q?ld*af?d-y&e fy@d&IM
N a b A suitabls Joint repair Iiif MI/ b~
mw.
18 Ft$mnwe'-kfnner emhY vdimf@-P#I,
b w p Q md gdBr (w ap!\mb14, #
W ' a h % & 5 & ~ @ m p- ~ .

noting which wap)aroupd It b fitted (sw

WWtmlm).'Enam WaVthe legs Qf Uw pull&
mt only on
oy~wp~&-~late
hBbWMh, oIhW&&M~'dhp&
~~~
dll
6 ~ ~ttret ~mstknt
h v s j o o ~ jt ~ b reim~vaci
~ and M > a w a yftrrm the oatw m&l hausmi
from the driMaft, k I h h tb8 joint using as it is m v e d .
 ...thewaide the g e m tnto +On
wettl~Jdnt
f8 Gh$ok the drivdkft ftsijlddr and outer
member yokes for eigns of wear, pifting or
W g an fhUr bearing surfaM, Also cheek
khtthe outer member p1votssmoothly and
I
-,
*gg..fi
with na tmcw of r n u g h m
Inspe&lon reveals sign& d wear .or
Pr wlll he nee-wry to rmw we
drlvesb'aft camptprte, 9tnm no eomponenls
ate syllable sepmtely. If the joint
~hmponenthare ln sadsfauhry condition,
qwnr ppslr Idt mWlng of a new g-,
.t&dnhg dipsI and t b - m e c t -@pa and
W&ofm (- ~Wusmtion).
.BDI- T p eawi. t h spBnea
~ on the inner Wd of
Wm d&&aR~ttlwi wefully slide the aubr
mtow e
m :Zi Release tha/Imge &inkg sprihg and the
W .Pack thrt,@jnt.with the g m m suppiid In
$Wwb&r*ik Walk the g q s e wall intb the
ipint, and fin the @ a r ~ whh any-wcma bee
-nr.
WIIl%se h fdPbteFsouerihejdnt, and msum
*ah$ gaiter limre c o w l o c ~ ~.bhQ l n
pam ma en the ddvesbaft and corn rheljrrint
C&AfllmWatton), Wlth the cawling albned
*~%-drlu-, iift the Ilp of fhesWtwto
,@pJthrsalr@ w@W.
a Ffl the b g e metal mtainlng dip to fhe a4 Bend wp &arntj-mpmde~tbwpwith
$$&r Rmnve any slack 3n the salter
retaln?nq clip by arshrlly cornp~ebimgf h ~
-,alpi.&&
~ i p~
g :~ln& b t
$ewre hd ~ ,
i Rbmom' the c l r ~ ~'asf &t M b e d h
ZP TO refit 3% 4mtibn damper (witen w a n 2,
appll&t#, lubricate the driveshaft with a 2-0"'- m md m m d b w
&lirtlm af wapy waiter. Press'w ddve the
vibmtiun dam* ~ W n the g shaft, using a
tubular SPWt M E h , !?monly on the .
dmn@r.Inw6r bush, d l k Is altgnd with the
mark made pKor to m k d I
P5 Wt the inner cmstant daolty joirit
cmponmts as r l W M In 8mtian 4 ~ $ 5
bwppll&e), then r&-ttie dilvmbft bthe
v d 4 d e ~ & % d MR -2.
G1WgrJIe ]em
Naw- A s~ite'bfejornt rep& Idt wl/l ba
E
oq
r
w t
I~p$bf~rnnir)g Mlw, then d d e the gait#
[$OM ~~-&&&ose the jmt,
+
4 U$ng,Piierg, q@!I{g Be_&4P tbs a*
se@afkm pfake tangsat the $2'gmw (see
neceswty4gwure l$wfo[Iwa-fR pl-p.us8Ing
tap@M& r&&$:r @? *bv ~ U W Tmh&&.,
' fhl,
rdlw are rn_d~"to the,@p@i$mt stems,
plbm.ta ~ m , p m t . w b r m e m b e r and it Is rmmRaht that k%y are not
WW low hterchan0ed.
 4s . ;~hd@ih#WIktcWW~Ii6enEWBm
b

the drtv-end
AT? Wpztpktt3 dbndons k r m-
fmmiMthe arftt~epatalfwplate tangs -

6 me tripod brni ~ . . ? i w h . r e r ~ ~ t(SW

sed
€hatmum).11H b tT& & w . ~ ) d i ? Qff the
ddmshaft ehd Wng a pGe;lihat tSle
legs.Mthe pullef se'lcmteel behind tfle']Unt
jwer membw and do not contact the-jdcjfnt
dl& Alteratlvely, -puppad '*ha' inner
oLit US/t~rra hydrauilo pms;agah m~lrlng circllp, ensuring that &t is correctly located In
th& no load Is & i d to thejolnt tdh. the drtveshaft groove. Were no clrcllp Is eetainlhg @q &&bt We%tetkhed dwhg
fit4ad,~p~urwYha loid h pasiXlon by staking O h e $ f i ~JPWDWS
the end,of kh8 dn%@h& ftn f hrere qlabe8, at 2t C k h tPi& i6qnshnt vehBiiy Joiut
hiqvabof 12p,w'hgrt h m e r and punch. mqvers f r d y In dl dlrmti-, then r d t tha
1s- Wenfy :WPlb& the mew mfftainbdIn d ~ , & i d ~n-S- m ~ c
MWEI$+ @amund-theW p d jdnt and Inside
€hd oihwnpmb~r.Par& tha gal@ with the
w-@ndw.d the g.- RG+WW joint
.B E m r h e the $ripadjsllnt, rollers atd outer .w Slide W&o& member.Into p&bn wer %o;d? A s W l e ]clkmf q d r kit wHi ba
gew~@r f@r any slqns of gcoxirrg or w. t h Mpad ~ 10in.t. *I@d
@it& thet tke rollera movemwthly on the ?5 M n $ s.piaca qf %5 rnm thick .sre~lq @ Ushoia pair d prfps, bend up t h a W
e;fpqd&ms. If wear is evldent, the pod joipt SIrnllar mateflat,.make l i p 4 suppd~-,to Ibjrlt cover& prSfnts where R hag W n
mid roller m b l y can b~ r e n e w , but It Is the dirnensims shown 1-e i a t l i , &a&d Illto ltYe outer m m w rwesses Ism
&i p ~ q t b kto obtain a rHaement outer 16 Posltlan the supmrt plab under *oh a-nl.
membw, Qbtaln a new g a b , rwriing anti-sepamtlon p l w twig In ouh M Ilshg a pdr of snips, but W gaiter Inner
d e quantity of the speoia! m e m b Ih h n , and* the tang dwn Q'W &lnlq clip.
the supprt pledw Remove the plate when J 24 Using a sofi I@IIdfift, tap the metal@lnf
the tangs haw W n #turn& ta tiwir-atQInd wbr off-m.0UteF member, slide lhe o w
shape. member df thw 4'of the, b i p d joint 1%

'pre@aPd to hbld #-I& rollm, in p l w ,

ahwise &IW I#V $811M the M odmB.@
the outer t~&wk ~ W J I if. w,
secure the rollers In PI- using tape-
m o w a l afmc oupr ~ ~ r r rdw f k am i
mat&& to the trijmd Jnlntstems3and ItC
)&$orhidWqt fhq-wena Inte&h@n@.
25 Semue the @ad IoInt and -6r
awmMy, arrd,wmlmthe @nimW
fOl' w*W> UElsdgl ffaq 'h7f~m#:&Wl dn. In
pate~tbphs8 tg g of thl3 Sedom. Obtain a
repair kft ~ t t : s M l n g ~ o f " a ~ ~ b r , d a t ~ f ~
m a1 :m mmd joint *mbr,.a,@ wm.~.otd
type and m mofsWgtmh
 27 Tape oVer k s driveshaft splines, and slide da~lsrge.tlp,driveshaft aplbgs or joint rollhsi
tl-mpker md joint EOUW assmbfy'olstp~ttw Alfernawdy; s u p p o ~t h ~dilv&ak
: and
driveMt press the joint Into posltien wing eiihub
PB Refit
' We tripod joint as d w b e d tn MWpr which bars .only,on the,hi112 Infhr
;?tmd-tQ. maybr+-
distklbute the epsdd . p a g e rlfr,-$%we<na-m~~w~n . P W I ~wmme
mPd#iMbdIn the repalr kit waund m%'tt@M Jml@;.&#fhg thatit Is c o w 1onW:in
Jdt&mi$&M~ rn~pnhr.Pack.ths
0,- ththe 'dW@?av grodve. W h W no dlrcllp Is
ndw of'thbgrease. fitted, secure the jolnt In posktlon by 8Mlng
Sij& the y t w m m k Into q-n
1,< o w the end PY the drive8haft In three pfacbs, at
Mk- !ritrit&.af 9 2 ~ *. ,h a a hammer and pumh.
51 Slide the m& faint c o w onto fhe,OW 11 R#ftt,:@v driv.eghaft to the vet~tiick as
tnefiimt ImnM it&flush UCththe OW ds'N&&d Irs'Mih 2.
the joii cover In pwilion 4.32 P i dimensionfor the d p h t - w
recesses id the outer d-.Inner c o d n t wlaelty joint
mmW, uslnp a hammer and a roud-mded
pch,
S.2';
Us1ng.a Hunt &,carefully lift the Inner tip
:wC*em r p%,wuW the air -ur& WWi
i h h d ,wmpre$s the joirjt until $e
tt)%mi3,
6 Owing -to the tip-ty@: seal usad In t h ~
bed@, Yhe b i n g and gait& must be
d i W W n from the Jnnw enci d 'the g&k to p , d Into pasltiqm If hamherand tqblrltu At the tlrnet6f fmp, ng:inf6m,ation bn
%h;lAat end We of the wter member k as drlff ~ d t drh,otheassm&yontothe
o drhreshaft dlr)mantGr~~ wwailable fw f h ~
q,mqQ,(w$ IIIusm~on).Hold me Mer drfv-, l b Is ~risk ~qf dist~&g.*& +. h-qdels. If gdtw 'rdewq! is the
m Pin this~p&tlon mcl withdraw the md. 7 R e t he rewing pl&e 40 the d t h h a f t , driveshaft' should be rernb\rgd 'f@m the
~ ~ F f t ~ . ~ ~ f l , m t adip
l nfd g Inner end
I nthe ensurlng f h q It Is fipqd ttw coffmf way ~ d 9 n W In W
v e h k l ~a%, an 2, a a Wbh
ofMa gab. h a w e my slack in the gaiter around: to a Remuit dealer.
rM#nfihg clt~py m t u l r y cbmpr~klngthe 8 Supm'the chlv-, and prassttw p i W
@&'.section of the ollp. In the-absenceof ~ k ~a tubular
b & d f h ~ & f b ' ~ flsli3$ me&
ih$ swcial tool, a pgr a7 ptncg* ma$ be whikh k s only the'bearing inner race.
*. Check the constsrrt velocity, Joint
PpsKion the bWng sb that the dlstanbe kam
the end of thecdrhshatt to the Inner fern of
@pv# freefy In all dlre~t3ons,then refit the the QmmISW S ~ ~ rnmm]. I
$.**rn:*r n w in s@on 2. 0 Align the marks made on &mantling, and
engage the trlpod ]Qirll WHh the driveehaft H'any of the cheeks desctlbsd In Chapter
spllnea. Usa a harnmer and s d metal drift to I A ar 18 reveal w a r In a&e&aftIdktt, R g
-%ip the j~[ritbm@thdTshaq.taMw c ~ l brlQt to r m v e the fp m .
d W h br-c&tre kg<'las'
.appropriate}and oheck that t h diivesbt
~
ratainlng nut @ htlll corrWy .41Qhtene#;,.iJin
doubt, use a torque wreneh to check It. ResHt
Note: A suTtsBIc Jofnt repafr kklt wlll be thwcentretap w Mrn,,and repeat the che@c
@
j 7 P w * ~nthe &st d m k a f t .
T Rbrnbv* the driqeLhft as described In Rmd test the veMde and IWn for a
$&ion 2 rnetde etialng from me /mntm .tha
UWng, drCIIp ptlers, ektract the circlip k'dtiven $lowly in .a ~c,hle,m fu!l-I&. If a
secMna +ha Mpod Idnt to the drtveskfi. e$lckiognolse:W hWd, mi$ i t & ~ B swear In'
on m a rnocbla, the joirff may be 3 ~ ,WBW
- Mq@@d@-ioL
staked in position; If so. rMeve the stakings W~iiii&h,~Sn~&@eht
with'kgtd s w d , Is
~ ~ s ~Using ; of Wnt ot a hmmwr
l ea dab . ~ t & m u g hthe vehicle when .~~eierating,
~ d - p u n hmark
, tR8 posltlon of the fdpod 'h&:ts'a posslbllity of wear" In t b lknir
i~ht In r d B t 1 t~o the dAveshaft, B use @sia
@&$"tb'mlkOO
co*f velocky joints,

4 7W tripod him ean now be removed.A tt 1s

*lit, dmw the jolnt off the Wveshaft end
wlng a p.uiler> Ensure that the Ibgs of the
@It& ,* tpwled bshlird tba jaJnt Inner
netribsmd4.d~ not WW the. Joim~ U D E .
,&nWWl& sujlport We inner W m b w d the
tripod pint and preeatheshanaut dthejoiit,
-' A n:msurlhg that it load is &@jd to the
! g ~ d l
m .
,:iO The .$alter and beitring asssmhly Is
bmrwed"tnthe same way, either by drawing
'Re'Whg M d~lveshatt,o r by m i n g
-t%,&\r~shaftout of the W n g . Remove the(
, ptdfiihg plate, Wing which way round it is
'W.
6 Qbtaln g new gaifer, which is strpplHtd 5.8a P- the hwr Mn$/gaRer 5.W fitling dimension fin mm) for tha Mt-
m&*e with the smdl bewing. onPo the and of the I--hand driveshafY hand dMahdt inner bmri@gabr
 -

n be ~I+?mtle~Iare amllable mpMely. Fgr !he 4npw lolnt,

Conslant vdoc3$ jInU a jdrrt will dw&We-&iw@8 mpewd;dD
and,lnsp@ked for- w w *as ~dwcfibedI n theW@d &?r#and tdip86sembb,bamljaple comwrnm far either &Ant are wallWe
~ n s S 8 , an&$,
.4 separat'ab, biit MW amMMdf the cthp
separately.
Qn rnbt%&q wWa,mand~ m b m we*~ in ~;arhwrrem On models with sABS,Yhe rtt!uctor rim
w l l +so rrecekitak dfNesh;sft
wdyb ah&> should be rmoPed ttw old ddmshaft
a 1% On ,~lP&l #@hd ~ m & tm~d$kt4
~ t d ww~ at-& $@a CW@JW@~
inf+~ompamen& Bb&rr~Wp& &)dlt&y $w&n.23.
 Chapter 9
Braking system
Contents
Antl-lock braking system (ABS) - generat information............ $
Antl-lock braklng system (ABS) components - removal and rdiitii ,g3
Brake W a l - removal and refifittlng.......................... ,B
--
. Front brake callper removal, overhaul aha m n g
Front brake disc Inspection, removal and refitting
.............
............
.it3
-11
r Front brake pad wear check ..........,.., .. ,S& Wtk$er I ' A al 1'B
[ Front bra!@ pads - renewal
, ................................ 7
.......................................
Genera! l n ~ a t r o n
Q
Handbrak6 cables .removal and refitting ... ................-20.
;
II
i Handbrake check and adjustment ..........;.$I& Cw'ter4A'&?y@
1 ........................
Handbrake lever - removal and refitting
... ..... ...... .WW y c w
Hyrlraullc fluld level check ,, ,
tG
5, Hydmljc fluid renewal .................... .-Chapter 1A oq.l'B
-
H wlie,plpes and h o s s mgmt ....................... ; '7
.*.
H$ta~lIc @ern - ............................... 6
bleeding

Mlnimum
7.0 shm
10"smrn
lB.0 mm
+E Braking system

cylinder brake plpe unlon nuts ,,-........................ 13

front brake dbp
le r irlo.u?it!ng holts .......,....,$ ........... ..,,... 100 !

.. .. ...,....
.... ., .,:,r,.
<.
'.:....,. *,',,'.. . .;.
'<..
...... ....;....
J

> *
. ... t i ~ b i t S ..;...* ..., i r ; . . . . . . . .
G d f ~ ~ ~ ~ ~ .+..+..-..
*. ..,...,.
,,.,tlh.g gqM . * a .,-,.
*trie w-n , .
- !..,. .*.,. .. ,
j.:.;,

. . .* .*. . .....
. .::- ~
. +

W:y@*5
..
.... .,.,
i 4 . .
q . . . . . : . . . , .,

......;..- - ..,
,.r .,.
r.........
> p> t t . . . +
-,-
.'V
.....,.....
..-.
i ....a i..
. . . .,. a .

r . ,
,,.
...I.

m$mm, blybr&pt~.utdatinuI3 ...,-+..

nqblts .... ....!....,,. .... ....
. ; . i a .

pr... * * r
R6wIid.G-h.;;;................<. ..........................
I r

-
*wMw;w
w$@iloh
' l & & i h m ~ n $ s wea~,WtbWB
~ q p & ' o p w a b a3.-us* ?&
7 tmk, Ph$% $aecrtlv,ely,SengthmW strut
Wqtn the and duem the t~nkg-to-
cmttd8manee.
The brakhg system is of the ssrva- On nwd& with rear dtsc h k s , the .brakes
awbted, dual sircult hydraulic type; The am actuated bp t5yndIeMan Udlng
arran~w af the hydmullc system Is s u ~ h which im~pombmahanlcai h m ~ ~
W,mch W R aperay me fronf ma one mwbnk~iii4 toad-whsidirs pr-w
qaP brab, from a tandem Master oyllhder. maulatha valve Is connected lhta -the brake
,Under nqm'gl Ur6msty1- both circuits link to &.pqr cgllps. ha q ~ u@vet h ~
~ p e m e J nunlson. However, In Yha evmt d gmilar to W thatto the rear wheel cylltdW
iy#qu,oRc fallunIn ane;eimuk full braking (on rear drum bake modas), and M p s to
a m wlrl s6UI be avaibbte at at Meekrn prevsnt rear whetal Mk-up dullw emergency
fftted with h n t dl= W h , braking. It d m thls by varying thg hydraulic
+,All
hAw;mr brakes may b of drum of dm- pressure applled to the rear oaHpers in pro-

$%for further information on ASS

opmtlmg.
ne m diw brakes a; amatad by
dngl+Nqbn swlfi~gi#% $allpers, WldR
r e f i w d pr@&~W%
~ ~ s uthat &pId ts eaah
mparl-
Bnmod~vrkhrewdrumbth~tha~
incaw ,andtralllhg *m,,
w k h are actllafed by t h i h - r n , m whml
Cyllndets (orfa *der b6r drum). Tt$ -el
cylinders Incoprafe Iniegt@ pWsarra-
wuWng valves, which mMthehydmula
pressure appllwt to the r@ar br&& f i e
regulating~aivmh j p to pwsnt F-P wheel
lock-up during emergenay bFaklnghk the
@* bm Is fltted &I the l@-&d side at
the wdJ. Also ensure that the Iw on i i o h

8 Remove the four n,& and washers

@!YJflhg fl7& 49~9,,~I,@k~ .f@ &igiW
m*-t b u l b & $%&w. k~ tbs -e and &WB ft h . p d t h ~ j t i ~ t h & ~ k
@&t@a$m?@:@U n&W4 -Eh@s'mol ndting 15 Recan- the vacwm h e s to, W,88mg
&&$as@ WhcS 1s f l t d h tha reat af thw
qqfi: -*
h@&@qJ
fdng $3 PrW tb WMhgi check that fhe smo udt $7 On co pletlon, Stan the engme .and
folw.
f W W ~ I aderation
B of ?he &mo unit,
d e e m the Gotbrake several ttrnes to
'&%hiustthe vaclrurn, &en sf& the englhe
p u & d bcq+tLp Musted as
tM<$WePr&Hi'&,
kho& jaw 11-dl.
~M~kftie
Wkh
dlmensbna wwwm hose; ~ o m t 4 a n . Chad$
If adlustmmt @ ,opsmi~n
*
check tttal%en, are no Qr leaks at the.-

,of the w e a8 dewtbatl:kt Me.

whliPkeeplng the pedal Titmly depmsed. Pis
Weftgtnb watts, thefe sbuld bB air'otidable
w@wa in thebrake pedal as the vaouurn~bullids
up, Allow the engine to run for at teast two
rpb#id#,'iwrh-&h "Lm ' b t T $W d t m by &Indnpi%ls-.
~fa&&"fiigt ~ ~eo a b r i u drepositioningwe,
p3@ir@l, Wevk, '@k~8hndnHort'@3CPyean
t be
a&red~Wtep@$fUonhgthe ndt.YP). M'H

--
fnlhutes, then swlteh it off. If the brake pedal @ ~ &
e*~i@Hw & ~tb * fM iha cW%b~kndtis
Y$ no& d&ressed it ahauld fwl normd,but
W C appliaarbtom~shouldm u t t Oh the p d a l ~9 r
qm m*rwmgl groxmm
q+Iirt$ 'fiM#, with the p&al $t&de Tor sms ;dfa&*'br WeFbmt'in; and
s ~ g w
wpad~n. mmrk,Pn:w@my. hmmml
rm 3 - e r ~' o~p wf - w d m , 19' 'kWw m t0.Wr&r oc*m3m .t :Gla&n .the M n l Q dip, and dismms@
fh@M h e I W unltO &ack valve es u~$~,aw'& &smth&l#nit m we JM&IIX~B
'i.,
rn vmuuln h ~ . , m ~ t b 9 ~ & ~ . r i & i $ , 4 $ 3 h $
db@lW7fi Swthon 4.7t'tW W R m e b dmtwbmw.. ~ewo wng [ ~ ~ ~ UIf the l p@hAl
u ~ ~ .
trpWiMh$ the mwo Bjr-AlW(%&in 5). ii ikatjtiiq.~nsicieftmVMCI~, ensure that the Rewlt c t l ~Is, all #ti$& at f h8 6llp:dd
a,:# iJw uewo ung MI1 Ml_s fh oij'erate sewa unit pushrod la ~ o m 5 t l yengi@ed'W d i w d It; use a shndwd worm-d&e-kw
i & G h k d y , b fauklies withh the un!t-&@, the .
&f$ yarn ~earZamilopmpqnepi, na~k@$%s n ~ -,yi&&1~
bgmRmqe unit moumlna GI@ on mWng.
w %@h&~heiin~t3 &
_ - - -.
( I

&Ml@Ie; &aa d8fsEt)ve seivo hubt be

?&w
rnmd
M*rAt ~,~~ Wll w mw on
-2
iff Rwmv@rWmwyHnWwS'd&derlbWIn 11Are rt'ltl pb46lh klff$
all the nmewty
w wr am
5 Slacken the retaWng cllp, and @sconne&
tbvacuum h m from .the check vake on the

standard wsnndrS\;eb s e G@ ~ n M i w
6 On right-hand drive models, pele& tFe
ratdnlng dips and remove ttiw servo &t
IfisuJatlonwcf f v m t h e d n g i n e e ~ r n ~ ~

tbikc&woftheserxruniL
7 WBma 1-m th? Virhld~,em Ihp
B@h$6$tip and wrthdraw the cf~vlsrplo
mrbgWQWQ urn pushW M th&mi
.Lfimtbthe spmw whI& f8 10- on
w m(wSl-Dm].
 3 If t h e n is any posdbI#iy of InW@pflflu)U

5 ~ e ~ l t % b ~ r ~ u ~& ~ t~t w
~ ~e t ho w e r
fach pmd;IjreM.th'e W n g cdumn.
and tog the mq~.~.cylhdqrasew~.~~
"W"l a e l link: refit the c b 'looblv.
~fmrn/thgsem~ + .

the ch~ckvalve fpr s i ~ p ad

~ d , w m Rw, m a y . TWjvalve
9'@W
&W$w..A
by b[owtw through # 41 M
li
sbuld. thfwgh the @be in A ,
pokPonous; wash d
amd,t&mmrrb~-&*
immWMm
Bed, GW-&m@&te m m f
~4faa~:~'am
u iM
d kw * ; J n B )
rn
o r ! h ? * * ~ q
&-~M~WWH~J~M hl.w
 Braking system 9.5

y u l eW e dw, and a rJngmm@:t reduce ,tM.p'resuYe~ In WA-,- t@q

fha4icW.The helpof an wishkwlkakd Da n o m l ; r&wtp$he @ b y ~ s ~ p u ~ J l $ @ ~
MIU~~. the.kit.
tS- ww we dm cap from t t IW~BC~M zs ~y aonnecttng4 prmurtmd, ~u~d-fittd
fmth~bgerqmme.mthe spanner and tube to oontahrr to the m@er cytincter re&&;

$6 ;Wet h ~~I s t a n t W l l ydepress W6mke &fegua& *ah& air Wrig drawn Into the,

.,"
Walservd Yiwwto build up'pressm mrndurhgrhhding.
n@lhWnit m$bflnalsmke. '97 &esaur&bJlaeding i$ p r W a t l y afhllve
tt' White p d a l pressure [g mdnfaind, w b m bkding "difficult" systm~,or when
.'w psrrsw the blaed screw (ap@mxknaWone awing ulo EBmpl* system at Ume of be pligged,fiWn, is faken to
I ttt8 ttnrr)and allow thwmmpwssdHIuid and air to WUtIried~iPrenewal. dirt Into tAeqyst&) et capped hnmedlately
lery. W hnto the jar. The aslstmSI'IOUW maMlifn s- they we disconnapbd, Plwe a wad of rag
Bast I?rjdaiwswre, following it d w n b#e flwr W under
,,,*a tfe&s~~w, and should not bleme b U ~ H I 28 W n blwdhg Is edarplete ard firm pedal uniana*ls.ta*b9df3-, to,
r air Ibstructed 'Yo do SO. Whm the fjow stops, f d b r e m d wash off any splk fluid, t I g h catch any vikfluid.

-
%men #e bl& W e w %An. Ham' fhb h s , b l d -.mwb a dua 2 B a flexlble how is to Re dkmnnecbd,
akWmt&rjaSethepedal slowly. -. wq~rew@ brake pipe union nut before
~ H wspdng o l l ~Mi* W U W the
jB R@wm&m givan h e q r e p h s t6 29 G h c k the hyhdta fluid level, and-tup-up h e ta b mounting bra@@ (#a
37 #ejut& merglng from be bid If V( w d W chew').
30 D M any hydraulic fluid thst has bsan a To the union nuts, I= prsfswe
,.$wjyF *air~ b l e . Obtain a pipe spsnmrof the ~~~
@e.Lnuld jn mgmaster cmdr Hdham itwill not be fft fw re~sa.

&&has d F wand
bcbwB p1d fmme fld s p G . fh
dr MS
*e fh"
at "I
Wm.
-.
emw&mOfm;I f w + m 51 Week the feel of the brake ppdal. H It
and
dir must 1 1 1 be prtsent in
further b b d n g is
=IZe (3' mm'f

this, a cl-ffwng
mrn ring); these are
motor^^ shops- faillw
ap~n-mdedspanner wlll
Fallurn te. b I M satisfactorily after ssveral be ' ~ 4 u l r s dthou@
~ if the nuts ars tight or
me-, ailow appmhatdly f i ~ g corroded, their flrrts mpy M , ~ r i d e off
d if tha
~ W Wstrokes for the masthi. &$Au& *wflons of8** blwlng p d u w m q be
d W to worn mWC.6lflnder sealsa spannsr sllps. In such a ~ase,a self-locking
pasqes to mll,
wrerrch Is often the only way to unscrew a
fQ .Wen no more air'buW~appmr.@httM1 stubborn union, but It fotlaws that tha plpe
the bleed screw securely, remove the tube and the damaged nuts muat be r e n w on
$@s p n m , and rMt the du~X@, Do nbt reasmmbty. Always clean a unfan and
0WlghM1 the bleed screw. surroundiw area beform gsaonndng if. If
RwW W.pq@Aw ,onthe rswdh 1 g dkeonn&ng a component with mare than
I - Inth6~hce~gllaitkremd Qm Unbnl make a careful note of the
.wm mesystm ahd t)M mal .fw firm, Note: &&m starting work, m%r to the
warning at the &Inning of s ~ o 6 n O Q " W ~ W b d m dleurblng any of theni.
@=dme m&w tM Wwm Whyhulie &id. 4 tf a brake pipe Is to be renewed, ft can -h
r#8~80mww#py~hrskFt 1 If any I PJp mr hose le to be renewed, 0bta(nd1out fa l ~ y l f hand with the unlon
and end flares in Plam, frQm. bnauh
,4
their name lrndiRs, fhm kib mhh"1se fluid I- by fernovlng the -master
Winder rss~rvoircap and t b n Whtmlng It dmi=. All fhat is -. Fg tp bend ft
I
8 llrngm of t&jdg wltt., a one-way valv* followlna the line dfh~tfis oQhd.
kt~d, topreventexpdldah and being down onro s plebe df poly-mene (tsking asre
jnb the *; include nIlt to darnige,ths sender unlt) $O rrbtaln rn m p
to
mnhl It the car. m ~ w , m-
tmslucerrt mntainer, whlGh be a l a i g ~s d . ~~msmwyi hoe- a-~
firr;d(b~e' m0tQrxcew s h ~ p make u~ brake
VGW ca&d
so that the Jr bubbles the bba be b&e-led, bse Aclamp; m a 1udng
requlrsd, bra~ r m %@,
i p u n l o ~ PIm* b ufrom
aepproprietary ~&%YW
d afthe ok@ml to ~ n s m theW
bra M l y seen flawing fmm fhe md af fhe
:. ,&btp%ail-on).
& h e kii is connected to the b M screw,
rBpI-Rt Is 6f the cetreet length. The
safest answer Is usually to fake the wiginal to
whkh Is then owned. The ltser returns to ths
tha @m.

steady &oke md slowly

rep- until the expelted
bubbles. .
eae kits dmpm wdrk au
pu& that it is easy. m ths rnawgrr
,
qylb!W w w o I r fluid l m & : a tM-?hi$Is
rn&taSnd at least aiwvet!~ WIW l a the
@allawl&.
bleeding
wmp@
-
a pm~#*bIaediw kH
?A Hydraulla @peeonneetion t~ a
m b t e haw
## These R I B are usually operaw by .We f U n h nut 4 S@fihedmd#ttlt~g
r & m t of ppressurised air contained In +he 2 FhWehcw 5 &dyw& 7- Using a brake plpe qamer:m,
cm tyy, although Et may he rtecf)agaryt O 3 Smng dip wwl unscrew a hydaulic union nut
 9 e Braking system

~ d r l v e m ~ u the M o
~ ~ & h f eretaining
Id nuts (arrowed)...
W&i fifflhg, do not' aVeMghter~ttl.6unkn to &&h my surplus fluid. M&% a npkof the
I~W%. spaifled torque m ~ ' h e #hf i Q ~ mrim BW @sItlons ~f take yrdona, than
'$&h'ghnr) are not 'high, %d it Is fi# wwrew the mian nuts ~ ~ ' ~ ~ ~ h ' r ~
u.m h bbt& a NW&~+WB-
r i ' q to e m b e brute f . , P N ~or,*
. mrL&TPik
-wjwnt W& g d ~ n & CJ)WF@~W~&&* Imh~&~
d Eodure 'Ibt the Npes and hoses arB Q & , $ & ~ ~ ~ Md.to U I ~mtb*
of dlrt intothe system. Wash off any sflt fluid

-
I 6 ttla p o t , m l b b to oktaln seals or internel
cornpone& for we rmqb cylinder, m,er@mIf

-
&~tn$# bay>
0 Ftt tho master cyllnd~r
ta thesmo,ptwutina
<-
 Braking system 9 y P

...and remove-,,pad'&
,
&m-$~
the
'&I&
thlokness of each br+
rrtmaftalmtl-bac!4ng plate). If any
&~ptsrondmerer. GaDpm wm a m rnm
djahster bo?&nMon w u l r e aads wlth
9.4b 'piate
y , crc@kWtne mbhr guide
m ~ l p ~ b n dand
sleeve gaiters' are undhm@fd,&rtrsh the d w '
symmlcal llnk;gs, whenis call& with a and dirt from the dlpst: and but do
4B rnm diameter boreipiston require pads nof inhare it as it is in&Rbua ta .hasam. hspect
wI$h o f f a l IinhqB &move (n the frictlon the dust sml~aroundthe pjston '@r damage, .
l%
&
kdi t not cehtral). The pad types aan aisa and the piston for evldsnce af Ruld leaks,
kdistingddwl by ti% &-outs In the upper mrrodon ar darnsga If attention t o any of :r
. comers of the frtHion material (*these components Is necessary, refer to
ilt&athn); symm&l@al Ihiws have two Saction 10.191s~ Inspecl the brake disc as
' @J 911 or grease, tram and redify the cause cut-outs, whereas the offset linlngs have only dmcriW In Section 11.
WMklts
reassembly. New brake pads and
are available from Renault deakrs.
a single cut-out. f O If new brake pa& are to. be fitted, the
8 If the b r a k pads are sfll sewiceable, catlper piston must be pushed back into the
e that there are two different typss of mrefully d m them udng a clean, fine wlw Wnder to make rown for them. Elther use a
available for the bndix qlipw. The btusti "oi. 8irnllar, paytng pattieular 2lftentlon l o G-clamp or slmilartool, or u s $ u W b pieces
j - 8 w t~p
depends on ~e brake caliper ~ and backaf the metal backing, Clean of woad as levers. Provid~dthat the master
i h sldm
out thPj g r d m h the friction material, and cylinder w w o i r has not bwn overfilled wlth
pluk out a n y large embedd6d particles of dlrt hydrautb fluld, there should k no spillage,
or debris. wily c t d n ' t h pad Iomtions In but keep a careful watch on the fluid IeveJ
the mlip bdy/meuntingbracket. while retradlng the piston. If the fluid level
g Pryqr tu Wtng tRe paas, check that tfle r i w above tlIe *W*loyal line af qny.;tlme,
gulde'slwes arefree to slide easily in the the surplus should be ayphond .?ff (not by
-
mouth use an ald syiingmr a
or ejected vla a plastQ t u b w
bl@d m Isw.*!Qn @A
1t M the MI-rattle a ~ r l m to W e MA sn
that when t h p~ a d s ~ j m g i i in
l ~the @par,
the swrinn end will b Iw&W ,stttim ogRosite
end t;f t h $ , p d ~thepad mtai~tngPI& {see
tllustratlonk

9.lq Antl-mttb spring (33 wrredy fitted to

Ben& Inner brake.pad
 . -- -111

R13 Bndk dUo pad &hbW p m (~3'

and spring dlp (1) showing filed chamfeB
(AS
I

atsa on a* dfpews,BMMI thtt

guide pin MllSXhldkrs t h guide
~
pb%ithanurpm-mUsd spanmr.. .
OiOidI~ d&=
nates SUI~+ k i m d - ~ o c ~mmpoumi
n~ MII
i tQ d$&
bs R3quM # i d s d fhe diMf
*w@J
1B SI-h
wmdmv1
m dmwPh9wl~uppmmd
1 ~ - ? P gslde,.@nbolts, udng a slim QWn-
m d & ~ m rto p r w t the gulde pIrr Itself
l5!
Porn d@ [see ilkWmtiof?S). D I w d
the pads in the mttper,,eWrlrig sups ,pin bc& nm bb mwl be ussd m
th&-%efik%&m~te~ial ofeach pad isagalml mfittlng: If genuine Renaull brake wds ate
@k;&3~ ,d&, and the pad with tjid'hhr p u m the h R s MU be aupplled whh the
mfiWiaT&ed on* tnsrcle. Alwr rcheck that
spIhg 811dS &
m=t.
*:.-~WB 0~-
20 b m,me gulda p b m w d , lflthe a&
&d &'&is u'dto w&b the W n i n g plate is to away from the brake pads afid mum-
hs.&'d. &I r r m b ~ s41th linmga, m ,@$@ to tRB auspmWn W & h g
1kaHtq'& 'from the front of the car, baaw~j3Iwedwire. t3a r l s i t ' ~ ~ w f i ~
~ m e f m &patl grhov$trIMh4 high# than to M$g unwppw cm thewele+w.
&&&uf&m~&i We. t
MgtWsuw Mthe pads 21 Withdraw tha3wQbrake pads from the
%@$w mrrsctqf *lliusmb*l. hlipsr w n W g k M , and -,N
$3@We the retafnlngpf& illtorplflet3, and &S .sdesmd &W ~n m g * B and
&tdj~kthp-small sprlng dip fit its hnw and. st
ffi&km ar
y ta fib an chamfer on
*@;d@ddIho M n l n g plate, to Wbk 12 ta
bkfiqq*@>SrfRe~Ity (see 1ilu&m~).
3 4 ( . ~ & n h ~tha bmb Dad.weqr serrsar
wvlrins t,qw@v, Jw8urlnpthat lhe wire. is
- WU&IYBW -
15 &?qrpr"#r'eIp@ep.dll s e w d fimto
bring pa&,lnto fim wR@Zhbbrake
disc.
16 Repeat tfm W Y e Wmdp on . t l a w d w
front braks caliper.
T7 Retn the roadwhds, then lower fie
vehile to the groundaddgMw@@>W
thk~pedw forqua.
t8 G W the hydrau.uDc fluW lave1 at3
desct.lw .in ' W y
 Braking system 9.9

m k that antiattls sprlnga arecorm$y

lmt~I(e Plustratlon),.then ~~ the

& & $ m y ' b, . *~

;,ji
someIb a p n & t ~~
* -.,--.
R &ould I &e -.
kunion nqw~ing
T .

gsnemtad by a fmf
reqvlmd, such as i~ a n p *om)
~
pump
11 Extrwfhwpidm hydtatlllc'seal using a
blunt instmnentsuch as B knitting mmdlew a
ci&& MI ~ri0110 fhe Qmw
CaIlperm.
f 2 mmmw W ~ k l slesvw
s or pins 'Wrn
ths caliper b.dy or moucFlng bracket (m
app~babl@,&dqs~&vb ,qewbkr g m .
I$' Ih@;&gh$ k l q q componerits ming
6dy1>nieU@@d.8P1tlt, l&ptopy! dwh'ol o'r
cleprt:hyClmu$e as et chaning medlum.
Mguk w,mhstr?-ba~s$l sglvertfa. s$cb a
petral or pare~n, wlch. will aftauk he

t
lb WI# q d ~uppprtt on axle s&w@ 'fgd'rn~b~
4 ~f,a;cW,
*i&f @$'m~mb,
l sly Wd
&#Jacldng and which si~ppod").Removs qpo.ner$ @mdptbQ, u*g compressed Bendlx caliper
lhf-f'@g~: c#nwd p Screw the dllper fully anqa the Hexibid
WL urtton nut. Position the callper.DKBK 4hs
a,k@ b o w deyth$WUld pa&w=.
'1& CK&K@l &:frpgentswd renew npy ?hat m;idsg,w n &r tha w 4w:mqm
y.worn or,dm@#d. t h e % parNctllarfy'the bolts md the mauntlng plate. Fhtewaf 't%i
ayl~nc!U Ba-@ @ ' pI#gtt;( If t h y are m o u ~ mtcsrhWm that W W M
w#n at cormdsd h ahy way, fh0Y wrvs rbwrds the aalipr b ~ d y tG6
tllus~&,r$ndwed(notethat thls means the Illushtion): MIS4t2 n m 3 ~ , W & d , ~ B
renewtyl a9 'ttie complete-body assembly). plate contacting the drEuash& gttef whm
SrmnwJy C ~ I F E @$be cprrcl@lQr~ of the gutde the stating lri "en 4ull-lq0R With tw plm
'

el~evqsar pi& and @HfB>ores;they should con@ psinoned; tlgMM M'mllpsr bD&
be u ~ d a @ $ p dand (when ~teaned) 8 to WsWled torque 8MthQ:
reasonaldy Y&@ dldlfia,fR
t In th3 bQdY oY 28 Tighten the brake hascwumlmk n u t b We
msyntrng bw&B$i If then p any doubt s-ed torque, then Fafit %h ~ ' * m
about ti5 &*ti d a arnrrorwt, W w It d & M in SeM~n,9.
15 I f t h e q s q n b & i s f i t f p r t i r - t h e r ~ , ~ i [ l
the arr~roorlafeieMrM;the' c6maohmts are
wqibbte'frdm 4hault:daalgrs;ln ugiqus
cpmbldatlahs,
16 R e r all ~ nlbhygeats, dust gouer$ *d
wps dlaft3j3d &'$l&mWing & a d g k r af
wuw;QRese s t ~ w ~ d . q@.rWsed. q
19 Bef~~d'mrnrn~~E~~
wwMnbly, v$ure
th$ p l ~ r n f o n ~ ~ ~ ~ m l idu t e l y ~ ~

L i n g a ~.sthgl ' q ~ o n ,snayrhg that the

M o n BW s W & vlntd the bra PreBir the
iihcolfybi08.fhsn pess me dust
bal3k; , b a j t l p & ~ ,
20 .QnMe.Qtdhg.wlirt.ins~lIthe dust seal
retali~hgall& msurlng) that it .Is mwegb plaw (1) is Wed so that its bend q g ~ ~
B a e d A,@e,~ti@af towards the caliper body
9.1 0 Braking srstgtn
I

hau@ng bra&@. n
8
-
ii$VwM@t.the ,&ltpqr avgr the.pa@. @at r &GI,
t h rear W ~ ~ I eS r. m ~amp t k
$4e.$hp@~.pfqn new lower guide,pin halt handbra&$ jaak. up the fpnt of ttp y~hbJsr
mitfi ~mq@g m r i , MI f ~ tthevw t l AMY a$%p-ppt mly.&ds 1 - UA&naand
I o C k r ~@B b.thnew uppar gujdsspin, h k @!B@ sugj5~$). Rdmpb. tl~e l'ppmpfla&
a;onrtpoaslwd. -
pt$ss tha Into8mtlon,and I% h bok
ChgEk#$the
r ' o q(
~ prIw amc~rrec@
~s
e.mL
t h
n.&6$@.bw
i ~iru~tra~@n u r a n ~ ~ ~ ? b
iea,oP&#
ttie Pr@keb i s ~ -,+
~ ~ I ~ U
sides can be &weed; M a k e
I I

guide. pln ba1M f~ the speClfl$d t a u %

&&I^ wrth the b mbdt h
;b&i pads, as dMerlbed in S e m 8, If
wcess Is mquired to the tnfwsrd
s ~ irn 1 the-britke
- hbsb union nut b the b&terwifa'ce. Light scoring Is normal In the area
!-@me. swept by the brake pacls, but If heavy wMrg
$#Lam@ lk bid,.tt$<dp@@ be renewed.
H B w a ,W&,bMd h ~ ~ e , d ~ f 4 g r , p p?l kIt Is nomiat to fjnd aTIp of 'fb;st and bfake
sad &lwd-*halhNmlI6 d&@w w l d #lq$cphqfw !hfs wn k
.ifi&Wn 6 X w M h m'doff ff r e ~ u1%~how ~ , tt fl@!f#
$@&,dm tp dear ~ Y t h ebrdm pad WF
Ilill'iiim~h b fluid 113% it &QU, only b $6 alse f h ' t c h ~ amua be ine,st9(1+
- b k d the relevant front W ~ S I I a~ m i ~ t m e b (we
r %~sWIoh).Take
r ~ . d ~ h & then
, . l @ ~ @ tihe
j m k u h p i i n b at mv6ml W1arbynd @ -!
yhlgle to the ,groundand ftghiin tha mqd- die,@$Ithe lnsrcle Iyld outsid O f ' t b piid
$@ hb bse s ~ ~ tprque, e d a r m R t k Gfsc has w& qt'q &h?t
tp spocitbd mintmum thikkness or I*, B
rnust'b"sjaii*.
4l f f h s d ~ ~ ~1PW ~t b3t a ~ ~ ,
CWI~ for p p ~ g t~ffealty
, by u611pa' dljai
gauge mwntd on my cornentent f&d &It
\hrhlle tht dim Is &w?y rot$@. 1-P
m~+mion).In the b h - t . &a &I gy@,
Jm*-br- tP mmwm (Bt wdpM
wound the dl*) c)'theB[& P ~8 w
 m+hs +djWef R& m'~fM Wndbrake,lever !#?-on
strqjghtf~rwardprocess, but on completion, d .Mob th& QR some mad&, 'kwill fil;sf, be r Wmk&g ow&-& 1 w
- ail traces of
mm
-.->.

&ctatld hiprnent is required ta clkck ahd 'b.rgargam&6Wernhuntiw nut&) md braw dud Warn #hd&.?, bUf W@J H f M h W
aka f i d d fa gain a-s the dust Hf ~nwn~id&L.-
I,",bp
sion
&u[ty, the wq& should bsantrusrted to g
Rehautt dsW, \h;hb wltl have the necessary
tap,e.Wudwn&
6 Insert a earewdriver through me of the
M e61bolt liMw k-Ptlem e m,$o mat-B
iSmd olean t h ' e - o ~and~
check it for obvlom dgns &w&tmridwt@ge
~

I ihe wtatathe @ hmdbrake.apmfingW 0 o : h

Wiiw p,mKqjshm Illustratlo,ns),Push @&rnlne $arefully tho inside df the dpm.
'thmlaver.until the .Wppqpsllpshh1rid Ne Uaht mxrlm of the fflction wrfm Is n&l.
brake shoe wsb, $Ile~lm thsh& sh- i o GII hew-wring 18-.f011nd,m &m%mtigt
retmct fblllv. WlWldraw the brake drum, and bemMwBd. h>ia.ww! to fJmd a Ilp en Be
d m % inh4a~:d ,a@& which- cpn&&s 'of a
m m d.nistand Wke Qm Wg e h d d k
PIOW B q r & &wing work m r f& Qe w m d awy la tww a w W ~ - ~ - ~ P
ww&q at lhe LwghnMg of Sectlon I* w~W.WI & ~JtshBj~B?\ftM-t@!ltQ 150
&h&hg fPrP d+gda of &@estq >dug.If grade1,ernw p a p . If ibt i Is ducr h the
Qr refidshtn~ f r M o n . e e king m m d by we%>
3qr .~equimsrenewal
~ s ma p@ ~
wfw 9.h qm 9
emuw even and' consiitent braking. In
4w drum must bu dnbhed Nlthtn the
spmifi& limits1or-remwd..
n w SM&sh'td-mfltwwqtr.
prfrre~b, A t0 If 'the drum ki thO&@M& ba
m*~ti.@y~& qdred m d ~ w wqm fir awal, If$ Internal dlamebeir must l?t3
measured at sewral pofnfti ushg artMWd
Rwmw ;rW m ~ w % @$@
mtWmmw
1 ~ h q *',+e front wheels, engage reverse ar ,righ&angll
s ~ m d to the Wt, and
@& Up'% ' 36 the h+ndbrd!&, J W
t&
2~Jti~wsaror the v+@eleand suppurl it on
axle am& (see wJa&nh ahd WM&

' a w ~ go~ l v m te
. ~r a m q ?any
~ pmdve
s UdQ erird krrrg bar,,s_!c@v. a,@ coating that may have bmn @pfled to its
'R
remove t e.w hub nui, artd M t h d M the

sad-
' is
falve
I'ear

bI.Ftr$&@,:$t $9 h+!?*.is Ob m:
.Mm* bd&h the vetilch. 'nl&en t k
9.12 Braking system

thm @>?p+l&Wfy Way M deQma$ing

Hi* h.wtktl*u-.
4 If any ofhe& M e shoes are worn unwenly,
orfouled '&h till or grease, trace and r W

@ m I n g ~B j a h dhow m m tm or-an&-s@e cfipaund will bb) m u h d - t o

-@ H W oA1boouh mer whiwkaat W 1 y b ~ eshue. ccm&c?t surfaces. on the
'm'@m'e\tt&€r- lmmr-- rn &a@: kckplak an re4iffingr.
5 'Tho prbcedufe: now varim' according
- to
og@ hob wh&L ag u ~ @ B
~ ~ ~ ~ Ism4.
,whch mk%&.t3raka ~ ~ d
k# . w W ~ : ~ g' ~
hbe m y '+&M WwM.Wke ah-
@#&&f&(,~j& &#a'- -$".-
I Uqna a mr uf p![w, rmove. the she
r&nor %ptlng 'cups by ;gfepressIng and
itpWili?$'#-w t#~.mh EQ.. WlUl-e
Thwd,;liff hw I si$illl** wit&q~e
"rqmlh* m.
7 '@&the moes out o m at a thm fmm the
lower pivot point, to re=leasethe Man of ttw
r&rn sriirna. then dlseonnectthe lower mtum
spring f;am:d~ stmw (se&~umattbn).
11-&mvt3'the breb drum as d&cdMdt'tn 8 ?hwthe UDLW end of'hth st!&& out from
~ ~
ik 4 ' lhsk whe&@ihder locattons iakhg nr$
d:i~rk!&carefully, remove all traces of 'ta dam&@ ,the khs$l cyllndei&als, i n d ,
baki &st from the brake drum, backplate dissconnna;;Y the hmdb[,& cable from thg
md&o$s. ttallfng Shbe. ?%RIB 'trWs%wand sdluster
3 .a$& the~hi&nessof each brake shoe
@'d@n m W a l and shoe) 88 S W ~ point%
. if
strut &embty canthen be hanoeh& w!
of position and away from the backplate. Dd
dt@-shq I worn at any pint to spedled not depress the bmb psdalpyl (he br$&
minimum t h & w W a!lfourshm must m B l , e d : w?& ii m w w e 1 ,-
@'heU;@ as a set.W ,the ahoes'&ould tie around thbwbel cylinder piatons to,mWn
@newedLif'anyere w e d with dl or3,w~sq Wm.

14.7 *$en& t.earb@Iqtt*&

sb- out ofthe lower piwt Wmd
 14 Engage the upper return sprlng Mth 'the shoe retalner spriw w p by $epming it and
WHnq shw. Hwk the I d l n g shge~nL* turning through ma1'. Wlth the wpmovd, Iii?
ather md ofthe sprtnu, md-l~vq theddi off the sprlng, then wSthdraw the m n s r ptn
a h a down until the adjuster bmkt b e d L and remove the shoe from the backplat&
w&lv located in itsgroove. 6 n c e ~ ' ' ~ ~ b b R Unhook the adjusting lever spring, and
Is ,-I M k lb ,&Mh%@'IH* moveveRh.om the-leadingshoe.
inhkhesbt on b e Ieadjmg EJgae. 30 IJeta~hthe sdjutw strut and r m m it
18 *ova -the. dmwc h n d fiW the fmm R s U-allin~she.
M e & cyJifldw. Peel bad6 ikw rubber 91 WBNIOW the trailing shoe retainer.Qpring
pmt&tiwcape, and eheck~tlmwh&~a$llnd& eu@,%pring and fhas,dmr&ed a- lhm
for flutd Ma& or other darfia'e; AlsD &@ cbtach tha handbmke cable and m o Y e #the
that b t h cylinder pistonsW B i h to moue shde from the vahlcle. Drr not depress the
aastly. ~ d e to r SW1on 1'5, ff necessary, for brakg &l until the bmhs am msssmblad;
. lnformatlon on w h d @ind& bnewal, wmp a &mhg ek@c band mund itre whwl
1s Prior to In~tallettkEm,(zkhfithe backplate ~ylindw,pisbns i a retain them.
and apply a thln mew~f high-tsmpemhr? 32 If awahe,mnault brake shms axe Wng
brake grmse or anti-seize compound to all Once the handbrake adjustment Is uorrect. installed,it will be necasary to remove tha
Wrsae &acesr.of thhac!+lata which b w on hold me @u&r nut and securely tlghten the adjusting devef ffsm..the w i g i i leading shae
the s h w , paffiwlarly the wheel Hinder Iotknut. Wkiet'e ne88sw, reflt thfr .exhaust and install it an the WW shor All return
pistons and lower pivot polnt (we springs should b e d , r w a d l m of th&
W@n ~hshldtlZo the vehicle underbody. apparent mndRi~ni.eptng kits am aha
Ilustrrrtlon). nu not use too much, and don't 25 %$t me trrakb drums as descdbbd ln
allow the lubficantto foul the f r l d ~ nrnanwld, S d b n 13. avav9dlaMefrorn Rana& d d m .
t7 Ensure that the handbrake lever stop-peg 26 bn cmpietldn, chwk me hydraulic fluid 33 Withdraw thsfwbd wdcfrornths.djllW
is mrectly losated again& f h edge ~ bf the level erg m d b e d h 'WesWy check". s b f . Carefully elcamina the assembly for
tralling shoe. algm of wear or dmaw, paylng pwrteular
'
18 bnoeuvm the shm and dnrt a@ePnbly
QHing:brakeshoes at4entm torthe threads and the knurled
Into poWon m th& Wahlcle. Engaga the,uppw 27 M&e a npte af ttue COW fM4 positions adjuster wheel, and w n w ff m. Mote
end8 of both shaas wlth the wheel dyllnd& d'h springsand adjuster strut, to use as a that left-hand and rtgtft-hand struts are not
pistons. Attach the handbrake cable to the qulae on r q b l y . Inter~hangeabfe$me left-hand fok has a
- , tranlng shoe lever. Fit the lawr~retuml d n g Carefully unhook both the uwer and right-hand thread, and the @ht-hand fork a
to both shoesg and ease the sham infa l w r mtum springs, and remove them.from l e f i ~ h dthread. The forks can also he
positfon on the lower phrut patnt (m tbbmke shoes l d M i by their wlwr: t h i left-bdfPrh is
Ilbbation), 29 Uslng,a p$r of ,plieps,m o v e hleading AIver; and the right-hand f& bs gold.
10 Csntranse the shoes relative to the
backplate by tapping them. Refit the shoe
retainer pins and springs, and swum them In
pwitkm mthe spring
20 Using a screwdrl+er, turn the strut
aOJ&er wheel untll.W diameter of the shoes
Is betwmn 179.2 and 47gd mm. Thfs should
altdw the brake to just pa& over the

21 SDde the drum into position over th8

tldrrgs, but do n a t ' Wthejhub nut yet.
22 Mperrt the above pmedktlwre on tfis
remwim rear bib.
once both sets, O-J mar shie have been
w,&just the Ilhlflg-to-d~m~ l ~ r 8 n c P r
b y d + e p ~ ddepr-lng
b the brake pedal.
!&/hi&- ddprmslng that p&a, have MI
assistant Dsten to the xaar drums, to Mwk
- that h e Muster strut Is fundonlng eorrwtly;
W W is so, ,.e cYekhg wuxl WIN be.mmedby
the smt as #re.-1 is depress~d.
rn Remoue both the r h r dam, and chmk
that tha handbmkd..lav~~&~p-pegs ,rn.dll
e a ~ d l yloat& amlnst thd edges of the
trailln$ skoes, and t I 3 a t . d lww epemtes
m m t h l y . If all b #ell-, with Phm ald &;an
paismi, adjust the handbra& -We .sc3,.that
the h ~ n d h k elever. on emh raw brab
m b l y atarts to move as the harrdbaalre Ig
mw~db&wen the flrsl w d second not&
0of its ratchet mWhshism, la, so that the - -
' A Wtngshm I Up;pe~mm@ng 0 - 4

s t q - p w -ye &Ill in mnW wRh>thsshoes r b'l.

when t h handbwke
~ is an the first Mtch of' B TrailingsAoe 2 LawmrnspmQ
% Lowerpivot point 3 Refdningpih, spn'n@andWff cup
F sSuf mechmism 4 Adjuster sf& fo Wllng shoe spring
 9.14 Braldngsystem

34 Rmwr me &gic band fmd to the r w i p w m ~ . . at~mt o e of dirt ~ U D tha

#
#heat ~yllnder. Peel GraW the wbbsr bra& ppipm.unlM at %tha war -OFthe W R d
pmamt~mw,anci+$i@-&wvorheel qlWer qylinde, ernd unacrsw ihe ut#m nit (see
tar fluid le& or aWerWmgts. Ghmk that ill-). qamfully~tbe prpa wt of ttra
-W&ln#m plst@@p.frw@Xo mbve wislly, w h d ,oylinde?, and @@!M q B mlrr $3 end
,R&F $0 '&% (4%I9 & naessaq, fy @ ~ l W W l b d r t +~ ~~ ~~ ~l p~ ~l f i
R F f ~ ~ ~ ~ ~m ~ ~' l@
i. i m d ~ miat*. .. 2 -

str ~ . b ~ i w h U & o ncktm

, the bacMt&e s unmrwrth.~u~&.)qina$rrPkK&
& ~ ~ p ~ ~h f ~ lhh - t etm ~ &
~U* ~ ~ Q f kdte W m the rmof W ' b M e
& ~ ~ W , a n t I - w i cbmpwnd
f e tv all
kwbC@lat&whifsh W On-
@&IJm@#\awer pivot point. Do not allow
W:tu- foul the frlaion rnatmbl.

AU brake dtms m
w, w w , a h v s have Ijesm fW1full braking 7 .Ensum the b a M ~ ~ wheel
~ w dqfiww
&icy,Mfi ,n@ be-owa~mduntil the Ilnlage mthp WHEW$ are dean, ffwn frp~a$ithg
W n N r piR and q@$fig,and Secure .It In &qd-@-ln. Bk ~t&at& Tyr I P ~ &4&e efiw and rngmlrr9. the . w h i
pqsbim with the spring mp m n n e . thp atnp$m$dj~cesa apd avoid hami W N 9yll~@rl n t ~Emsltion.
h a n d p d able ta?Ws+h#. m &i posslb~e~r heftrst hundredm i b a B Engags tb.tir&!3.&e9 end sr;mw in,ths
Sf4 S?kw in t h adjostei! whed until fh8 SQ slfier fitti* new ahoeus. un34n,nutW+q .Wturnsfa s m t e W the
minimum Wt l q t h Isxo&ned, th6n i n k thread h a q . s W
#p&kIt.JrRa @ l ~ l 'wt the Wnhg w. B Inwrt €he two wh& Winder r#t&iq
R m t m t h ~@dj&prmt fotked end s@ thaf bolts, an& tighteqthern wwmiy, W fully

P ttre Eut-oklt or;#==Soti Wilt ewm *"#he

k & & & i w a d j ~ lwr [see1Uwtdon).
rjs&
&jl~I@glwr,
fhe spmg to the Im&g Ao'e
a9 hft&ssho~sr
s@n$qmJ138vkUH'h I€M$
hmk @ftMH M - s e w -ng
w ~ m 1 n.&'
tbh@nhe.brake p i p unlan nuE.
10 Remove fho amp from #e bkke has%
pr $he ,polytbns fmm tb W e r qUndw
w&, mfe? to $ha r e s m ~ l ( r aap@WM)).
j the ~b'eglnnln@of Swtbn 6 11 Ensunthat ihe)xak~&c+88Lwm @ ~
40 Slid&tW badfm s h a &wmUlY( Into , W E @ ~ I Q fR8 -&-of fi$A~WfiC Wd,fvtd Imted Iq th+flhdg~p.lgtam. Gmful!y (MI
dt'B&ik@nn(ISg.d S W n 14 mn~ernfngthe thy b* sttoe upbg,mutnW n g , u W 4
darrgm p f ~ s & a s W WwFlrluq.tp&&&~e sprm Mo wwy
la R t tb;e.&W &urn dgscrIbed n
Ems*, t h m u w hp i& of t% shoe h-*e
wh&L qLrI&r8~m; the@emure thwekw1n t R m ~ v eCbp brake drum as described In
pq@um with ib~~retalnar pln, swng gpd &tian fa,
WWWP' . 2 Wslng pliers, carefulty unhook the b r a k
di I&t +beu w r and lm Wqn springs, shoe uppi3n &uhl w i n g and remove fmm
Qhsn tap the shoes to Wdiae thiem 6n.m'~ the trre@,shoa~.PbII the upper ends of the
hw*. ehaes away Mrn the Weel cylidw ta
42 ~Ushsg)a s m m d r i i , turn the Shut #id#&- d j s e w e them fmm the piston^.
y wheel until thw dkrr16C)rof the shoes is 8 Mlnjrnlse R'uItl I-, @thw.by m o v l n g the.
hW&n 178.7 ql17%2 mm. Thleshouldjust master cy)lnder rssw01r :cap and then
alltnrv th.e hab drMtn b pass over the &we. dghtening'it down mo:a piece of pdflene
"& th5! drqrn into pdsEnon over f i e to obym an alrf[ght ma1 (talilng , w e n ~W,t
linrni b 3 do noit@$ $heh$b nut"y&. &a& the settdet unit), or l
# Repeat as a2iove p r ~ c e ~me the hase damp, a &clamp or'a slmiiar tool with
q using a bmke
~ w b @mtW,M
515 tmy out the proceduirq d 8 S M the nearest mnvmfent 6oTnt tb the wheel A
~faweto c h p the flexible hase at
Warning:RmewMih A'obW
bY&Im,€mdB
m#mnew WpeBon
at~mem time -:
prevhWy In mmQ)*apha23to !36. c)lNrfdt%(seeIIWsbrrtlon). ~ ~ % s ~ ~ ~ ~ n

@&wvfi
l,!@rnli:&e h t wheels, engag&rwpepg
gear (or @idWwh,thb h&M!e. J&
Irp.the mw ufUls vablcleand support St*,
16A h 0 ~ theunion
m nut fmm the axle .dm& (see *daoWng m d I!!
w@f&,mh&! Wldar swppoR"). Remove the redv wheels,
tha
reel
866
the
md
luld
tlng
ow
~ I G

2 Wmt themeJI spring chp from Y h e pad before &s5rnhiy. New b& widI'or ejected
pads and an old s y ' r l r l $ ~ ~ u t &
*

Whining plate. SlXda the pJa@.bgt of the s p ' ~ , y w ~ a ~ ' a l l a b t e fRen@ulult

pm $ & I . via a g%Jl~ -*p%.G~onn=W to fb$ 1 4
der cauper taw inumarans). I If 'the brake pads am sU1 l1 mFvlmbla, &&W :
~ Inner pad from tbt3 qliper, 8gr~TuItycre.~rn
8 W l t h h Yh'k : h m using a dam, fine w h & P ~ i o t l - ~ t ' ~ l ~ h th@t ~ , .thse smeltl
( r
6i pIieis';f mssmy. SIaeW and retnw~ ,brush ar&hilar; m g particular atfentl~n'to g t w v e ~ ~ i ~ ~ ~ l d l n t s
'

.gpter pad retaining scrdws* then the sE@s and apl&, M-tha metal @l$ng. dim%ion of t b d b 6 bl@ne&v: Thb$
a
&hdmY the ,outer pad from the ciil~prw(see Clhn aut&i g & W ' R the f W mtewM, MSWY fa;o&:W@~$~~w@p hew
Hlu~mlong.M+s a y e of the dortect md pi& out shy laye embed& p@ele~d p d will locate with the a p P p & b Jd em
fie& pbsillnn rrf tha m - r M l d api'fnps, and did w d&ls; awn me pad Iomtiorrs In the InstallaW .(see Ur:-l - .
remde W springsfrom each pad. Q Refit the af&fptttle ta s . h e ~ ~ 4 0
4 FM measure the thlcknws pf each p a k - that whef~.thapa4 are InstdWh4Pmw,
ad {Wctian.qatertal an$ backing ~latq).If s)&v* am.- to,slld~easib in the callper W-~primgend will be I W aLthe'9pite
~ttherpad Ta hat m Mint to fhbS R & W body, qd #@ha$uMe st* rubbar mifm eng of Yhe pad ih telatlarc tg thepad WdEtnQ
p$ntrnurn thtdmew or Esss, qfl tour w d ~ y s t rti;e urrckmged Brush the dust,mdditt from plate. The brake pad wlth the lug on hs
Gi rancbw*. blsa the padrt-shuld be thwdpir 4-& men,mu jt do not rnW@f ~ , ft b$~klfq piate IB the inner pad (W
renewed kf any are fouled with oil or Q-q inape& the dust seal i i l ~ ~ ,
IF Injunaus to .healthtfi.
tQ0i.e Is ng satisfactory Wy nf deg.&$rMg a m 1 We pi- .form e , and ShB plsrln 49 Locate the outer brab pad 1n W eaLtper
Mdon mgte@l mce cuntmioat+. fT any of fDr eviel$nee of fluld leaki corroston nr body, ensurlmg. theft tts ft?@ianmaterid b
*e bpk8 pad5 are warn unevenly, *Y fouled dqncage., If attentJan to any qt .thew agamst the brake &e. InBert .the ~44tFnIng
with ~ i wl grease, trace and rectify the cause components is newessav, refer to S&hn P. screws and tighten them smmly.
 3 Fw~hRan&r&e lam mbls from fl+
pi11&91~1fi~@h&~pe~mq leva, then .W
.we g@br_qBj$ qut 6fb br&M A ~ Id% .

bmkwp@" wlen 9n~ thwwllpfa, ard-

the union nut GbWtl$ @"B tha pipa out of
p*o$[tlon,and Hug Q t a p ayer its end to
~ v ; b r i tdid el&$. W@eoff any sM1t WuFd
$lide the inner pad into pslfion in the 17 R M W @ @ 8 ' h ~ g ~fitted, m full braking
efffc1wwdIl fnrt be obtajrlbb ~ t l Xhe
l I~~ irnrnWi+
&p@r, ensuring that The lug on the-prud ~ ~ P Q ~GWHPM
~ +h
-king PI&@ [saligned wiih the skt in tiw haw Wc#tssl-hr. 6e prewred for lanwr 8 Backen t t twa
$6-r plstm, W ~ Jthe c the atati-rattle E r t o p p i s g ( d m ,&,avoid baEh br@RirQ *up E o w w , w ,+mmQw Wll
dong with t b buntlne p h e , nPtlng MW!
~ @ e g ~ o n M p a d s m a t p~ f ox r~ r . ~ ~ M e ~ ~ e f l m t h t v r d d wgy
~tl~ar
,+qrrnd, !lq plate IS 1~
a n d & ~ c ~ t c t w h ~ h t h e ~ n l lmaffefWwliwfl&
ug~~i S i h r LJff~ fh8,~ dl
~* Fm3ernbllb a w g
% he bemezted. from lhe e k r @ ~ ~ ~ ~
12 Side the reMniwg plat@into p k w and
:w~ d l - m ncllpa at it$Rnw md.4t -*@
'may~~-kr$tleaneotlyoMwan Not& Wsup @t a qIW4 Wper overtw~
tbdg&dk;l?et8tnlngW,to~etttab~ k$i@w&befom~hgm,
. ? t @ I . ~ ~ t d f l ~ ~ ~ 7 Wt& fheymIipw.oqthe b@whrwIpawayd1
.a -&PI- the bmhb pedal reWqay until M W , Beforb .stedng 'wotk ref& t~ the t r w Of dwi and dUt, 61rfa d d inhatrha Wp
with wwnin@ at Me, h g h o f i of MOR
.#& pads M B p r d into fmn iznpta~t 6
ms bmkedtea Ghwk that the Inwp d . 1is~ mrmdng tha dm@ d h y d i c #&, alrd

-
,@@mgy.&i~gpdwith one afihe-adiwr @ thea&~n@gof Won f6 concmiw m e
@Nnh81*,@ea-m)., -of asbmo$ dusk
$4 ~ & p e t ffb pra~edumm 3 h a J r ~ n l n g
I

rsar- GalrP(er1
$5. &!!*-ablwwuma 1 Chwk the front wheels, engage reverse
1~~qafid me hw- J W ~
rl'@@~~Wr
crf W i c k arrd,ayppoflft (on
&ends ( d e , "~&ing akd ,WIkle
wp&@?).parnove t b dmt w w ht
d .
hydraulic fluid IwJ ,as P2R~hm&-thebra& pa& as dWfiW@On
:$eMIon;lB.

rear d tba @pe$ M.& a m~-df-th$'-

W d positlow af-,the datiw corn-(
w as a guide an reasmbly. Remove tFi$l .
1

i
-
9-1 8 Braking system
1&9a Refit the spacer to the rear of the
brake disc. ..
@ Refk the spacer to the rear of the disc,
noting that its slightly blgger protrusior
should face the hub bearing. Slide the disc
onto the stub axle, and tap It Into position
using a soft-faced mallet (seeIllustrations).
10 Sllde on the thrustwasher, then fit the new
rear hub nut and tighten it to the specified
torque (see illustration). Tap the cap back
Into posltlon In the centre of the disc.
11 Apply a few drops of locking fluid to the
threads of the caliper frame retaining bolts.
Offer up the frame and refit tne bolts. llghten
both bolts to the specified torque (see
ILstrations).
$2 Refit the brake pads as described in
Section f 6.
'I3 Check the handbrake cable adjustment
'
as
&cribad in Chapter 1A or 1B.
14 Refit the roadwheels and lower the vehicte
to the ground. Tlghten the roadwheel balts to
the specifted torque.
Removal
1 Chock the front wheels, engage reverse
gear [or "P")and release the handbrake. Jack
up the rear of the vehicle and support it on
axle stands (see "Jacking and vehicle
support").
2 Wohlng from underneath the vehicle, undo
the nuts securing the exhaust system heat
shield to the vehicle underbody. Manoeuvre
19.5 Handbrake lever warning switch wire
(A) and mounting bolts (6)(carpet lifted)
18.9b ...and slide the disc onto the stub
axle
38.11a Apply locking fluid to the retalnlng
bolts, then refit the wliper bracket. ..
the heat shield out from under the vehlcle.
3 Unscrew the handbrake cable adluster
locknut and the adjuster nut from the end of
the handbrake lever llnkage rod. Disengage
the cabte equalizer plate from the end of the
linkage rod, then free the rod from its support
guide.
4 Working from Inside the vehlcle, prise off
the trtm covers and unbolt the seat belt stalk
anchorages from both front seats. Make a sIlt
In the carpet, just to the rear of the lever
assembly, to provide access to the lever
mountings. Alternatively, the seats can be
removed and the carpet llfted to gain access
to the lever (seeChapter 11).
5 Disconnect the handbrake warning light
switch wires from the rear of the lever (see
illustration).
6 Unscrew the two bolts securing the lever to
the floor, and remove the assembly from
inside the vehicle.
20.5 Drive the handbrake outer cable from
the brake backplaie
(rear drum brake models)
18.10 Tighten the rear hub nut to the 1
speemed torque I
i
t8.llb ...and tighten the bolts
Reflffing
7 Refitting Is a reversal of removal. Adjust the
handbrake as described in Chapter I A or lB.
1 The handbrake cable consists of two
sections, a right- and left-hand sectlon, which
are linked to the lever assembly by an
equalizer piate. Each section can be removed
lndlvidually as follows.
2 Chock the front wheels, engage reverie
gear (or " P v n d release the handbrake. Jack
up the rear of the vehicle and support jt an
axle stands (see 'Jacking and vehicle
SUDDOrt").
3 working from underneath the vehicle, undo
the nut(s) securing the exhaust system heat
shield to the vehlcle underbody. Lower the
rear of the heat shleld to gain access to the
handbrake cable adjuster nuts.
4 Slacken the cable locknut and adjuster nut
until them Is sufficient slack In the inner cable
to allow it to be disconnected from, the
equalizer plate.
5 On models with rear drum brakes, remove
the rear brake shoes from the appropriate
side as described in Section 14. Using a
hammer and oin nunch. carefullv tan the outer
1
cable from' th'e brake backpiate (see
illustration).
 16 On w d a b Nth re& d i s c ~ l i a ~ ~ , .m
d ie
' o .~tte,&.p~ap~_dbrl'~n~
of me system are
b e inner cable from the caliper handkke Torn wh&l%&5w one per wheel),and a
Using a hammw and pln punChLtep*@
!ha.
~P;h k d lts munthg b m ~ & ~ h
~ a b Mit
rn~deIaww
oo*ubr,
1
&h contahs tb mg
W $ y d w l b s o l m j d wlvw and
b e iUusWtbn1.
'? h~rofing along tie -length of the cMl& 9 kSjBarn@$@
aocumuhtarsi and+ 1 ~ ~ 1 ~ - d
as an option WMn Clla return pymp
r@-~~Dvemy W n l W b o b and arPw% WId h~dels.Th6 pumose, of fhqpymhl re fa 3 The wlemlds am cmr6lW by the
her e e t w m ttie *lw *"acw* p r e p ~ ~ w ~ @ ~ : t # g ~ ~ g @brakihg.
g,& cornputs, which meIve$ eignak from the
~ ~ Z cabla e u,dw the vfl,@i
h Worn m~
t9 a 6 h # 9 & : @ - ~ ~ d h 9 a the whwl v m . The saensbm Uegd the<-
bfm
' W ~ W - brake on-he mleygt wb~qbl;@llowed by of robatfgn of a toothad rlng, !mown as a
mppliwon af ~ ~ ; ~ ~ l f l ~ fil@or ) , attaofied to the wheel hub.
o n rlgg,
~8R&t$np Is a WE@ of ramoval, A$m&e
handbrake as described h Chaptw AA+&'l a.
M e that on models wlth rear d m b r a
the Gabla [s adjusted before tRerbfab&urn 1s
Mitt&.

Rsrmowf
3 The stop-light swltch Is located on the
bra&+ beneath t hfacia
2 To,remowtheswitch, ma& up behM the
@Ua, dfsc~nnestthe wiring.conM~r,and
u m r e w the switch from the bracket (em
~ ~ W .
, m w qa& mu-t
. S > W wtha W h back lrito~ppsithnin .the.
muflir~gW k e L
il''\CbnngW a mthuiy t4ster ('bh'fftm@$r or
~86lf~pawweCr
. teat light), acp# 'the: witch
.
Tormlir$s. $ d m the'swrtch-In.Wl
-k,k @ b m tb
@-ow
teFrni&
rssiStance, or light goes oUt). Bsnfly
mr@&the oedal and checklhat eentfnuh
_dip b,m&n the witch wrninals (zek
I ', w llghX o a m on) a b r the pettal
I E Z $ [ l . e c ~ 8ppmnmatsly 5 mm. rf
~ ~ B S S ~ P tsposMon
Y, the kwltch untH h
o~=.m".
$ In fh8: absence ot a contlnulfyw& ?he
m e a d j ~ t m m t mn be made 'by
I Wnmbting We swttch and havlnp -an
, m , o b e e m the $t$plig& (isnltiun 04.
WQnw stop-tlgit $bPtcR $3 .corrbtCy
%dji~'fd, *aka the original wlrl6g
:&nNortg, mtl weheck the npemtlon of the
.*I
9.20 Biral-iiri$js p M m
. -
- -

zt.3 dlBS system normal awmtlon

I Fl@Wy:flMe 3 , p~kecal1w 5 A& mhi@u69r 7 Wmulator I
2 SO~??O&W~J .a>~ ~@@r~rg, 6. ~~ @ t u m $ ~ m p~ 8 , mum&^
..
,. . d
a, mw.-I*al , ?

, .
&f.w
.
"

. !m4d

I
i
&4 ~ . s y r f f e m ~ p ~ ~ ~ l d ' p ~ I

m r w /IWW3EP,SW*
4

-- -
 Braking system %21'

225 A3S system U ~ d e c r e a s ephase

"
Refer tanlusWon SWfor Ire*

wrrtparhg #hespeed si@s fmithb'fbllr caupels owate indepmdontly, but ihe valve
Lk t h h . ~ h p u ~ . .detQdne
cq when a an- &;the .rear CapEm, ~ t c g s t h ~
wrth

t&e b h b g cir& Is splk dlsgo&Iy, e

sepamta m e c M e a l . plume valve In the
n?od~l~tW,bIbbh divtdm the war solenoid
valve h y d m t i ~mll& tmo ,Wo wpermte
CJEUm.
a Thsapdrattmaf~WWam
L entlw
4epen$ent on slqtfid.ignals. Ta pmvmt
-As,
s w e m W P o n m i $QrEY mw2$?p
a buI#-tp gafety clf~ultmanlt'absdl
signals remivd ,by -tbq cmp,@wI If>an
i n w r a b @[gnator low bdtery,voktags IS
d4tWedl ABS sMfl bqi!&on@pq!ly

. B T& vdm
~ddpid An- tithe front mwrt&l-ss~s Illustration).
 ID$$C?OQ@B~ tlw ~pnpeEfat,and mrnova *sr S. ROW&, @,e hub tlrrtll m e of f he.reIuctor
;s&is'w@~gmhrnef from the vlng valance r I h g , W Is;dl@ wffh.fh@ammrf lp, UBng
~ ~ ~ 1 .
i&~@ga*..meqsur&fhw& gap between
@t Pull: th& sgr wiring lead thrpugh @om the~toothmd'the m m%p~ t a e s H l ~ ~ ~ .
:t~&~h pZ
reh, andlfree iha i n s o r dotm fh* MIB an+ re@e?tbeshrrik on
& b w o n - t k p +pension W swwd <nthsr:t@h.-lftheflrgap b.rntMWn

b
.&hip
4!WflL*.W)- 4h.*@gvj$m CQEIS ~ I ~ W ~&en&@, ~B~S.
'k Rpn$@v@me b,gksewring~thetsenaorb ~ a & k e o f . a ~ b l e r r n u s t b @ ~ h t ,
*ywlv,el hub, ahd ramave the m s a r and Ensure 4h6. sQnaor wiring is wnectly
1 ~ ,as&tb!y
d from the vehicle (am routed, men dip R btl~kinto pdsRIon tn%s
q!-mW)- strut bra&&
-m P Feed Mqt.wiring through Into the engine,
,a p m ~ r w n g , a ~ p , ~w&of.m"kl- mm6afimeh, a M rsconawt tne w ~ w - 2&l%-.l *ind*l*.l*fhgm-
q m w r . ,R& the connador la ilr ratairing
pwsk b thd sewor flp. then'mh ~ m m t@ owewi~ theswivelhub
re ~-8 th.t the seneor and swlvalhhb
27 m o v e the bdt securing tha sensw unlt
ssshg .ndean'Fn =*or'
hm $msme only; In particular, do not bi It 2R"% th..m.dwhd. h . M~
Veitilcle to 10fie tmi]jng Remw? n- and
&b,wm. ~t *e stnnsorawning fh"0untfsnd t i g h the b o b ta lead assembly from the vehicle (m
and &hbn it to the s p d e d tqus. the speciflad trkqm nl~tionl.
Reaf wheel sensor R m g
28 Prior to rsmhtng, apply a bin Waf ~ u M -
Removal. purpom g m MPile slartssr @.
24 Chqck tho front wheels, etrgage rbV619e Errsure that the W W t eritd W t h g
gear Weaw the handbr&er..Jack seattng fa~gw m. Fit : t h e w , uahlng
up par sf-~~,y*rclaand support R on hand pf%&rs.anly: ?rlw o ~ & r ,do nbi hit h
axle etatikia (see BJacWhg and vehlde with a h a m m . Tfghbn the reMnlnq bolt to
support"), Remove the afibrapimte tha spec%dtwque.
madww 3P Rot* ,ha dl% unW on@of the TAU-r
25 race the wtdng back from the m s w to rtng t d h Is allgnd With the w r tp. Using
the wtring @onfi&br an the Ilgnt-hand Jde, of W1er gauges, mmure the air Qap Nwem
the vehfde (seJIfwWon). i3- the c a p me tooth and the' msw tip IWmWn).
neXar w,&nlm clip,'Ein'd disoanned mt@ethodkand -3hefmCmdukbn
the wiring earn z b a d n wiring to6m. m e & &WIh, If w:drg@b M3t within
26 Work back Bfdrig ththp'wsr; !~
WMflg, qid @.mg_8 @w J?.- i q m I IM tfie
freer # fram any retaining $ips. &@&c t3hh8utf.r@i%I!#mrn~=W 8agM.
.-
- -.&
-r:.

coat 6 . b W m g fluid to the &ISMof the ring.

$7 L;aeaYir ihi.'mlu~r~flng on the-@Vfolnt,
I

--. I:

N h - w,aE-
n ~~ h3~1#Wbri",pn
Inb ~ i F - .4r o ' r : ~ & : d t e n ~ ~ n e f l d m t h W ~ .
Ffont:suspension

t
 -
10.2 Suspension and steering
 Susp~nsionand steering 10.3
I

...
;$hi&- uppet mounting bolt ....... ....................... 115
ak&W.M r mwhtlng bolt .......,,. .........,... .. 85
?

1 The In@ k tfrorrtsus~m Ts af ttre

M m P h m ~ ,Wt;v@~,
, Inqerrp~ratTngcall
spfingg and -;integral teJe=~plo %book
@bSMbRH6ih&WoKt), ~ h 9
muts are ipg-$d by b n s v ~ m &lower
suspemtan m,wHch uflIr;he!nrbbr Inner
rnountlw.bushw and n-I a WUolnf
- &-fie 'outer ends, The f M t wlel hubs,
te w W i bwh-gsII
which carrycaryh bmkedipw
-andfhe huVdiisc wmnM1Els,W b M ta the
MaBh-n smt$ .arrrl eonmehd to the
lawar arms vla the balmits. A $rant W-roll
,19$r18 d W .bdl I#gqf+f@lfCiad mWs. The
afl-roll ttar Irr . W b b r + W n t d ohta ilia,
I suErhm& .and &nd&Wb@h the t m r
$ ~ s i mms .
2 The rmr suspemhH'dlffjfj. a$cmding tO
, k r Y d ~ p b 0w
f ~ @@ b&
%hldm vvftR
p r dmiii b r a b &f f h ~ 8 u - r " ~ ~ ~
hw me' War p ,w h l q m n ~ W bZ W o
torsjbn hqm wlthin a tubular w6griisinber
- whfh minh@te bath he r y w;llnqvarms
[seeibtdlon): h ;4n-koll%ar Is situklwd
f =t ~ r o m - s e d ~ofthe
,> .n fhmtaugqdon ]!st to the War ebf rhe'~ras$mempey,aR&:ls-
also canm$d to both trafliw amis.
10.4 Suspension and st~&ng
3,v m w wm ~ rw d+ bm@s we fitted with
an opn-bar w axfe which condste of twa
.@mto.n bws$ ~ W Panti-m?l b y s and an L-
&cfinn m&al eroSsmamW whl~h rs
mmcbd to M b the>tratllng.m.The twa
t&dn wsand twa #tti-ro~~ bars are
mnnecYd at the centre w3+ a link, and at
thalr outer w& to W trallhlg d.
4 Thn *ring column 1s cormected by a
unlmkl jdnt ta an tntwtriediata qh@, whbh
hasaaamnd ! d i v e d joint at Hs lower end.
The lower ~ h b r bjoint
t Is gq@elietlto the
s b d gmr ~ pinlon by means d a clamp balk
6.Th$,*ng gear ts mounfed onto the.front
auMWi&; It t m n d e d b $ ' W tra& rbds
and balgolnt~30 stewing arms .proiWlnq
read- from the swlvel hubs.Yhe W'H
~hdw~m-~rdaded twwabte wheel eli~nmmt
adluwent
6 bower-assisted steering is available on
mast larger-engtned madels. On F3P erghe
models equlpped with air conditioning and
sower M n Q , an e W r i W - w e r e Pump
ia used to power the &&lag hydraulic
spwrir; this Is due to la&. crf'sp@ in thb:
engine compartment to h a w both the air
carrdltlonlrrg cclmpr#mr+nd a OeV-driven
pump M othothet modelsequipped with power
Me@& we TlltM wrth a bad@nal ,bi$-drIurm
pump, which Is driven off ths eranWtafl
PUtiW.
.Removal
A nw;dirppk@ nut wirr b3 b aW on
rafMiR$, arid suitabk IocRIng flujd Will hs
m qwW to wtfhe&-?mM SPfineS,
t Chock'the re& wh'eeJs, f l h l y 'apply,t h
handbrpke, then Jack up the tmnt of the
b support R on -axle stands.
~ h i c .and
P&cking, wd wehfclemppd"). Remove the
appirr~.MmmdWh the two swhrer hub-to-~uspmlon Mnrt
2 Refit at Jaast two roadwh$$l bolts to t h ~ rnbumlngk h b f i m the franf sWi oft h $m,
fmt hub, ma 'tlgrm t p m s ~ r y yRemoye
. t h e n r d l h ~ a $ h w m d n u t s t o t h s r e a r d should be
the driv&sbaff nut (-Chapter 8, W b n 2, the k~lts.qndti~htehthem Xb
for full dqtalls). &card the ddvwbaft n* a torque.
nevp amshoufd &,used on drtt:inQ.
I:.',:
aa Slackening ohe l o w Jgn,,m id RWt
b~lljdlstehmp botr n&
3 If 35s hub bearings are to be disturbed, tI@Cn its retah'ing abswa. the ,bfdce
*move t b brake dkc as des~rib8d in ccntiper +mW Rto p s p OF me
Chapter 9, tf, not, unscrew the two bohs dm. Applya few d m p d IaFlring fIuid to.-
sekurtng the breka Ealiper.a&embly to:the miper.@lt P ~ $ sFM. the bolts a(l$ t l g M
W v d hub,,& sttdb the mlilllpr a s m b l y off
tn4 disc,Ush-fg 3 p@e,$ w i n .or string*ti& th?
$ham-to t h e . s ~ , t o ~ ,9.
$6 Insert and .tighen t y o <Mad
callper io the front wspmlan .dl@ng, ta Tlghm the dilvershrtiff nut to thi sm1flflad
*&..
( ~ w
avda Amlnhg fhe,brakb h*, wrque [Maptar @ , pqlpg tha m @ h d
4 On modela quipped with ABS, undo the employed duHng remomd to p m t the h&
mtaining bolt-Wd Wlthdraw Ur,e fvnt &MI from w w :
s e w f Worn the d v d hub. Tie the aanm to 17 Check miat the hub m t
b s f M y , Wen
tlie Wswnsl0n StNt.Sb that lt-does n0t.g.t @fitthe r@wbel wn tcf lower the vehk@40
datnagd dvrlng the'mabader of the rwnwal he grouird. SPgMen the r ~ a d t v bbofts,fo
l t k
~ U ~ . ,speeffd Zarqkk
6' flism& ih9 nut Wuhrig W t m h rbd end
baIgpjnt to the swivel hub* Release the ball-
tmshank uslnp<a unhrerSnl PdlloHt
Iolnt-a
W W .
8 Renrowk the nul and cl@mRhdt sewrlna
the lower suspension arm t i t h e swivel hub
(me JUwtmtlon).Carefully lever the ba1l)oint Mote: 7ha WaYIng griWed+ pmstdfuste4
out of the swtvel hub, taking care not to a d pre-Ihbrl~tsfid,doublef-fiw .Me,
darn- the balljoint or driveshaft aalters. and is h f e W tp Pf-m car9 Brrflrn'Swy&e
Note &ti;e ptaatk p r o w v r ptata. which is fW Ilfe withour memfe~neeor a mfib, & not
to the blydntshank. ,attempt ,& ternme the beph$ untes
7 Remme4h two ntds and washws i r m t b aQsohteb necssargc, as It ltfi bp &w@$
b d b sekurlhg the $ w l v ~ l hub -fo the, durlq the. rayoval o p ~ t f q n : N B v q
suspendon strut, nMng that the nutsme overb:&ten tha d r k s h l l n u t h an a##npI t6
pbilttonwt dn t h r@r ~ sid,e aT the ' q t , "Bywmeww-
Wlthdmw the bolts a d support tho w l v d A press will be requlmd m d B d I e and-
hub a E sm v
l. mmi! the &-My; fl su@ el too! k not
-
8 Release the driveshaft joint from the hub, a J a p bend vks and sufaMe.
a(~~lii&l&~,
and remove the swlvel hubasmbty from the sp- (such w large s~:+rs) MI1 sewe gv
vehicle. Note that kcking fluld is applled to an ~ d q u a p subsf)'tute*
s The tfeadm's Innef
the joint spline$ durlng assembly, so It I8 likely VaWatBrn 8 n m m Ifftpq the ti$; #ttmr
that Zhey wlll be a tight fit In the hub. Use e hnef m remeins # the hub when It is
hammer and soft metal drlft to tap the jdnt ppwdccd oftha hub m f e r I * , . a , ~ M%
;w
out of tho hub,, w.use a puller to dtaw h e &$red bearing guW will be requimd b
6whd hub &mMy ~ f i W
joint spspllw. m*K
Remhg '
9 Ensure that the drIv&shaftjoint and hub 1 Waw In ttie 'front hub bwlngs can be
spllnes are clean ddry,then apply a coat d ~ b &by &measuring the mount of slde-
Iodrlrtg BUrd @*B jofnl:@tlti@% pay m nt:Ta 40,mthb a d U gauge s W
l o Engage thtrpntspliv with h e hub, and be~xedsothatbprobeis in mntact~h the
sfide &s hub,fully onfb the drlveet~ff.I h W disc fa@ of the hub. The play sh?uId %
between 0 and 6.95 m m If If la greatar t h b
~ t h k the, bqrtngs are mm i m u , and
$pe$f led
Remoral
f Y SiWd on the w-r and flt $4 nmw No* rl n e w b d n g d i p will krequitad an
driveskft nut, kightenig It by hand only af MfiW
~ l s , ~ e . 2 Remove 4ho swivel hub assembly as
3 2 Ensure that the p M b p r a b t ~is r all h $&66n' 5 UO~Q mle
fft@dt~ the lower m f@joinoint, Ren Lacab shield retainins s c r e w and rmove the
the'hjdntshank h W~erswivel hub#w f h d sMe!dfmm tha.hub
wljolq.damp bolt, and ZlgMen If8 m l n q S Support iheswlwl hub ~ l-on h cyk s
nut to he Spmlfied w u e . or tn, n,$ vim. UsIng,a.uitdq t u @ k s p
19, Racwtveqt the ftw$ rod en9 @lUdnt to which bearsm l y on the lrmer md d the hub
the wjuel hub, and tighsen its f&lnlng nut to m g q , press ther hub nangi out of Uls
the epdffed WrqW. bearing, H the bearing outbsard imw race
14 On models dqul~p@d with ABS, r&lt the remlW,ong% hub, m o v e It using -a
m r to the hub, Srtld Hghten ha MaIdng bearlq puller (we noteabow], ttim did@the,
hdr to #B. qmbififiidbjqus Chapter-& fh-wh@- &$he hub flame, W n g wMeR
saon m way r o ~ d dIs A &qd.
mk d b t-t~ r n ~ v daMlng
h ~, 4 .actr~ct?bbadng tetgnbg circllp Worn lhe
&e marks made on m m a l , and securely Inner end of t hW e Jhub w.
1. Suspension and esteriring 10 6

;5] n m , Mlt the, fnrrer race, In W B OWm'n'lhe*pr we. =JaMng and v@?lcle$Up#orl"). Remoue the
p&Etloi~ OM- tha ball eaQe, and sewrely 10 Ohee tRa' bmrlii~lh correctly seated, spproprtata mama.
..ypprt4ne, Inner f&e of the swlvel hub. secure R with @?. p v clrcllp and remove the 2 Remaw the two nuts and washem fipm the
Udw YWtslble tubQlarapacer which beam plastlc stme. Apply a smear of gtwm to the bolts swuring the swlvel hub to the suspdon
'y!y $h Mir mu, p m -ffre cmpleu -011mql lm mrkgthatwn~ma~ltlortgdmtha
~ f $ ' ~ b aut y t h a W hubi
l of 11 Slide 'the thru&tva$her onto the hub mar slda d the &nit Withdraw the hob, anand
1:s Thohughly clean the hub wCl w ~ v e hub,
i flange, msurftrg-that 11swt surfac9 ~sf m w r l tha-1 hub e g 7 n b Q .
M o v N albtmas of dirt and grease. PoUsh the Range. Securely suppart the mitar hcg of 3 From within the w ine compartment,
g w y any bum w mkbd M esi which ,might f k hub Aange, remove me mfcay6@hew flttad). Slacken
hinder remernbly.me& far craoks or ahy 12 Laate he b e a d n ~hner race over the end the susperpsian drut u p p r msuntlng hut,
. ~ r 9 i s n s ~ ~ w d ~ p , m d waflhe e ffmw.Pr* U@M n g onto ?We
t h hub holdhg the strut piston r9d with w Allen key
m@n,$nts R nebsaw. As not& above, hub, udng a tubular spacer whlch .beam on& (mailtwW&ioq}. Rmiove~Wntst
q~>ewhlpmdits clrclip must be renewed o<nt+ jntr-w race, uml it se'+a .againstthe 4 Retease the a t from the &W Re, and
whene\l'sFihy are disturbed, A replament t h r u s t w h a t ( b e Itt&atfon). Chock that w W m w It'frm under fhbwhwl arch, " W g
b l h g kii, which consMs.of the b e ~ t n g ~the hub flmg rorcmPBs ,frwIy.Wlpa off any c a e to prdveqt darnage ,to tow d r b s k f t
&allp & thrusiwashef, ta Bvallable from excessoil o r g w e , aaitir1- I l l ~ t i o n ~ .
13 R&flt.J,tre'Bake d i e phTel4 tP the swivei
hub, and t p n Hi rpleeinrhgscrew. Remm
19 Rem $e, s#lvel hh% assembly a$ 6 Mannwvrer the shut assembly inta pitkn,
I *T,W ~ ~ b lchekk y ,fl posqlble) that ttle descdb&ln&ction 2- W gw n bt damage the drW$haft.gaifw.
baarlng la pacbd with grease. Apply a 6 Insert the h a awivel hub-tD-suspension
grut mounting Mts frpm the Wont side dtbe
BM. M R the washersmd nub ta th&m of
bob, tighten ,them to thusp=M$d
torque (ma8 I l l W i W ~ n ) ~
'gbut ley? the lnnw plsWIc sleeve In
I
Il&ir k& hold ~ t i ~ rams
e r methat.
.$ h r d y support the s w i d hu6 and locate Rmmval
to the Bpedlgd roFqui
When ap@ltaBb r&$he c o w .
&
7 Rsfrt tfie upw moutr#? ,M,wd f f g b
Illda*).

L
L *tk tin m the hub. PW the r n Q tnfo t ~ h p c kthe rear whml8, firmly afiply the d .WlpWmhw,to&@ the vehlele-to the
p w h , -muriw that it matwo the- hub handbrab, then jjrck up the Tmt of the g q n d ayd%pbtanWroadwheel bolts to the
W U W , MMawitdde tubutw~~ejTWiChW c l e and suppdrt R on .axle mnde '(see s w tsrqU&

and balk N W t M mbolt beads-

fO-s
10.6 Suspension and stwjng

&:@s:++r~ng c m n p ~ ~P W W
W.&spen%on
strut gtnrt!l s p h .- . GI$...
6,3b-. .; d a r
and imnovethe re~at~ng

5.10a Carl spring lawer end wrmtly

located in *rfn@ seat
spring compressor; and cornpres the coil Check thh strut p t h n for slgns df ppiwng
spring untll all tsnsiafi is rel(ev@dfrom fhe along Its fmtin length, and check the strut
upmi mounting fdate (see Illwtrafion). body for qigr$ nf Test the opMkhY
3 Carefully prise the retaining cllp cut ct 1t-s of the strut, while holding It In an uprl&"t
gqve in t h top ~ of the stnrt p ~ o i lmeft,sMe
, pslthn, by rnavtna t k pistan through a f@I
Warning: Refom aifmpUng U off the retaining collar, n~lingwhich way stroke and then through short Strokes of fib

A iiismantie Pite front susp&&m gr~unclIf: is fitted Isee illustrations]. DI,&ard

sfrut, r.suitable fool to hbfa-ibrr thO retahlng cllp; this must be mewed
coil sprlng In cornflmsd~onmuat ,h whenever H is disturbed.
&mild be smooth and continu
m W m e 1s jerky nr uneven. ur If
obtained. Adiwstabfe CON spring 4 Lif uff the upper mounting plate, the NsWe sign of wear M damap,
we mad* avellable, and are beqing and the upper sprfng seat. Remove mr;esSa?y.
meommended far thls oper$tlon. Any the doll sprlng, grtd Aids t h s rubber dust 7 Ifany doubt odsh &put the
attempt to itismantle the strut without cover off the stru! piston, the wit spring, gradually releas
such a toof Is likely to msulf in damage compressor, and check t h ~
ar pknmat injury. dlatwtlon and signs of craching,
5 Wlth the strut assembly new camplets(y minlmum fw length Is specified by
dismantled, e m i n e all the samponsnts for the aniy way to &heck fhe tension
1 \?Mh the *vt r e r o d h w t h ~~e h l d eas wear, dsrhags w defomtion, and the spring Is to m p a r e it ta a new mmpw
dewdbsd ln Section 4, olean away all wterna! bearing far smoothness of apwdon. Rehew Renew the wiw If it Is dart~qwior dis
art. Mwntthe &ut upright inma
uh. my af the cumgnnents a8 n w e m f y . s if there Ismy doubt as to Its tsndltl
2 R m w e the upper msunting W e r . Fit the, 6 Examine the strut faislgns of fuw l e w e . 8 Inspect all athw camporients far signs.
darn- or deteriatatijon, and renew any
areE&peGL

Ib
&l ...then the upper mounting
p M e [wb I l l u s t m ) .
12 Sllde the wtalidng ~oilarmtb the
m piston, and secure It In posttion wtth ttm

retaining dip (see iljustraiian). Ensure, that
the dip is c o w f l y seated h the stwt pHm
.. groove. Slowly and cafefully ratease the
iprlnQ wrnprerssor, watching to maka sura
that both ends of €hespring m d n c q m d y
lac&$ m the spring sSiats.
13 Flt the upper mourrtlng rubber ~1 the
mounting plate (me illusttation),
14 W i t the strut to the v ~ l as e dweribd
iflSeMon4.
R~rn0val
1 Chock h a rbar wneels, apply the hand-
time,then jack up tfw front & the v&lcle
su oTt It on axle stands [see "Jackhg and
&h suWt2'). Remove born fhrn road-
vJOl&Q.
I RmoGe the exhaust downpipa as
c b S ~ l n # n e , ~ Partm tof a m 4.
B Oh rnedels fftted with a manual gaarbox,
dhonn& the gemhangs rne~hanlsmfrom
i$&g&rbx Ref&to Gh-7A
4 Rmove the nuts and bolts se~urkgeakh
Md b'f 5hs anti-roll bar to the low&
WpWwion arms, noting the pasifions of the
rywr'maurrtfng spacers lee i~hstrat~on),
8 h b d t the anti-roll bar mounting clamp
(Wn-1.
6 h ~ e u v r ethe anti-roll bar out from
pIdmh@th the! uehlek ahd rehove the
w b b mntlng
~ bushes.
7 Carefully examine the .anff-rolI bar
compa~rrtntsfbr slgrfs 05 wmr, dpnage or
deterlmbn, payIng partrcutar attention b
and the rnountlng bushes, Renew Worn &m-
ptmkits as necesmy.
Ref7t#n~
8 l-utsrlcatetlm rubber mounting bushes with
a suitable g r e w -(i#eatly, mdlybbnurn
disulphide.gmam), fit b u h onto the
mti-roll bar.
9 Manoeuvre the antl-roll bar Into pmition
underneath ttia vehlcla Pasitton the bushes
sod~attheir splltsme against the subfme,
then refitme mounttngdamps. QQ not tighten
tharnah8ng damp nuts or bolts fully yet.
10 Secure tho enda d the am-mil bat to toe
lower suspension arms, ensuring that the
rubber moqntlng spaced 'arb mrri3aIy
ppsitlcned. M the nuts and b o w but decnot
tighten them krlly yet.
da r m ~ n t i n WP
0.5 Fronf ~ n t i - M g plastio protector plate which (s fitted to the
7.3b
li-
...wdr~mdvethebarfromtlw
b, I 7 A a RemoveFee bdljdht clamp trolt
suspension arm plvot hall
Suspension and steering 10
.
7
It p m p i ~ ~ r e @ t l m d*
seteztw mechanism as.dmrlhed in Chapter TA
t2 R& .the Wpst,d,~.wn~4@ as d&cfiW
In the &want Part of Gh@tar 4.
13 AMt f he roadwtleslq, I- the vehicle to
the giound and tjghten the wheel hitsQ fhe
speclfld tcrqrpe.
$4 Tighten the mtl-roll bar fa~tmlngsto tha
specified torque, starting with the,mounting
cmps.
uenrow
4 Chock the rwr w M s , agpu the hand-
bralfe, jack up the Want d the v e h l ~ l and
e~
suppft ft on We stands @e mJac:kingmd
web/& sup*). Remove the appropriate
fbnt roadwheel.
2 Disconnect the end of the arrtl-roll bar from
the lower suspenslofi arm,as described In the
p ~ w l wOectpn,
s
$ When ~1WIe7 remove the Dolt securing
Me support bar to thefront wtng valame, ~d
me out 58,curfn'g it: in front pbpt halt.
R m the support bar lmmf ho v&Ede @e
Uluq4lionk).
4,Remova the nu1 and clamp bit securing
We Tqwa~suwpgjsiwr elm RaltIoint to tt7a
~5$1uslhub. GmfuIk IM~r'thabll1dnt out of
swkd'hub,taklk care not to *wage the
ballloinr or drlvashaft gaiters. Remove the
balljoint stiank (sea Illustrations).
...
10.8 Suspension and steering

6 Rmove the two pivotnuts and hdf%,and

temaua the lgwer su$pmsim arm from the 8 mer up the lower wspension a m and
vehicb b e I U U ~ ~ ~ ) ~ rrwert tha two phat bbb fmm the of the the lpwer suspamiw arm ,@, ttp slpel hubp
owm4t1 auspmsbrl arm. Rdt-ih? outs, but tf@ty~ C w l l y Ider the ballJdrd auk of ofthe
them by hwt'only at thls Sage.
0 C I m tha lower am and the F a around 9 Wit the p l d e : p m t e to the lo we^ am huh ta@ngq n o i to dmtggetha batljoint:.~~
*. ahn mountings, then ,check fgr Cr8etcs,
d&&ion or my OMaigrrs of damage. On bailjoint,
driveshaft @*. Remove the pMtF
then-lacateVm bdflaint shank lit the pmmq plate ,which b-TMsd to the WQalol
awtvel h u h rteWt-the @dljoFnt clamp M,and
mme modelsi a brake disc saollrtg shbl b t l g m fts retainlw mito the spcW torque shank.
#lipped 'to the am; thh shwid also be (!mtlhrstretlon). 5 Remove the Pwo n , q d b ~ k t 9 . s ~ ~ ~
rem6vd. QhscK that the tower m b-dJ~Jnt10 When applldfe, r e 8 t W ~wpport bar MI the balljoint fa the I m r wspalin #m
mwes M y , without any sign of roughness, thwfmnt pivat &It shank. Flt the rMnlng bolt U I u q t b l . Remow the bdfohk
that th& baftjbtnt galier Is Re& mrn cwkS and nut. fighteirlng both by twnd;onty&t&Is 6 Check that the balljoint t?bves freely,
and splits. m i n e fhg shanks of the p1vo.t sta9e. w!fl?outany sign af wplhness or free play,
bolts far elgnlne of wmr or acorlpg* R&%W 11 Kimnneat the md d Me an4-roll bar tg m l m the ballkbilit gaitar for signs qf
worn Cwnpnants as necE#my. tknagmnd deter1wationsuch as na~k OF
ma tower s u s p d m arm, ensrrrlngthat fhe spllk. Renew the wrn@@k b ~ o l ~ ' B B g
7 In- the l0WWaSm phot b* If thg rubber rndcinlln~~ '8pacWs a&' .mrrep if damgsd; it is not possible to renmw fhe
are m,cmked, qpljt or p ~ r i J d they , po$iti&, Do not fully t Q h thefgghnings Gallfoltlt gNw sesjawbly. The MUollrYt
m a t M.wn,W,d, To eenpw W!I busbej
siippurt the lo* a m , ad ~ B S YM'fM H- wnewal Ut crbtatdb from Renault:dealem
S
42 w n We roadwhet, lowerf he vshlch and COMS thp-halljolnt, the<p1Wc PratmpX
b q h aut using a tubular 'spacer, s u d a fghw?, the rq@$#h=el bblts O< th~~spe~ifl@pw@ dlfkdngs.
mked, wHIch bears only on W I h&U, ~ cd
iW
torque.
edge of the bush. Note: Remove only on@ $3 W M thb vdhkf8 m.drkQ,dn Its Wh~ts~*ilktit@
bush at a tima ?!Dmt& &h, to ensure
a h new bush is cmectIy podtiand on bushes In position, Tighten the tow~ram 7' & thq MUjoint to the suspension
TO& the vehlcke to .settle the lower -arm
fhs'taXa~m, Thorough& olean the lower am pivot h d t s and the antbroll bar fixtng t6 fithe l k r t ZRe MRk anrl Wh?, and #9tmW
bum, remodng all lmws of dirt and grease, spgclfied torque. When the pivot bolts have 8 Fit th&nuis
mtalnlrtg to thespe~ifldtoque.
and pllsh away any bum or rdsed edges been tightened, smr&&e suppbrt W In shank, than
which mi&t h6der massmbly. AppIy a ptsNon 'flwfi,wW)by securely tightening
hub R m
plstis pro?;tor ta,thh bdij~t
lowe the shank'In the S W ~7
Wljoint damp bolt, and tEghW
smriar of a wltable g r e w ~ tfig o q r edge 5ts d n l n g nut and W * Ph a
it^ M n i n g nut t~ he spdfled twqua I
.of fhe new bush. Prws the twsh Into paltion
until the dlgance *AF Ww&n the Inmr edge? 9 Rwonri&t the end of h e Wtl-pi &@,f&
of ?he lower m bushes Is ,a$shown taee
?llbl?itralionJ.Wipe away surptus grease a,&
repeat ma pmmkmon the mminjng bush;
lower suspension arm, ~ r h g
ruZ>ber rn+ntlig spaGers am- co
ps~t~oniwl. ~o not ~ t tighten
y
A =-

thrc'T~stehl6~1
.yet.

t. mo& thg rear wheek appiy t*

haidbt-&ei Jack up the Wont d .the vatiiele
wirg support'rt on axle atads (see "&E'Wnsl
and vehfcte . $ u D ~ . Remove the
appropriate front roa&h&l.
2 Discon& ihe end of the anti-roll bar h m
the lower .aspenstan :arm.as describd-,ln
-S&iori 6.
Q>griuZkc the ngl swudng the au ort bar
(*mi flhsd):@theb w a h fk,ont t t b b k
then Amken b@hthe lower suspmIan arm
pm'tYoftg.
4 !?move the nut and damp bolt secudng
10.1 0 Suspensian and steering

-
bmrw bar"
4 Prlse OW the cap h.om the WHng a r y
baring mml~,@n am- &'the W o n
bax,w.
6 Mark the j$&fik$ -Bf "fbd.fe@on'W jn
Watlpli td'the l ~ h g an the b w
mrsarde,a k hirk~WbrinM m ta
the centre Ilhk @lq~&,.:Wkh'the kaI1tng wrm
urtsrr~~~Mi d-b tr$tw&n
the *,$ thth8.*@ F@@M u p ~ + , m d
10- rnou*, &$.hob N F thq~I@FK;#:
if the wgrnllr$ !o be tk4 win be
fi~Waiwwrdsofrearanti@lbar n&ed on Mflri~.
brack&s @mallarcw'sl must face thef ront 8 The torsion bar a n now be withdrawn
dttrevehkle ouiwards* e t ~ Q a stlH% h n r n e r sqh @s
R e n a Toal Emb.p0 at.a.sultabIe &matI+
mmng (see>3ii&aw9.
A RMtt themi%tl bar t~ the vehicle, noting 10 tf a new torsfon bar b kielrtg-ti, t@,
th@ the cutaway en& of the anti-+PI)b$t? tralnng qm rnqs be'd* until fhe distlan'crs:
mbimig bcrt bfwkets mLtStfwXOwaWYh~ b m r h the ~enenttssof tbths ugper and bW
fm g ihe vahicls tsee ulustrsfion). sh&k &9'a&y mounting bait hdm is 403
5 PodTlon W m&nlng^nut platas on @-LtvP mm (572 mrn on models wlth the WP/1&
ofthe *$ling m.ReM the mtainlna bolts. M v e ' e m 1 . This measurement58 known-a
enmring that the handbrake cable r&Wng dimension wXn.Wlth diitien6iqn '!X" wn@g
cRp are corrsctly posliloned. Tighbn 4 h 8% all the ladanat forces wlll be r m u v d
anti-roll bar retaining baits to the.spec2rred from the bar.
torque: f 1 Ralsl the traitin arm to the reqdn
8 tow the vewter to the ground. 7 O m the .8pllhm d the"torsfm bar ate We posltfan win@ a ]BE[ AkwngtIv?ly+'.a .-.:
thh bar.can be withdrawn ccrmptetdy from Its sirnil@tb that shown can b fabricated mma
lomioh, Note that We, 1eft;hand attd right- [en& ~f th- @r,qui u& to w&y
hmd bars a@0 9 i ~ ~ P e h a n mthw i q can tIletdt9g r n . ( ~ . ~ o n ) .
hs.iderrtfflfiad by the markinds on their ends OrWnal bplr,{qlt @mi]
(meIllwHmW~).
bar to albn #te
12 RWW%ths.'f@tohh
R8M.g made r~nmmoval,then engaga the bar
Rqrnml 8 Enwmthat the bearillg tM.acM,and torelm the b W i b r j i ~ ~and
e t @aling/c
Mofe: dl eu&i@k beion bar mrn~lyalibm' will bar splines are clean and dry, LuMogYe'tW
be required-w# twk s@ine& wIth malybdmm disulphlh grease, RmprmdmAwft mefal drift.
1 G h a c l r t h e f # n t w h e % ! a m d e ~ ~W i nmtfie bar into the,b'ra.cKet. Hew 'bar (errdowd-bar mar m
gear (or ltP"). &li up ms few&? thq vehicle 9 R the rrytghat bar Is being &tied, pftion 18 W e the Zorstm bar untrl the p
md Wpport it wl a l e stands [see Y M n g .the trailing arm 80 fttd the d i m b@Wmh fd,w whqw ttre b8r 4 x n . h fr* en
and vehtcfe w p p ! ] . move fhe 'th$ centres,b ttte uppr and tower &I&-& wkh rhe eplfnes on the baarfng
appropriate madwheel. sbso&er.muntlng hltholesIS not4 prlw trsarlng. Having found thfs, tap the bar'
2 Rem~ve'th& Mar shocR &Wet, 9s ta m a l . home using a h&nimer.aM a so17 rl~e€d d
d e m b d in &&ion 16. **
3 On model$-tittad with qn op~n-baraxle, New bat ( o m b a r rear me3
undo the d t n l r t g sc.rew(s) and r m ~ ~ ' t h 6 $4 Romovs the cap tmm the ap
Wng b r a d d and 'OM thwpo@m
drill mark on the end of t b torshn bar
I l l d o n ] . f!o&te the ntrw b r go

7
8 lenglfr of
$211A taot r n ~ l m m
+I
thkW bar qin mted to 4re shock t L l b c..,,.--.-,-,.- prtbfthc~-.:
ddU m m ( a m w l l on the end ufthe
-
absorber m 4 n g h o b and used to set
# m & W 'Xr w a e x t tomon bar

barfully into psklon M g a hammer
bmbn bar cap(s) to the b a n g
4uld -1 by removingthe
?wCyltdtu.aHmm~esd .dMaround the
7 WB
h,pkw plpe! unton at the mar of the wheal
~ioysndw,and ut-scrw the union nu$ Qrrrfully
meVte pim out of iha wheel ytlndw, and
Suspension and steering 4 0111
plug Br tape over Its endb p m n f d h $ . H ~ ~ +
Wrrshdf any-spMWd I-W,
0 5 u
' pwttbWht d W t h s ~ I l n ' $ ' ~ ~ &
hk.
&~fhemar~Eush~n"tgBaln~t~
theddllng m bearing,bracket mauniin$ MIt
h W -
ID F F O ~ndemWh
~ the dlbh W mhe
Wling euni W q hscJWmounting n w qn
W.sMtwbs m m . Tap fhe bdts thrwgh
the bb.&rhg brackySt wRh a suitable drift.
Loosen the mounnng nuts on Yha opposite
tMarh$ bwW 14.3 ~ u h ' i o fur d r e m o h g the rear
13 Lower the Iadk until the trfiitlng h n
as-ly :Is clqr of tho $14 then pGll the
s u s k & o n trailing arm bmtm -
tMllnp arm. wt bf tbe opp&lte am, and
m v e I t f p m the.yMle.
12 tnspsot the trailing atm baarings aBd
tmW!for signs .qf we& w damage. Renew
warn If n e m w y as described Ih W b r
~74,
If a new trailfy arm kbMg Mtsd undo the
roilr reta~ti~ngboits,.ahci rehove k e Hoke: k wfil be M&@ @' gbMq. qr
backpfate. Mthe bwkplate to the ~ewW1lng improvise a whbb sp&d td $ , * ~ the
arm,appty ihteid-lockh~gcompound to fha Wn@-m t&
mnw rn,>F@ h m muw. I Remwe lmth trallihg wmiwith rdkhi~m ka
S>edIon13.
R~mm 2 h u n t tka left-hand traillng svm in a Ww.
13 Ensure that the trailing arm bearlnqs are s Totemwe ttrd prhgs, it will ba n w - w
sufficiently g-, then engage the removed to oHem fhe Renault tool shown, ar to
tmllbg arm W i h the oppmite erm. fabribdb a slml[,q . W l as foItows tsee
TmpoMLy p&im Wmtl-rdl bar aver b Illustration). FWnote the exad pa6ltkm of
m6ldnirng bolt hofes, eaeurlw that the the b w h e .
cutaway ends ofofthe.retainlngbolt b r a o k h 4 Obtain .Elthrsaded rsdl ~ n'MoUnh s ~?s&I
fabe towarcbsthe fto@,0fthe yehide. Pushthe the Inner beam,a tube ofsuitabG diameter
traillng Into position until the aM1-fbll b;tr as shown, two thick b r s of diameter wual
brae!@ bobs are m l y altgnad with -the to awh W h g , a q q & r p f r E k ' W &
bolt h o b h the t A & g arms. than ma tub, and Wnuts. @&two . s W off
14 Once the W l l n g are corr&Iy srndw washer $0 ttpt just e vlat strip wltb
IMoEbd,remove the afil-Toll bar. ki5em: a hde in the'centrerhtriris:'Ihii wiIl igrm the
trdw jwk, and lnsm t!p w i n g h~acket swivelling end part shown on the M ~ ltod. t
mounting b&s from Lnslde the riehlcle, Pass thra thregded kxi Wraugh the hole in the
ensurlw- that We bdt ratdnhg plate is serlpJand W& an a nuti F& the stplp wd
c o d y f1ttr9d.Refk the mounting ntiti md rOd through b d h e SO thq*
tighten thwn to the sp&fied torque. Lower I~eatesbehind thd b@Hng. Pf-m the t ub
mseal cushson. weKtKe rod and 'gn conwwith #he edge of
f S Refit the bmkwpipe .to W w h d cylinder, the arm. Plam tha l q e washer QW the end
md W U r & y tQM$a IB tl~rk%h$ R ~ O , * w8 of WtuM, q M W n kyqy OR*$maining
clamp from th? b.r& hose or lhe .polythm nut, wd fhsxc4 uN ttl+3pt,,and21gMaFl the
from the mmer eyltmh twgruoir (as nut,t~~ Q ~Y ~ $ kpdml!hw
oporatlm to ternam
3 9 + remanlng b&ng
fhls
-1-7.
16 Tag +ha handbt&e eabte bwk Into (set3i w o n ) .
puslti~nk the brake M e , and seewrt,if
In .pbsitton wkh .We tie$ ay .alips, Mt tbe
b p b shm B descn'bed in C w 0.
17 Refli fher topsion Bgr 'as descrlbd Un
Section 1 2
18 Refiz We Mtl-roll Llar a8 d a r i b e d in
Sedlm I f .
i s %teed the<brake, hydmlk eysifm ss
deswlbed in Chapter 9. Prwridjng the
pmcautlom descrlb@dwere t&n to rnidmise
brake duM loss, It should only be n e c m to
bleed ttrq mlewg war bde.
20 Reflt the, madwhw~,l o w ffls veh14Fe tb
thagrpwd +ld tfqhten ih wheel blts.to the
w h 6 d torque.
21 Check the rear underbody height m
desdbed in.Section 17,
10.1 2 Suspension and s t d h g

pmMon, wing a ktbub.spam which p m s s IS ~ a l $the Madng braehi bush in brake

an& on the hard outw&@edthe bearing. fluid br somellrm4to mRen t f h~ W r u m r
6 Mounts the right-hand frailiw a m In the 3 Wgs off all r;rf brake fluid, then mark
vim the positlon of the bwh inner edge on the
7 Matk the finract position of the m n g Hner W h g m sbak
tracks MI the t@lJrrg.mp~. Brrt w grind almost 4,W;sing ttw* d h & t s 4 ~ l w dpullw,,dm
thmugh both W n g rtl& mks,W i n g the beahiq hawket off% trailing ,ahn;t h ~
not tu stam- thb WB.Us1ngyi:cotd &led, r u b b i of the Bush Nll t ar.during thls
q i t t the t w b arid remove them from the p@aw,h d n g Ah8 inneepart of As bush on
tubr Also cut and remaw the seal from the the arm (see,BMMon),
h b WrU-E
~ B Rempwe the remaining irtnsr part df t b
8 Cleanwmd#ktMw&. hwh by cmg with a l t a c w * taklnq caw
8 Ptrtss on the new Inner me,malslra w not* &inage W tdlm arm 5safft.
that Mad chamfer goes on>fl&. When 6 Thoroughu clwrl the walling arm sMW,
doing thb, k the lcaad Is Wen o m the r m ~ v i n gall traces at rubbar and glm,&
~ , ~ ~ makesur&tMthe
~ ~ ~ b Polbhawaymy
l l ~burrsw~ebd-wftieh
,
Cd7 R e m * g t h e r e P r r - ~ ~ - ' r m e r tarsion am coi-raly lomted 3n rrrlght hlnder raassmbly. Apply a sg?eM-gf
b.aelrar uslw awlrider awhor ~ Q W % suWle~as?laWinm~d~en
5 MmughIy clean the ba& .~wlt-ig all 10 kt IS twt n m a r y t~ g m the WIw bush to ald insMlMm,
&&& d & ~ taM ma-. PoIM~aw~ty ;yly -8 r w s . as €heyare supplied alraady 7 S w i e l y nuppoH W miHng arm, then
bum or raised edges whlch mlght hinder m. pn&tlonth8 n w W n g bwk&ln relmn?
m b k .Apply a .meat of muj(-purpsa 11 Rw&arnble md r6flt the trailing a r m the Wing m as shown {B lll-on].
grease to l b outer d g e 05 'We new bMirtg& d m m e to S ~ Q ~ I P m the bra&& onto the Wltng sb+
then arefully ptws than .squarely into untll the bush reaches the a4ignment mark
madm gar toremvat.

- s u s p ~ l o b8arlng
-mm
n

x=mmm
IrracIWd r a & n o N M t . l m ~ y h ~ u ) o n a f ~ e n a & ~ n b . s l f n ( l qb, ~ -
endod-bar akle shown, opeh-W'BXPe dmlhr
Y=lbSB*lrnrn
I

3
 Suspension and steering 1
0
.1 3

mmnml
t h k the kwtt wheels and m g q e rewetsh
"P*). JW up t h mar
geageat(or ~ Mae v&i~la
&support it on axle &an& @eei13@ng d
a l e *u,ppoP). R m v d 'bath rear ma'&
*.
G Reme thd reat
d l c r t b d In Chapter 9;
3 v*,
flqr WW,i$
~rrtke calipers a s

to be hstallert. m v e
w @mowed) --bar -
18.7 Handbrake d l e mMnb~g
clamp
mar d- om-bst mar axle -
16.10 Two of t h e j ~ g b ~ m o u n t l n g

h%&d~asd&c&edih~er$: OWdYauI ttire~ ntrailEid

15 l % o r 6 u Q ~ ~ q X ' &M Wre.
4+bmin+ equtpped with ABS,r k v e the M s h awqy $p bum or lrdSed edges which
12 Remove khs two torston bats WRh mlght hinder reaaimbly. Afiply a smear af
tkr W sgnsors a i dwribed In C h a w 9, mfwme to Se- 16 (sw illustrstian).
SMM 23. Riuffl-purpmqreasef o the a&r 9 i e r of
t 9 Mark the ant[-wll bad in Yelatton to. the
W b d t pkd&W, tP a IiWdW~ln.
$*,hi& a mlr of DIM ,
unhook the brake treltlng m s and centre link blook. Exlraet the 17 Supportthe imer edge of Shewlinga p
p,&r&u~ting.valve spring fmm the top them using the same m m d d as mat PoGlti~ntK6 mw besirlna brad& Q shdwil
of me axle m e m b e r . mploysd when moving the torsion bar&
b,MgFonn@& the rear brake pipes at the $4 ~ I n e a U W s p r n ~ W ~ a m
relation i~ the tranlng arfh...pm:mbracket .
nite dthe trailing arm shaft: unit tttg dUanss
fblh b,mlons,wh#~ am dl$pe'd t,a #e damaga. Ch* the wines oh, *the hi-$lon,
top of the axle ammember. Remove h e be, anti-roll - b a ~W, f e link bto& and bri@-had w w n h e r t;ok hob c e n t m ofthe I&md
h~nirjg442s;f&wlhdfWble hg1* Worn we tranlnQmm. Ira ttailing &l or L;shnrn itlu6hfftm W rm braC$ets Is as m
l 5 q . Wipe away m y excess
yv nh e
rnrnernbrq and plug or tape overths u n h cwsswrnkqls damagedqit will k m w m
+:f e pftW;BPTt
--L. dirt emfW h ofT ~ , 3 p i l t ro &dri a new fekPale,(supp!iwiwith the g&w,, 18 COmmenos reassembly 0 f . b w a l e by
~@trnrnedt~td~= beqrln~,mkehalready fitted, but nequlrlclg pl4cing It upsld&down on blocks of wood
-, F$fl$er p
,.$ h
tg sor~ws secwins :the ori@nal tph'wn ,maqd #IWOIImto
fahdbrdk cabb &Inin$ clamps to the p'bnad under the L-shaped C&
be fittd). If the bearlng b r a ~ k dbushss so that thwbdng h c k W am free.
'@@MIb-W~i& U1-l. wulm rehewel, P W 8s'debs~m*w3
$&ptmrt-~he weight sf the rear axis an i noting*at k IS not psslblb to ~bbin,&th@r 19 Use a tulw ah showni anti mark each
@&I&,. bush ahparately. If wWqm,the mmplW trailing m omthe a& @Ween tilec-c d
Q,UR the real a& cushlon ta galn scwss tp, W n g bracket and bush assmbly mu* k tbs tonton bairn4 antl-roll bar hole& CFaan
m ycrar axk beating brgcW munung MIt. #new8d. W 'It Is hot wkhed to renew the mewbl[ with
bar s~linm,'findQwse
rndlybdenum dtaulphlde grmsk
well
Insert
haeds. 6twh&, p e e d to p a r a m 'f 8.
10 From mdme@hthe vehicle, unscrewthe 18 ~QMalna nut of wwifable,diameter which one a&-m1l 'w so that Its drjll mark Is allgrred
@7&r ixb bWm Wk&t rnijrmnling nuts jus't flts W - t h ebaarMQM a k i t plmt h& with them& fktde on the trailhg irrh l-
, , p a i I l ~ o n )Tapthe
. bdts up through and w i d it s e u d y fo.4heshaft Ihnw -6. Enu@rstion~).Flt &e:mtre llnk block to De
*W@bWlwb&$@t ~ l € fhhdm. T trailing m.
SuFvjwrt M11 o W i ' $ u ~ % . othe
#! WHraw the handbrake cables from the ~rega 0ut5tt~ b ~ ~ k$hn,
e t using a
'IMPIQarms. Ldwr the Iacli.,kttd pull the ahbh be& on the top of th33 W d e d
:-bly out from underneath the nehiclo. nut.

1 1
rat* MaFthelmlhg arms (43 as
d
-
M Eir%&tWoh Mtthg thean&
rda b m open-bar axle

I
lG.19b Flt tha anti-roll bars $o that the#
drlll marks align with the previously-made
-
mark (A) on the tralllng arm open-bar axle
10114 Suspension and st9~fing
- -

anti-dl bar =that it la padel wlth the upmr @tioW, use a Q4amp*tbpt@~dhe certYre 33 reed the ha.db&e cablw through the
link doWn 3nYH If is p@allel with tSre tpillng anns. Refit the hdndbrdca cailq
mossmember, ~mgatadyr,efit lbtdplitn r&aintn~ claylps-tp .the-mtotays30n.bars, and
bare. Rotaat9 &qh k
w
qntil Pha position is tjghten-Wr r ~ n i n@.M.
g
found where, tha M fi&#,q%$Wd 54 W the W t brake dp=.and

35 Refit ~+,WWI%B, t,wq tfle ~hl& io

#p gmund and tlghtan the w t - 4 b o b b l t ~
m u & lusi~g RIM m the ~'cjr:M&-hrqus.
t h w of-rnFdfdhIng blh 38 Chech the rear und~bcady h g h t &j
th&WoW*adjwQmnt in-term@of aplinw, db&bd In M W
l r 17.
rrecr;m- R@fiww
M m e m (mm) Number of s@has BQ Plad Wig rear axla on a trolley @k, and
to tornpens& lift It into position uhdarbath the VshtilB.
2to4 1 Indrt the beayin~b~aekptmounting bolts
5taB 2 from 'lnskla the vehlde, edsuflrlg that the
7ta8 3 mtain~ngpr$e is -FOW& fiW.'Refitthe nrrts
9 to lo 4 and ZlQhteri them fo We speelfla M m . 1 Position the unladen vehiib on a
11 to 12 5 NW d e only surfa~.e,.with the W m correctly IrYRaW A

13 to 14 6 23 Rmwe the G-clamp from the t b fuel tank full.

15tp10 T ~ ~ r n r then n wl$dfaw
~ , the tors'm b W Endo$edcbarm,
. 1710 18 8 suspensfm
aMn. P d o n the idling arm as dacrlbed
19t020 9 h ~ Q a g h S ' l ao d ?i of 12. 2 It Is tonty p.o$.sjbbbto @Iud tks zear
21 WIth*w me of the antl-roll barq from the ydEqsuq that tha bearing black* centri susp~nsionheigp in &ips ot 3 mm. Fir#
Wlhg arm. Snds ~e cenfr~Ilnk afi Wend of Ikik and torsion bar splines q ctem and dv. measure and redwa the dimendons H4 and
the m&mtr-~ollMrI rotate the link awy ~ u ~ r k g#hew spfines wlih mdyhdehum lj5 pn bath sides of the vehicii ak shwrlr '
fram the crmsmmber by fhe speclfled Wlphide g m . mid Insert th8 b ~ 1 ~ 0 , f l . l enoting that dimenCon H5 Is; measuredf y q
number d spWn'm2then qfit it fo the anti-roll bra@@, the cent,m of the torsion bar ta fhe.gr~ua$
bat end (seentwtdon),Mngage fRtn htl- 27 Rotape ttis [@-hand h r until the pasition (SW i l l ~ t i o ~ . ~ S & @ ~hPm
~bH I# 5to
mlt bar and Crrrrtn link q~qntslyfrom She is found whey It>- be fteety engrtga &I the underlmdy height chemqg di3lensian;
irallipg arm sp~tnas.RMW th6 hs3x by, the SpHW on ffle W h @m ket and c.mtIB fink. Ghsck that this dit-tlsnsion6s wMIn the ran@
3 p d f M nurnbqy ofwJlnesryssMthe umh Not* the pmkion of the ~ m l w drill mark bn given In t h e $pBclfl~atiomat the e r t tliir4
I'mkls p&el to th p&&nTam&"rC@n, then tbs I&-hand br,R&a+,the Hght-hand har so Chaptm. If adjustment Is nW%ry,
iiilcq&+ J& M-YQIIbw ht-the?trdlngl arm that b dffll mark Is in fhe m a position, a d as fallam.
&&L how& the e d
l
i r n r a l l ' bar by me Bs splines with those of the beyw 3 Mennim bp haw many s pH w the tmifsn
same numbr of spl!nas In the opposite bra&& ewtd cmtra Itnk the bar sllda bar must b movad, that one spline k$
dlkdon, saqtMfts &ilt mark L ht the &m df hejgm, Bc;:
h l y Iqtb wMm. If ML.R Is pepissJbb to equg to a 3 mm EM*
w o n as the om an the oppaslfe W, then t&te the bar dlghtiy, noting t b t tKe dfill &ample, tf th9 height needs djudng hyr ?a''
enga$ ita Spllhw whh th*e of the tmllng m ~ g n b o # ~ m W b e n o m m t h m Wmm, ~ the t d b n bat should b6 moved by Wl:
p m and ceiitre Ilrk, and slide the bar Into sptlnes way from each oth& once thdsNhes
p S * ~ f l .I
s e Bhgq@. If thfs p r m ffdkult ta ghbve,
22 Wth the anU-dl hats cwrmly withdraw the l&-hEiKJ b i and rotate it
sllgtitly will It frealy ongaps with the splines
(them will be wyerid BIifims wh&e thlS
be the case) b&m wing to instdl tha right-
hand bar. Repeat the' pro,cgldyrF) unti! a
pPsaian rs foundwhen b t h tmh barsdltle
freely into psltlon and the drlH marks We
s#faciarily maned.
'f* ?he torsibn bafs fully Int? psition,
then ref3 the torslm bar uam to the bearld
ma
Z$ Carry out the pmmdum h'ths fdIMng
para$iGhs.
New or oi.lginalaxle
30 Ref# the mar shack absorNf8
dg~@W In W P n 10.
31 Refit the brake hoses fa #te bracws on
the tpE,of me c m ~ r n Wand , secure them s p m torque.
In pasrtian wtth the WMrIing clips, RqnnnWt
I I the brake pjpw to the hosw, and sefcumly the sp~clftfbdrange,
10,21mC&leulaiethemwni of agosbnarlt tightsn the unlm nub.
'
adjustment p d u r $ .
reqldw, then tnmove the cwlm wnkawej( 32 Hoqh the brake pressure-rggulafiw valve th@:aWstmsht,R m y
f m m f h e e ~ b e r b . y ~ ~ Hsprlng ? ~ snto lts b r w k ~ on
t t h i top of thd the h d H g M ham a(i
-
number of splines open-bar axle wsrrtember, f~ mapt6T 1A0t 18.
 Suspension and steering 1[3.1.5

Open-bar 'marsuspensIan
8 M$,wufearld m ud We dlmens~onsM q d
H5 on b b h $Ides of thd vehicle $how,
noting that dhdnrriam H5 is rneasure;l'from
the centre of the tutslan bar to ht;leghund
(see IliWatI~n172). S u m y f m m H4 tu
obtain the underbody h e h t &@Cki,@
dlmenslq~,Chpa~kt@t 2hls dlmemibn Is *in
the taw? glvm In tttk~pedHictiaitoat &e
@&I that on these
BP 'this Ghapter., Nowta
&io&% &'-rnuUfiWkti@ M w w th a
h~4gb>rrrcearrh side ls"&nin. IfnmesfiaryB
atl&tf%bh&$It@):L&@ WH M & WQ b
underthe nlwantant.sub.hedlng.
Undgrbody M O Mwrred on one
slde. but diPIeremce between sides
ia&whs -new rear axle assembb
173 UnCLerWdy height rnmsmlng poinPs.
9,~~.diff~nw,WWem the ri&dhaSd ar@
&Lyar~d s i b & Wap coWmW .by,&eri$ d t h t d o nbartothem
M a n of t M mtl-roll bpr on the tow?
sldei,s~that the hwsr side Is raised tD @s
s a m ~ke&m,a~the hjgher Jde. C a l ~ l a tthe
e~
difference In hebhCs b e t s n the two s l d k
then adjug as faltoys.
10 Mark tha retative positions of the two
t(1Woa barq and the 'm#-roll 'bw'to be
@~oved,both on the centre Ihk and on tho
b'@@iQQbWk*lh&lh!l m.
11 R a v e boYh the torsi811 brrw w
-xibe& In + c t I ~ n 12, then m o v e the
marked anti-roll bwuaing tt7e rnbthod.
I 2 Ensure that dimension 'X* 'k corrwdy set
on bthside, as$- In pwa$raphs 10
and 11 of SB%t+on1 2 Measure the dl- I T Re&& the underbody bight. If 22 Gany out we- procedures des&b d In
from thb cmW W Ihe t u b axle mAWgroun'd, n e c e w , 'r@p&t the &]u~-t P@CedU@: phragraphs 15 to 17.
m?heside on which theanti-roll bar has been Not? th@ a l t making ~ fhe adjustrrPmt, R will
b&d, S u f h e $dB-t~-sMe
~ difference be nwesb&y ?o @just ihB headlight baam Underbody heights incorreot on both
fmm.Ws heigtkt fp &tainthe cow& height at alignment Wtth reference to Chapter 1A M 3 8. sides, but difference between sides
wMch stub axre &Id b,then towq ih 1t.k atso rkchmedsid @ktWe o within tolerance- new rear axle
~ Of ~~ mm b 4 b
Wlhg -muntil Ure stub axle Is atttlc m r w t b@@ prmsum-mgulailhg vdve bz
harm. 8hwkN by a ~ ~ ~W lue r at 23 In this ca%, th@underbuy Mt~htIs
t &ksf
l the
I S R d t ?& anti-roll bar, rotating' It until the ~ o p p ~ r t u n l ~ . adjusw by reposltionhg We torsion ham.
p&ltlon Is found wh&re,It can be ffaeiy slld fi+ ~ W B by Wkh the @ual
the amount
w n
it o p&tIon, and tap tt fully htu posltfoh. unurbwiy hqlgf~tdimenMon ddates from
Uel'i"th'cs m a w made pfiFto kmobd, &&kc Underbad$ heights incorrect on both the w i & d IWI~@..,
f k t the om& of the an8-roll bar splines in s $ d q and diffemce batween ddes
t&tldv,+ the d l m e e W e milifts m was exdesslve - new rwr d e assembly
W M&~r@@ve~pmitionsof the todon
bars In the centmlink and b d q 'brabk&,
moved is as shown in the'fclllowhg W e . CalcalcJale. the .differmm k hejghts 'thgl'E. rmb\le bdth bW a dqrtbsd in
TmilIw,m Nl1mbwoQsptane9 @ t m the two sides, and the m o u f i t by 8mtlm 12.
movsrnm(mm) tocorn- wtilch the high& deviates' from me 25 En- thai dlmsnsldn "Xb'ls o t 3 W set
5 2 epedfied hdgM on both sides, as d@crlb& In paragraphs 10
70 It IH Carry out the pmddures described In 'ma 11 ofWatton le. Mbasure thp dqtan&
18 6 paragraphs40 ta 13,
from W wntw of the stub axles to the
20 8 Xi With kWi $W!inQ@%Nt.WWgM, - gmund. ~ a or blaw= bath.the tramng a w
25
90
10
12
-54
ht)axle to t b e . g r w *.&
measure the d m c e w m 3 k w n t m d the
s.m,lase w equally
lower both tralllng. m s $+usrlu b :tn,hf'$tk
59,that the d3fanee Is t n d Or
decreased (as appticable) by thb atculatecl
35
4Q 16 dlstanee Is Incmased pr decreased (as d~~ (PWW n).
4E 18 appHcabh) by tRe,eJMe5 Mpht , M w 26 Refifif the torsion bars, rotatlng a h one
90 20 d hhi@'wd@( p m g q h 16, unul the pbslttun Is found Where it enters
1'4 dllgn the marks made prior b moml, 21 R&t the toi$on b
&
, ruhlng m h dne freety, and tap them Into position. Mng2he
m ~ t 3 a t h m ~ o n ~ . until ~e positt~nis found' where H e r n mark rn- pribt io renwal, *kcthat the
15 R& thashonkkW r b e ' i s as descrlhd In f&y, m-~if tsp thmT hit6 @&on. WnQthe met ofof-the bar epllnes. In relatloh ta the
&&on I b. m$r;ksmade prior to mrmw4, heck that the dfstahb the m l l l arm ~ ~ virw mpv,$'(i is as
96 !Mt the1mdwheek, lower the vehicle .iP o 6 6 t d ofbbar spline3 in re!aqQnte th'h d w n In t ha.cable Ira wegraph 13.
the Wound and Qhteh the w h d bits to the distance the trailing am w&,movsd is as 27 Gamy out t h prdbUur3 ~ dwwlbed In
sp8cIfiMItwue. shown hi W-tabb4n pwgrafih 13. wwphi 1520 17,
10.1 6 Suspension and -steering

Underbody height correct on one 47 Once lhe 4mlthg arms "are corrscfly
M e , but d ~ o sides a ~ postranad, ao that. bhr t a n mpiy be
-
exmwslve usad k e g r e astrembly remwep and re-
~ r o t
without reslstame,
k d ~ , ~ t f
a The difference b m the right-hand
the upper and lwver shock&soe rnouMng
bdt Ides. Callthls dlrnrtnUsn "SC:
tower.$&$ so tb&W tower side is mlsd to 48. m,ursthat dm* is-conecbly &t
%w@,@i'ihY'' f@t Flgber side. Wwlate on "bothMe;than m & ~ , , t h & d-

~~$sfl&k'*
-%
Wfrr diffmenw:& ,- &hfs between tfie G b
&MWS.
@rn the m of -ihestub mIes.,io the
&om&. W& or loiver bpZh $?;eHllng ar*
29 WmawWm rear shook abwxba~as equally, so that the dbkmae Wmm t b stub
~ ~ .'Wtlon
l 10. n M e "the relative axlm and tlda gmunq Is hct~<aeed or
pd0.m 01ihe two torsion txm and the anti- dscreaed @ppp[rclp~ej hy the catmliW
6 U b*tg be removed, both on the centre link hsjghi Watbn (pmagraph 42j.
end on the b&ng bmck&rrti ling am, -
retaining nM, m c d s wffhMR @&ag 49 Refit tha y o n lys, mtdog eaoh one
30 Phcd gtmlley H& u W lhe tdtlng arm, ~laleulatedheight deviation of tfw hhhw side until the pasltlq ts'fakd M e r e It can*4
and r& It until the la& IsjuStsupporthg the (~aMmph 8Tj. pefya!Fd b* ,hf~ ,pqseflon, end tap them
w@ht ,%move the t9o tgrsson bars as 40 Reflt the W s l o m h, dating each oie into pshliin. Usin@tfk m a rn- prlar'to
d ~ i i b e dth Secfion ?$, R ~ YW Brnm'itecl d t ~ t h i ~ n l s f w vwtwe l d ft&n&freelp rern-, cheek that tha nffsert of the bar
mtl-roll @W wmg rha same,pethod g d back hto pasition, and tap them into spines m mblkm to the 'dTWtm the Wrlq
31 With the bars rmoved, msurb that the po$itition, Uslnq ihe marks made prlw to am w a n~ t ~ ~ aIsdas ahom h the tabla In
splines are dean and dry. Apply a smear of m v a t , cheGkthat the n f h of thi bir -13.
r r r o l v b d m dlsulohide grease to them. In relatbrr ta the &tan& Ww Wng arm was 50 Gatry auf-the pmsdures d4scHbd in
02 hfg? the rnark;m&e prior to removal, m w e d Z s ~ s h a m t n ' t h a C a M e I n p a ~ ~ 3paragraphk . 15 to IT:
w d tefit the removed entl-mll Mr. If 41 Carry outcthe pxoi2edm3 described In
necessary!allghtly rmh@,or lower lhe +$ding ppwaphs 15to 17.
arm until lfw posltlm is found khm fh@bar Underbody heights Incorrect on both
stJdes freely iW psition. sides, but.difference beween d e s
W bnoe the trailing a m Is, cgrraaly withln tolerance used rear axle
p~$tfaned, so thaf me bar can freely be
-bry
-
m o v e d md tGflPtad without tesislanca,
mm;* dlstartcse.$etwece(n the centres of 42 In this case, the underbcdy height I s
h .and lower
~shkk Wwkbr W g adfushci by repos?tioythg the tarsbn bars. Remowl
r
tmk holes. Call fhb dirnmshn "Y". Remnve ntst a ~ ~ ~ a t em to
huenf which t~ w
Wepbody height deviaPes h r n the a#& Set the :fmt wheels in the smigM%head
t h a M - r o l l bafagaln. mlt!qn, Release ?ha stedng lock by
34 W r i n g that dlmenslon "Y" ts &ill height. inswilng~ihQMonby.
43 Rmwe t . rear
mrM$rist, measuh tIw distanw"fmq th? dssctlbad lil S'Babn 10. Mark W rdagvg 2 &!ly shock W r b e r s as
qq affthe steerhg whml e l W
E g nw of -th@,g&b axla tp ~ e , . p o u dtin'the
, pad, f hen mmwetfie stmilrig Winln~
sids' on w h l a the gntl-rblt @r W. b * ~ posMfibns d . t b ~ M mbarn in the mtte Nhli
$d M ~ Q hmet. Wt,& I n ~ m 1 .
rernovd. Subtract the slde-to-sidb 'hbtghl S Matk the stmting wKw1 and stwlng.
difference Tmrn thk hejght, then lowst the 44 Placea bplley jack under the Wfng arm, c a l m aa5t In rt)Mon rs & other,then M
Wing am untlt the stub mde Is at the height iurd Mise it udil'tl'ie HGK 1% just suppwtbng the
Xhw calwliti3d. wfilgbtt. Remoue the two tominn b M a? the sfwing w h d off fhe mlurnn S pY w
I ;J f 4
W r l b e d In $ e m 12. 1s tight screw thq, nut back on a few turns.
35 Refit the ant[-roll bar, rohtiw it unM the ~ a p . i h e& e m w h d n&w the'wf&, Mn@
p a s l t r o n i s w w ~ C t ~ b e m ~ ~ s d b46a oWith k the bars remwed,ensure WsplineS the ,palm pf the hand, or rmk It Tram Ude st&
fmto wition, and tap it tnb ~ ~ Usingmthe .are ckah and d<g. Apply a smear of
sMe whilst pulling upwards tu release If ffm
marks made p&r to removal, check that the molybdenum disulphldk gbaseto them. the,shaft ftspsnos. RBmove the nut agdn.and
OM of me anti-roll bar spllnm in relation to the 4B Align the rn& made prior to removal,
lH ~ f thW&6d4Q
f wW~.
dktanqe Wm ImHing am was mwed Is as and raflt boih Sorslon bars. ff nwes?ai&
dawn in the table In pmgaph 15. sllghllyreks or tower tkWling arm the
$@Fa# out the prawdures descrjbed in
pasWon Is found where both brs stlqe fr* 4 Wttlng Is a ~ v d remoral.
m Align the
p ~ ~ a io 1 17h 4 Into pwition. m&s made on removal, W tighten the
U m d y hdghb incomet on both w n h g nut !tothe spedrfied torque,
sides, anddtffernnce m e n $ides W e l a wIfh airbag
ex-b - W mar qxle m i n b l y
Note: A nek? m n g wheel nut y!
37 CalcUktb thfs dlbrencet in hewhi% kmquiredan reflw.
freWeen'W'WoIldw atd the amam$ by
which the higher dde devlat- from the Removal
spsrjlfied hdght. 5 Rgmove the drba~as described fn Chap-
SB Gary. out Ole aperatrohs dwswibd In ter 12.
prgtraphs 29 to 3!5. 6 Proad as d e w b d In pwagaphs Ito$,
3B Wtth hoth ballihg Brms at the s h e Wgm bearing In mind ttrr fallwlng point& [sea
m&ure the d f m m W m *the ebma of the llmtratlon).
stub axles to the gfwnd- Raise or lmw W h a) Jhe&&rlg WW is s e c W bye b M
tr'bflim a m Gqualljl, so #at tIw sllsuan#
between the dub axles and the gra~fidtB
Increase@or ~ ~(as applimb1~1
c bythel
 ' I
Suspehsion md-steering 1,0~17
I I
fibsfdon).
l o o n j md&,markthe ~WreW@$tj~
bWmflld mtemhw shaft un- '$dirt
avd4he &e#dngwar m e phW+Y S whr ~ *a&. F & ~ W ~ ~ w e r ' f o r
marks, or a h m r h w ' d punch. Flsmwd the a~sBPQ:a7@ unllwsd Jcdnt clamp.w
nut and clamp bolt sscurlhg the Iofnt to the (amwad) - sirglq'e for c b t b
$don,
11 From Inside the vehicle, slac)tm and Remw
tb~ovtsthe four H a n g crrilrmn mwmlnrj t% Manoeuyehe&&m Edlwnn aWrnW
nutg m~d h l s . Ralmae the shying wlum rim pkltbn. Ehga@.,fhqur;& jornt w i u ~
Remoml from Rs mounllngs y d the b o l a panel, On ihe steering gear plnfon splide&al&nlrg the
7 D18cofiflW the bi$kery negative I&. mudels6tqyipped wlth power st&ng, alsb marks made wioto renwal,
P h o v e lhe stewing whetel as dwrQd In &as@ tha &wing c~lumnlower gaM fm 17 ReBt and flghien the g&@g polumn
Wffbn18, and ah models fitted with ,an the-bulkhead. mwritlng nu@ apd bdk. (On m ~ d e l ~
&bag, where applikable mmwe the atrbag $2 D h g a g e tha uniwssll joiaint from the quipped vlth pawbr stwring, r&i ther
$m$w ring wsembly as dwrlbed In $@ring gear plnbn, and remove th@Stwrlng qlwng@ibr,tothe bulkhead.
ohSpteri2. column aswmbiy from the vehile* 18 F~okunderneath the v&lda, reM the
3'PuIl the bonnet rdease ievm ddwn ta un9veW jpk.rt amp bolt and nut, and I&en
.expage the release lever a&mb1y murfng G - it to the speclftid fbrqua. Dh ,mod&
men Y ~ gtlB.baJf.
W M o m Qhe M T3 The intermadiite,shm~aKaW@ thg auipp@l wM mmud stwing, Macatrr fha
w ri
l
n g mews h m the u ~ p @@-ofg the W+M of 4hev t@q Gdurnn i ' a prowthe cove? on thp Wg.g m , and
'p& @, tRw cereful!y lower the panel &&
the P6ckt6 gain Wi dmnm n e w w y
~ ~ !i-ii h Z Z 3 a
t e l m c o p i c . ~febtWg.
fronvapt! c,mh, t h *Raft ~ collags$s (and
ai&qrq It in poaitjon with -a n6w ~ b t ti&,
L a w the v&lcle to Me ground.
e

'k*It"" m&. p w e W the ~~~l IrrplrIr(gth,eddver. 19 RMt Le two bolts saklling We facia ta
d b n *odds f,tW with a radld~wsette Befon rW-ttr@g t h stwrlng
~ coltom6. the' the tbp of the gtbaring crJIu.rnn, and tlghtsn
O W remute mntrol suiritch, dfU@M Ck fW length of: fhg IritetWigYe, 8h,& mu& be .?hem mcurely.
bver ftum the front of the swltch assembly, 'chkeke:$ as &own Illusfrattonj. If the W EljSIldng that tNe MrEng L mwectly
snd l w e n the switch clamp screw. length Is ~ c ? rspwm*, t ~ %owplete I& routed,,mcorm& the wlrlfig mnnact~reta
a. W~&in~-Cndem.th the sfawing cdumn,
pn& Fethree e m h g screw; fheh pull the
,mng:*pwt
ttwint9mq~@~Fi&R
b e r e w d . D a b kt
is:@@a Implleg if # Is
the wntbMtbn swlmh-aspnbly. Locate ths
s w i M assembly on ihtfie t ~ of
p tll~.$8rmg,
'Iwdtrrdua down tb retease ns retalniiig fQynd p l @ : t N y ~ p ' @ taf b M e ' c a m t darknil, ,w@~-wurs& tt$tm ifs Clmp baitft:
slips. Wkhdraw the lower shmud, men beimww?$VHW My@ ~Wumn. R e c m m t the wring PQ We'lgnit'lonmWh.
'~&aug the noto retsnlning horn the 14 Ghp$k~tk-st&@ &aft fbr signs of tree %fit %he uppW ,$roud, tightening its-
liont d t b~ p p a i ~ h mfdf*~ W We q VppgP play iM ti% &)urn" &$M@, and chwk fhe retaining B C ~ W Ss&ur+?dy. 61ip p' lower
- ~ . ~ ~ ? q ~ . $ e : ~ column.
$l.ng wnliksyt 3 4 h b for s1Qns of .damag@ at *mud @to fithe @wing odumn, and tighten
$ &&ken t?e,Coryblnertld~awlm msernbly roughnee in Zhd$i#ntbeMngs,If damage or br@Inlng s e w , \n!here appllcaM3refft
t~gr?pprdt,.srrcla fha SW~M y t
~ ~ = m b l off h w k w IS found c$ the @arlng shaft UrirVml b e Md*eW remute contrd,swlW.
@erlrf?g cdumn, dikennephg the ,wiring joints w aK& BGsh,&, the coIuma must be 2Z 61lp the l ~ e fag@
r p m j beak into
, o ~ n e c b r sas fhqy became awisslb~. re- sm>asmrnbly. pwdtlo?,,>anatstaaure d in p ~ ~ i W i ' w ii?s
th
hi wtrirrg tmrnthe $nltfon swfBcb, +5 Refer to W p * , 52, Section 8 for retaining - 6 nd fotm~ ~bannet
tha
.M6 from my tW3ning dlps. Infamationm Ignitlon witch mnekd, r~r~Im ? w i n gbo9t:
~VW

*
--
Ri&t.hand drive m&e/s wiPh r?xmualM n g 446.0 I mm
Right-Amd drive models with powsfawing 3960 i 7 mm
Left-hand drive !nod& wlth manual s t w h -.~3&%5 & 1 mm
Left-hsmd dtlw models with power steerk,g- 346.6a I mm
10*20 Suspension a d stwring

Refitting
8 Manoeuvre h p pump assembly h c k h t o
psiti@, Wd Z iW fbmorlhting balk.
g
8 Aenaw thB fluid @Iw' mlm O-rfria$),h f h
tl19 p j p & ) h w e ~ ~ ) ~the
t o pump, wlalng the
mark8 hide bn jnvalw msuw that t h ~ y
are mmdJym & n d k l . ~ & e n 9&uplp
hN8) &QF h b dip,
~ , yrppli&h.
7 M t b"ptrml;r, nralu'Kg wte it
t the puI8;~~to
18 the bcrrr&t wey wound.' Fit the pultay
W h g M a d W&M~
8 %fft it@,dHYp$t to ttre p u w , and gdjust
the dhbdtJWimas &%b@d h ChWr
2w RWl??vhrgh p u w w & e g pump
-
pultw D-type engine
?A or IB. @n& wcw ! s w T W l y tensbed,
ughrmthe puUy tefalning bolts. 20 1 matted r d t the headllgM ;a$
P On mmTjWoh;ap-qpand bled the power d w r l b d InKMpl&d%d,Sebtfoee thwn l o w
stmring hydraulic system rrs described In the vmde ro fhe- gaund.
Sotlm25
€.type sn o models witbut
air wnd&ing
NOW Newl@.yera w i n g Rufdpjpe O-rings RemoVal
wlll fie requhd an mmg. 21 Re.riahia €h8 alterriatot % dss.dbed tn
YO P m W as dm~ribedprevlausly for D- Chw~ar%,and thq dghbhand headlighi as
type mglnss, noting #at on gosne E-type hctw in'Chpter19,S a m 8.
eag1n~ith4 fluid w m a i r ls intqdwith 22 rPikconW,~fiui$wply hme ahd @ci
driverbait wlby to the pump, then release the Pump* pipe as d&&l# h parqrsplw 14and 15.
ddvdxlt tension a8 d e b & in Chapter 1A 23 Rsmave tQ,e Pwq upper mourrtlng bolts
';ji.IB. flbhdage tho d t l from ~ &pump
~ Etype m n e model* with alr and w a d ~ mand, ~ sla&m the bdtt gawlng!
$lfw. condE&'airhb
- t)ie pump' X p low+r rn~untlnpbracket
2- RVVB the pulley wcihing b i t s and m@paw~f:'ste&ng*id W p i p 0-
Remve-the two bolts s&&riog the Iqwer
w e h q then ramme the (jdky fi&bthe' mg wIICW ngul~@mr&@~g~ rnountlng bia&et to to eql?e, and m b #
trirmp, .Win$W f ~w.w.rqdYt
h 18>rt iw Remawi the pump<.-andbraEtlrst a%ehbfy from the
illustrrrtim). m i n e cpftlpxtment
a ~aitftiie ~ n i p ~ bgmure
bs wJihetj 4 1 To Inuproue amas tothe pump, apply ?he -fJ
w v d y 'pasftlohgd bn m&entbIy3 .enhambrake,qa~ jaeh up.* frrmt of tha M U e
e pipe yion nut, aii'rstems and suppott It on,* stmds
u w ~ f t r fe@d <*
4J~M@7f@ g4 M a v ~ u v mtlle pump, assembly Into
vWd6 SUM). To Iroprav~accass emn @&iUi&.'WIf the two h M souring the lowet
the dm pip w r i n g ~ R P ,or @QII nut$%s mowtrw b W 4 to the imgihe, 'and W,9
a~plt~cabk);be prepared for dud spillage by further, remode the rl$ht-hand h w i d h t aB
tkqled Irl meqrter12,saion 9. uijpw'rndutmg ~ t sm . htt,nboth the uppar
pSaclnga mntzllht h t h w p r d @ h r r a e @ )
whilst unscrewing4 b union nut@), The s@# f2 Slacken the bait which w u t & tlte pulley mou&ng bits and the lower mounting
M d mLat be dis&W 03, and new fluid oF&e to to pump R e l w the & v e W tmsitm aS Radid boas, then tighten the $dt securing
,p.y%d type (me "Subn'mtsand fluysr described in C m 1.A or 16, then itle h e r m u m p ~ : t gump,a ~
m.Fit,inew 0411%
m6d when i6filllng. DZw?M-bQth.pip&y dim-e pre driy&elt from *e pump pui%$. Mti~m.aattheply)s*be pumpid s b e d y
,Po?b ?+pipe Uritoh.
hose+), a d plug the p l p d h d f'hds and 13' Unscrew th$ puII~t$,reWnIng bolt, .and ti&wn tFie unlca, q. RMt thesupply pipe da
pmpmloris CworKing quickly to minimbe flufd remove pJl&y from the pump, n&g
Ipss), to prevent the %myof .dirt Into the whbh w g mund a h rw. the pump, and 'tl~htehiB rmnlng cnp.
the brakb hose damp usad th
hydrwowm- 14 Clamp the'flufd.aepplyh e as mar to the RIMQv~
minlmb fluld
4,Unsmew the bolts ae@uriw the Rawerr power &eerlng p&$ as posWe, udrg a fi6 RefE *-theI-. alxematar ati describad in
et'~gkIng,gwrnp.!o!ts mounting bracket, and brake hose.clamp. Thb will rninlrnih RUM lw Q h p M 5A, and the fight-hand hsatWgM %
:mqvethe pump Trom b e Mglnrt campark- during subsRqUM QgerafbjlS.
,rnm.(~ IM~S~TWIO~). 15 Sladkmthe retaining dlp,,anddlhnriact d m d b & ih Ghaptet 12, SWfm 9. Top-up
the fiuld svpply hob fmm tha ,par of the and bleed the p w w <s&srIng Ky@auaD
(;ymrp. Itthe original R e m k CUP Is dl1W, sy&m as d e b & it7 S6k)n 26.
cut the cllp arid dlsmrd it; w b ' h with a
-s worm d h e hose clip dn rdielng. HP.(l.&ralve) models
SIB&& the unpn nut and disconnwkthn Note; A nePY-p.*f fluid +dp i p &
feed ptp'from ihe piimp. Be praparsd f q rhrg will b~ reqdrad m mWng,
!&me fluW spltlage as the pipand h a are
di~onnscted;'~lu~ tTw hose d p@.eWUs R Q ~ Q V ~ I
ind the pump unEo~$~~to rninlmlse fluld lasa 27 Remove me' alWmaW aa dsscrilbed In :
and prevent he enby of dlrt Ida thg apstem. Chapter 5A.
16 Removb the b.ob sewdng We pow61 28 Rm-~ov&the pulley r W n g screw,
stewing pump fo its mourMg bracket, mdw preventing the pulley fmm rowtlng by
t h iiha ;dWws Qlls W mw1tiw s p a e and ~ raahiw the pump 9hrtf2 with an Alen keg.
23111 R-ns ap ow steer* pump. washem: Remwe .thG puMp frmn the ew'na Remve the-punw, noting bMch way round k
murlng bolt- O-type etPglnS WFmam c m [WllldonsJ.
 2 I
Suspension and stewing 10
.

-1- und@t G - w ~ e y e y k n i nscrews

g 23286 ...
then.~thaprrDeyfmmthe
~ ~ ~ ~ ~ p s m w t t pump n (l&wah) m
h a-.F7P bl
e
Allenm... nP F8iValve1m f i e
I , thefluid supply tto% and fwd
U&nn& the wgdniq rlgo~ts. c ow r&yq trath8Mwh1&rn alweftuatd
p i p rts -ribad In paragraphs 14 and 15 gS Refit the alternator as deskrlkd In In the MayfluncfIon b X : rsnet bTtt4w Is W
(r#ee I U w n Y Chapter SA. When the belt 1s :co~rmq on tha Ild of fher box, ~d-tjmother 1s Inside
t w owhkh r d n the Het fksiorsfd (seeWIaQter 1A or 181, tighten the t h i bmwn of $t#
90 . U ~ o , ~ ~ .bits M.
&plfddbte%hand suppbrt b&W. Remove pump pulley r$$irrIng bob. 9 OgeretIon of the @ern bmplm. If any
%bmketfmm q e underside of the manifold on completion, tapup and M a d the fauh deuerlw the vbfircle $rh'bWdba tWtl Q
&Won)# power stmrkg h y d d b system aa d m d b d ~~nault'dder W t h fawk to be -.
$4 Aemwe We four large b o b &ng the In Ssct'on 2S. m>
ptjmp itself can b r q w d and r&ed
p e r asteering #ump rear mounting b o k @ as follow. ,
to ta? qIln6er Mack ,and ths small bolt Removal
W i t h e bwk&.to .harear df tkd pump
(see l ~ l u ~ o nR) m. o m the war bracket Mote: New power steerlw fluid pipe &dm
hhe-&$nee will b i mqdmd 417
4 R,emov the battwy as described in
9 UnWphethw,scrmssecudng the pump m*&m
fo b'tmm o m $ bra+&, 4nd manmum GememI infomation
5 Apply the hmdbrah lack up the fro& of
gp.p~?llmp
but T r m behind the b ~ ~ k(m &
1 Ori F9P enghe nl'adetls qulpp@ c !air the vehicb a(d stlppptt R o ~ mle
z Wndg 1-
IMon). vJddngmdVeHIdewppoq.
en et&ri~aliy-powered s t d r r g
q,~~dit'qfng,
-a pump Is used. TFirs is becau$e there 1s not 6CtampthBfesBd~d~hoses@~h
t Man- wax in the m$ne cmparbn~dto
the pump Inio position behind ~~McIenHlt the power 8tewt~gpump-as posdbfe, uslrrg
thfrbni mauntln$ bracket. R$flP the thm mount a i:~nventioti^slbdf-driuan pump; the braicfr'Vow clamp$. Thls wiIl rnInSml& fluid
rebtn1w'Mtsand gghim them d y , air omdtionlrgwrnpmsm ismafedwhere ImdlRhlg s u b q u B P ; t o W m .
&4 Rdit the mar rn6hthit bra&&. Tight@ th4 pawet stwrlnp pump.would be. 7 MBrK the p3pe bnl?rYs Za ,msltre they
mounting trob and the pump rear 2 Iha aperation af the pump Is controlled tr( wnedtly p RI0nd on n&&bly, Wfm
, *.ll*g Wt smhlb. a.-ij sMch In fire pump OM@ pb?, and 9B
.ummw$B $ ~ and d pipa urhq nutss
96 R&t the intat ~ i f o M support bracket, by either three w f a r relays, depending on be prepad 'fbt fluld sptllage tiy ~1&!7Irinh
$nd fihtibn the retain189barn. modhl. The- pgwer stwlng pump rwlay4 comqinet .beneaYh the PIP. The split ftuid
98 Fit q new O-ring to fhe feed pipe union. are sifuated In the .en@fie mpmtrnefit, must be dle- of, and n'ew fluid pf the
-ttpdb'totb punip&d?ighmYl?e h u n t e d the Mae of the. left-had specIfW @em 'krbrkants and fluids3
W'W nut. Refit Z b supply pipe ta the pump, su~penstontwiret. On thm-mlay vektbns, the used when Mllngl. DlsciHlw killpiw,
and tighten the r$balnmdip.WwwW M e control way I s Wed on $heIM of pe and plug Ohe pipe ends and pump unions
clamp used do mlnimke fbr0d I-. , relaytjunctlm box, wHch Is m t e d on the (wotking qut)sly to mlniinlse Wuld to%?]>ta
fl R& ihs pulley to Xhe pump, Msurltrg ft 1s frgnt afthq fef'-ha@srrspensh turret. Qn prevent the entry of dirt tnto the hydrAUltc
the ~qnqctway round. Fit the washem wid four-relay v~rsknS, thare are hvd syst6tn system.

s32 tkrdothethrm w i n * wmw,atrPt

rsmova the plnnp fmnthe fronP mounW
-
b b s t m flEk-1 EnwME
 I

10.22 Suspension and steering

air rernatnlng in the %<+ern.FEepeat thjs n u m r af turns notq on rmuval. Thh

m d u r e untii bubbtes @ e h Ip appW In should blqg the bdflolntImMul to withiti 8
fiaflujd resewoir. q u h r ofatumflthr endbfthetmqkd,
i3 If, w h f i turning t h a s m g , art &normal with the digntmnt m m h $ h & wer4 rna'd8 (If
rnrq e heard froq wfltt@pipm it,indicates appitcable)on rNyN .Iy@up,*
tbakthere $,MI d f tm;#&@&efnb qqmL thb r o ,w ~IIW ~ipow:mwx~ mes m h e
b'$ tunling #a w w 8t ~ - t t p d & { ~ ~ - ~ h &B XdI ~ttohten ma @lnlqgbr$f-tq the &L.if$ed
pvss'tlotl end aMrftt&Mrlg off the anglm, # the torqw.'k dIffiwIty i exp&encd rlua7fd+$
fluid lewl in m?wdMrlses, alr is still bdubiht $bank rotati@, $3?nIf by e31~)dMg
present In the SW&: a@ f i
rm bb&lng is prwure.nn the und&&& of the WnjoInX;
.-lf l&'Skia$ tym WP'W m.'&
a Once 911 ttms of air hqve b m rmw@, 11 Refit the roadwhml,-1 the ri@hiCleto
stop th~f"mt@flewd dlw 'theqsbm40 m 1. the @W?d a W t@hteRthe &wh& bDlCto
~6Using a . u ~ v ~m o~ t nsepalator t Once d , . & w k that Zne fluid lawel Is up to thespwfladtorqiL
to ndmse the track rod balljoint from the the mayimum mark om the powW SeePIng 12 GhWk thb'front Meel tae saklhg as
swlvelhub fluld rawvolr; topup if nwmsw. described in %tI0h'28, than tightan the
8 , R m the two pump upper rnwnthg bl&int Whut to t h spwfied torque.
b@kket bolts, From uneerneath the whiclrt,
~ ~ M ? o v BWD* ~ S~QWH r n ~ ~ d l bQ&&
ng bD1t.S.
9 M.LII We pump until Jts .wiring eonm3013
aceesskle,thm~discondektttiern-framthe
base of the pump. Make a note of the
lo~ationsbf €ha.wires, ts,e@ure,thgy am
wW1y r m n n F e d on dfting. Wemo~e R e m w
'the pump and feseflair &srjmbJy from the
Nab: A Wljoint separator ton1 w//r he
mglne.wmprhmt. r q u h d TOrfiis;~wYgn. 1 M o v e the track mtl and balljoint as
1 Apply the hmdbr&%, then Jackup the front de3Cfibed IrlWt~,26"
-1- ofthe vehicle and-suppw I# on ate, stands 2 Out the tekinlng dips, and slfrle the
10 Manoeuvn the pumplreswolr membty (m"F/r!rRd.g and vehfcfe s u p m ) . Remove stewlng gehr gsibr off @Mrod.
hrtp poslti@. Recanned the wlring,.uzilng the We approprimf ront tdadwh8~I. 3 Ustng a sul~h~e.palr of mpa, un@wthe
notes mde on m v a J. 9 If #a ball@lnt is to be re-used, m e a track rptl inrf%r'W~@frwn the steerrng ack
I? Refit and tighten the four rnauntlng m g M - e d g e d a scrl&xg@rnlW, ta mark end. prevedfh'e stWrtg W k Mqt m h g by
b h t~ l ~ t s 0 t t S , its WatIbnship to WB W k rod. h o l d ~ gth8 ~001~lnt joc)num~ vuah a =ohd
I$ Renew the fluid pipe urir~p&ring&. Refit S Holdtnqthe balliblhl, U r m m w Its locknut by p+r d glps, Takb. nd tir mark the
the *.l~ thy PWP,,mh$' W Q ,~ ~ d~ ane e q q b r df % W?, Do not move the lodknut of the raclc and Wljoint
an removal .to -ensum the$ ire, wrt6dty frQm this positron, as # will serve as a 4 Remaw tho track rsdfinaer balIj&
f m n W , m d ~gbMn%he u d ~ nub,
n M w y w mark on retlttlng. &mnMy q d d W r d the Imhashw a w
eernoue the h m darnpgr. Ri3f1.t the. 4 Remove *& nut &curing the tm# rad QWmust be used on mfittitl@
battw ~s 'descrfbedin Chapter 5A. balljdrrt swivsl hub. Release the bd- 6,EWtner the inner balljdnt for signs of
14 Lowar the vehicle to the ground. Top-up Ipm tapwad shAnk;uslrig a tmlyer%al balljolht sladmas or ttght spots. GI&thit the tra&
a,M W@d the pawet steering hydraulic lseparai~r.If tb B?lljoint Is to he reused, rod, batf IS szmiaftt and free k m damags;..'#
systm a~ &scribed In M o i l 1% protect the tfrrea4&J en3 d the +Rank lay. n e w a r y , r e w tha track rbFftrmrer bai!)oInt;
scAwIngfhe nut back on a fiw turns beTom W hew om ~ n bst suppld complete wtth 8
d m the sepaatoi [seaHlustrqbn), new lockwasbet and a nw end Wljoht, t k
5 CounPiq the m e t m b e r of turns also W,ornmandstj that the stearfng gear
nemss8ry to do so,u n m the ballfoiintf m gal&. ba rm13W,
the track rodand,
0 b u n t the number ,of exwed thr~ads
%ween t h e end of the baHjOiht and thn Rofftting
t WBprowlure ~ 3 only 1 bs necessary when loolmut, and record tht$ figure. If a new 8 If # W h k t d k b d n ~h&died, r m W
a-ky @ft of the hydwll6. sy&mhas Wen bglljalnf'ls to baflfted, u h m w th8 lddrnut me outer Wljolht Worn the m k h d ehd.
~~~d~ or ifair tms t 3 n W bemuss at ffopt h a M WIidm. f LaptB'9 s, n eio,chmherr
~ assembly ~ f i
-1 7 Wefully clean the baUjaht ntd W W r W s h the q d o f - h ~ U b h gmsufirrg ' ~ mat
aR ' gifiwthe fluid resewoIr flller cap, and R e n e w ~ ebFinlqMt # iQ rnov?m@ntISstoppy begti& taw $re~orWcf!ylocated virth"the
top~5-;tf@""flqM Lkd .fq ttrl &mum mark or if'Jt is too sWf.d kH.Js-ex~!$$? MYnlYlr If fiatsonthe tack md.
~ B q Id *.b ~ spwjfid iluid, R'efw to It $5 daf@~edIn,kyym. Cawf~lly the 8 Apply .a;f~ drqpa d lo~kirrgflclld to th8
"~um*@m
f'
and fa ~ h b & o~ ?
'7w-R spw.mdm. sbnk W r and tmds. If the Mlktnt gklter briar bil@WQhrWds.Ww the b8UIQinth t ~
&-Wafis of the la daWgsd, the Wrnplete bqljjolnt must be tire ,s$qeEJmg ~ p . a@ 5 tIgtlten it aeau,dp.
mewftym&r~u&r~wdr rnwWw. mew&; It Is7notp&&I@ td 6Wnthe gmw Agein, fake mr& : h ab 2 ~ d m @ or Q 0mark ihp
3 with the m@ia.sEfopp&&&OW .mw *the i&aat&. balljolnt w steerif'@rack.
stwring ffm l@&.p-L~$~,~ve@ f o 9 Shda the new g&&anta the W rod end,
expel trapped sir, thsn #&-up tl-@+ l&l'Snnp@ Refmjng &d I~~atklP rn tha # l W ~ , gear
g housing.
m
n~ltir e ~ ~ k . thk P~OEQCIUW~ w I I 8- If a p p l i " & @ k i , ' ~ . Ioanut onto the Turh h e \stwir~
the %rn Idckd6[wk to &e@
fluid level in me reservoir does not drop any nw brhJoint,-4pmMurl Itw that the SWW that Ztle gaW Is rza~eotlypositlaned, then
further. numb6j.d exp- ithw#$ are vWk as w m o m r e it with new retalnlw elps,
4 Skart the wine. Swly movb Me s t ~ d h g IWWpdw-to removal. 10 Refit the tra& rod end balljbfnt as
from W-to-lock.sewemI time$ to expel my 9 Smh the' balUdrA fntu the track rad by the d a c r i b e d i n S d h 2 4
 Suspension and steering 10.23

&%mtf m that s@ecified+ ttm yewle mud $2 Far actrate Ehe~klhg,&s:Wjhiclt) FyH
be tmn f ~ r~ar&t c h d l n g by a 'be at the ketb weI@ apmlfiid In " G e m
professional, m't.t@Wltcad only be aW@d d ~ ~ and o WgW*.
m
by weiv or &mags t~ he body or auspemlan
cornpanenis
:wqwmlinkmation Checking general -
11 DUBtb t i r e , w a l mysurlng w%P%nf
T A ' W s sXebd~Igand suspension geomeom@W
W ,&fined in tbur basic FfWlt~g(sea nthew skill, g y to check the w h 4 allgnment,
tequird to use It pru#qb, the
rlllustuM): For this purposei dl an* are c ~ i d n and
e x ~ In d degrees (to# sbttingls ~$130 g adjustme~tof thee d n m &
&e&ed as a &asument of Imgth). The W M t f a a ~ k & d w o r a t m l l g r ~
Mdst t y y f i t t i n g shops now pdss~& 3ront
stdm 8x1s is defined s an Imaginary llne mphWc&d ChmYcihg wlpmsnf. pmitbni. ,go&$ both ends to, 9eMs the
&awn 'ihqugh the ails of the s W 6 t m subpenslon. Rel-e the handbmke and toll
W,extmded whek nsc.&sary to canfact the v&fcle ban- 1 metre @ f@@, hetl
rn@~+. fm& -*, r? @ ! - r w s t m w In the
2 mmbw Is the and$ between a c h steering Wd s u s p @ ~ tWhBOnentcf.
'i
and a vertfcai llne drawn lhmu@r&'
W m m U iyre bnt* patch, when viswed
mrn the fmnt or rear d the ck-Pm"tivc1
Toe sewn$#
checkiw a d W*g
-
h w 1S wnbn the roa.Wheals are tiitd
q w f d s k m the v@tleal at he top; tlmall~$ -
Fmnt wheels -Wgg,
'him kwhm they'* tnwds. 15 Two meffio&sart? av&l&Ie+he ,horn
3 .Wbaisnot adjustable. Vdw are gRsn meohank for checkiffgthe ?ioM 4hWl tee
far reWemi:eohly. Chwking is H e r us@ settTngaOne method is to urn a gauge to
a camber &ecing p u p * Mt If the 'figun measure the dlstanGe b&mn W kont and
o&md Js sj~nlficmtlydHarenk fPam that mar imde ectmof the rmciwhaels. The attier
$pscWed, the vehicle must be taWn for methad $ to u s a scuff plate, In wMch each
wefu1 chwDr1ng by a prof~lonal.Wrong frmt wheel Id rolled across a movable plafe
qmbw se#inp$ mn anCy be c a m by w e whlch records any dbVi#Uon or scuff, ofthe
or damagb 'm t h ~body or suspmsion tyre from the grdght-ahead pmitlon as it
ppmpomnts. moves across the pJat'e. Sqch gau- are
4 Gastor is, angle b m t w m the stking avallatllbIn elathrdy-Inexpenslve farm fr~frarrl
a& and a vertical llne &Awn +hYaqgh each accessory autt6B. It Is up 10 the owner to
roMwh%sl'scentre md tye contact p a w , pldtdp whether the expense I s j u s t d , In
when ulmd from the dd4 d the qar. Pasltive vlew of the Miiall ernoutit of use such
~wr 11whm the steering =Is fs tllt.ct so
that it contacts the gmuhd ab&l;fd of 9
&Upmnt W Q U nqrmally
~~ mcdw
18 Prepare the vehicle: m dmrlbed
y ~ T e a I :negative -tor is when It cantacts pevhudy ln paragraphs 12 to t4.
?he groundbehlnnd ttm V m k a l . 17 If the m$ks.surem&t pwedure b being
6 @stor 1s not a d j u a t e : AS with camber, used,we@lty mwm the dstanmW@l
values are g l m f6r I7sfar,Wcemly; deviation the fmnt' sdgw d #@ mdwhed dms.md ttre
WI only be due to wear ordamage. re&r edges 05 the rlms. Subtract the p~
'6$brlltg M s hCJlfi&rn - also known qeasument Wrn lhs Wmt msmrement,
-
w kingp1.u lncKnatfarvIKPl is the. angle and cha& that the result is ,wWtln 9 P
between the starlrlng and a M c J line -if& f&rtw*If @, adjust the toe setting
drawn through a c h rdwtM1"soentr+ and as d ~ ~ 'paragraph
l n 19.
w e mntesct &<Qh, When viewed from the 18 tf scuff platm are to be used, mll, the
~wr~offliscat, vehi& kikwards, check Urattbe r w h e e l s
7 SAl/XPI is not radJuatablqand is given for are in the stdgh-ahead,pmitio~,then roll I!
Merenm only. across the muff plates scr thkt Yt5)nt
8 Tw b amount by wh& the madwheels rM-t pas= squarely ww ithe cem d
pht outwards or Tt~waMs, viewed from Its m p e d v e plate, Note fhe mc0dd
hu.T m l n * la when the rmdwhds p i n t by the wuff pl2ttw. 70 mmsureawutaw,
inwards, t o w s &6h .&er at thsfront while
g t b , w p Mis whm~iheyspiay ~UWardsfmm
w h other af We frant. mg value forbe a n
bfr m d as an q h taklng the c e d e
I
TOE-OUT
npeat the check three tlmel, arid take the
average of #e three rwdings, W Php
madwheeja &e' mrllng - kt, €herewill of
course be no angle cecorded; If a dhvlatlon
itme of the cai as Per#), w &s.a mwurerrrent %he is shown on We,souff ple+s, GO-
,of length @king measur&nts Mwm-the thereading abtalhed far &ft Wed wah that
ins!& iims of the W h d s at hub hdght). sp&ed. lf .W v9Iv.d i-dwrQed la outside the
9 She front wheel toe sefftngIs'~idjtl~d by spedfted tolwance, the toe sbHftrS( Is
w i n g the Mljohrts in or aut of thelr ttack M O M ,anU mu& b a d j W a s . f o l m .
r&s to alter the .decfiv$' h
rod assemblies.
r
rg
ti of th.e WC%
t -
Front wheels adMdilg
10 Rear wheel tds seithg ts nbt adjustable; 18 Apply t h handbrakk
~ jgck up the front of
&'is givm fw refwen~eonly. Wib it fie 1 I the vstilqte and -aFt It murely on axle
&eaked, if tM figure ~ W n bdaignMmtly 2&1 Wheel dgnment and M n g an@& stands (see "Jackinga d vehlCIB SUPPM?,
I 0*24- Suspension and steering
-- - - - - -

thb during adjustmmt .Mot= If Is i m p o m 23 Whm thn-wirigia hdtd the k k

that* a h r &@stmwt, the w m numb& of rods and s$ewdy tlgHtw tfie balfi01nt
q?rtirplbs b vtsWon e a c h M m d end. locknuts. Ghmk that t% balUoEnts mmtd
5!Q 6imt ctmn the fraGk md Mads; If they ,~bn,wlyIh ihdr SQ&W md count the
am cmvdcrd, appb gmatr&ingfluid bbTpre e x p o d threads. If the numbm of t h d
d d n g SSajusMnt. R m l . % s rubber @er q mig n o t t h e m e on bath &I& then
0 W . d then e lb&k a* the adlt18fmsnt @t iiat&&nmade equW,
apply,& iji'@&sbI su 9f3t.MIl a d problems will % ! manibun~rrd. Wh tyte
dm mand w l l l ' d b e t w l M ob Mnad as mIibln$' in iwms +Is?, , b ; s t ~ e ~ l n*id g
thdr ~ v e 'm&W3pWdh
~ k ~ no long& be ti&mW vdhen4b
. B P Q will
23 U k :a, str&jht:e&e a& a ~ d b w or whe& ane I w ~ sttaight-@l&
, pmh-
.sknllarta mark iha ;red&o&[p d each track M,eni h e w k rod lm$th are the w,
rod to tts b#@Int. H~s!d't!ge ~ c k t a d ' law& ~ y#wle to,the gmund md m d M
wm, unsorsw k lo&nvt"rUry. the tw.a&lng; -just If ndcaWry. When
22 AlW the lenm of bwk d, -rig the s&ln&l+'+rract, Vg,Men the t m k md
balljoint !odmuts to tha +~!cIfrMtoqua
Qrn*-sbatjmg wh&l onto fuI!-M I d ,and Ih rnfndYtlemhin pagraph 18, blr&mymg Ensum that the rubber gait- m.*d
&wrd WI mrt?bwof w- threads an the tfi
m i
n Po or aut of #-& tratI&ts. Rome the mmtly and are not Wsted ,or sttatnee
fight-hand tr- rod end. Nay turn the W @ using an open-ended spannC svurd ?h4min position with new MMng
&ring onto full+ght bck; and record fie to the flats $rwtdeil. Sh~rkningthe fraek clips.
number of t k r e on the tsfi-RWtrt.elde:If rqd8 46bmgl& O m mg baH~ffhI$~),
~ ~ ~ h t h e ~ n ~ o f t h ~ d r t reduce-h&h ~ t t > t a ahd ' m m e a t e o u L Each Rear mrhd L e W n g
on bath side% M'sub@q~e~It.srdjust~fitcomplete turn of the traEte md efffiativejy a5 The p r o m for chwking the red-tbe
&wd Wmade equally on bath &es. 4f- adjust$ W IiiB &Sing try 30' or 9 m d n g Is m e aq dwcribd for tha fmnt tn
are mote tM& m a en one slcb than the (depndlng m the method balng us@ (sas @ara$@ph 17. However, na adjustment t6
MI, 1t.Mll be necessary to comp&e for llhlstm!on). possIbb
1t *2 Bodywork ahd fittings
Tha general WnSfMon of $ vqhicle'g.
bod@wk is th@ one alng that Jgnlfieantly
aff- Its value. MalnWance Is' easy, b ~
need$ to be mguk. Negld, ~ c u l w l aftar
y can b dmind OM. BrlghWork shoutd be
rny:day1WIagn lerpd,qulekly-to m r
detetlmMhn. ewlly rapdr bllla It is
i r o p ~@so~ t to keep wdch on mose parts
of the vehicle not Immediately vlslble, for
Instanm the underside, Inside I .the wheel
ar&esr and the lower part d the engins
Corn~~rrt.
B e basic malrttanance r'oulne for the
bo-rk -
Is washing p&r&y with a lot of
w w , froin a hose. Thls wlll mi-1'16~8 all Zhs
10- ~osolids w k h may have stuck to tha
valil~le,It Is Wfp~hantto Bush th9s.e aft In
such a way as to prevent glt fmm scral~hing
me nntstt. The. wheal er~hesand underkame
need washing In ?hesame way, to retnove any
acmmulqhd mu6 whlch will retaEn mdmq
and tend to meourage rusk ?a&oxhlly
sfiaugh, the bmf t l m rb ~1.w the un&rfmm
and wheel mhess is ltl wet w m r , whm'ttte
rhud 18 thoroughly w e mdwft. In vary w?t
w m h r , the u n d d a m t~trsudlyel& of
J#ge a c u w t u W d ~ autamat'ily, and thls is
ago~d trmafor Iiispection.
Perlockally, except on vehicles with a wax-
based underbody pPofWlue eaating, If &a
good Idea to have h a whole d the
melerhme af Wr h h t ~ l eateam-dsand,
e n g h wmpafiment includ* so that a-
thorough lnspaetion m be Wad out W w .
what rnlnor repairs and renavatlons am
mcrrasary. St&&m:ckming Is av@labte at
many wrap, and ic necessary for the
rgpovt~l07 the accumulatjun af olly mmff,
which s o d m e $ IS d h w d to be~omethick
in rixtrta[ir mas, Rsteam-cleaning fmtles are
not av@a i , f here are me or two e W e n t
lib%
gr- s$Ivmtb aw&IabJe, which t a n be
bmah-applled; the dirt can then k simply
hosed N.Note that these methods should
not be used o i ~vehicles with w&-bmd
underbody proteethre mating, or the coatlnq
will be removed. Such vehlcies should be
Inspecfed murnudlqr, preferably just prior to
Wlntir,, when the underbody should be
pshed &own,and any damage to the wax
edlw rapaid; WmllL, a Forn@lWyf nsh
mat ShOUldbe amffBd. It wwld als~be worth
wnslden'ng .tha.use of such wax-based
protdon for iniectlm Into door psnels, sills.
n i t prdd$ b,G male, manufwtum.
After w h b g pahtwork, wlplps. off wdM,'a
chamds leather to give an unspotted clear
finish. A coat of clear protectlvs wax polish
wlll glve.added protecto
in agalnst chemical
pollutants in the air. If the palntwork sheen
has dulled ur oxidbad, use a cteanw/pdtsher
~.ombhlatlbnto restore the briili8nqb of the
~hine.ThTs teqelres a little eff~rt,but swh Apply twch-up paMto the match ~ l n g > a
dultlna 'Isusudtv caked becat& reaular fine galfit brush: contlnlie to apply fine l a y e
wht8hGg has bee> negleot4. %re needs to d paht umtll the surface of the paht in the
be taken wlth metallic palntwork, as special sct.iitch Is level wlth the surroundhg
non-abrasive cleaner/plisher Is requlred to paintwwk Allow the new paint at teast two
awM damaae to the flntsh. Alwavs check that week td harden, wn Mend it Into the
the door rn7 ventllatiy 6peniG drain holes surrounding painhvark by rubbing the scratch
t and pl* we m p W y c M r Lsrr that vvdter ~ ~ ~ i t h a ~ Rb ek ~
cutkg paste. nmlly,applywax polkh.
treat4 in the saw* way as paintwork. Where the s~t'abhhas p n e h w dght
Windsymns-and window can & kept clear through .to the met J of @IEI bhWorlt, causk
of'fhesfna~~flrn whiich offen appeam, by the the n$aal to rust, a dffPerent rGdr technlq&
use of proprlahy @ass cleaner, Never use is requlied. Remove any loow rust from the
my form of &ax or ather body OF @trcrmJum b w m d the p a t * &ith a wpnrn, thy
polish on glass. apply rwt-lnhibitlrq paint, to ' went'the
form* Pf rust On tIy Mure. Ushlp a rub@
or'nylon mplicator, fill the 8crmti Mfb
bcrdpt~ppeapasta. If rmbbd,thls paste can
be mixed whh cellulose t h i n m , to provide a
vedy thln pagte which Is ideal for filling m m
scratches. Before the stdpper-paste In the
Mats and qpe'b $odd be brushed or SCMC~ h ~ h n s wrap
, a piwe of mogth
uacwwrn-cleand m a r l y , to keep*%m free of Cdtonmg~thetop~faflrtger.Mpthe
@Ht, I7 they atre M l y d?ed,.remover'them Qer .i.ncellulose tbinneri and qulckly sweep
-. hvehlcle f
w mm orspwging, ahd tt across the surface of the stopper-paste 01
m@kequitesure they are dry before Wtthq. ~e ser&b thk will q s u ~ tJ h the s u m s of
S- and Inlerior trhn panels an be kept the stupper-pad8 b:sfiglltlp hollwM. The
Clem by wfplng with a d m p cloth. If they do %ratoh can~ bspdntd over m descriw
Q W
become.stm& (which can be more apparent meiIri h i s won:
cjrt ~ g h t ~ l m yphdsfq,
mi lrss a IMte liquid
detergmt and a SDR natl brush to sodm fh'e Repairs of &PI& In bodywork
t
m g i ?a d the grain of W
r
m e mabrlat Do ?ot When d m ~demm of the vehicle's
forget to keep ths WHnirrg clean in the samq bodywork has taken pl&, the first task Is to
way as the uphdsiery. When using Iiquld pull tRe dent out, untll the al%cted bodywork
clean- Ins16 the Mble,do rwtOW*& t
h almost attale Its orlghal Ilhape. Them b little
surfam Mng EZeaiW. wive damp could point In kylnp ts -re 4he orlglnal shape
gei thto t h ~m s and p a d M hterjbr, qgrnol&;bs the met@in the d&aged,area
W n g stalns, offenSive odours or even rot. H w l hate ~mtched an md czmnat be
the Insldeof the vehicle aets W accidenfallv. R ~fyOytob~Weontwy.Itisb&W
Js ~orthwhiletaWQ BO& WuMe to dry It-& tD brhgth&Wof the dentu@ toa point whim
properly, part$cJarly w k f e carpsts eua Is qb~pt3 mm b l o w the lwsl of the
In~ol,\Fsd.Do not leave oil or W m ,~urqndthfigbod,ywwk; In ckses 'wheke.@e
tm%fhe whkk fmthlspupxe. dsnkk very shaltow anyway, it is not wbtth
tr$-ii@to puli it aut at all. H the underside of thq
'dmf Fs accessible, It w n be hammersd out
$enfly kom Mind, uslng-g mall#t wlth a
wooden w phdc he&. Whllsf doing thii hold
a w W e Mbck .d wDad limb agalmi t@
outside d the oanel, t~ -a the l m & h
Note: For more defaIIM InfamMan about the hammer blows and thus p w 0 h . g 1-6 1
bualnv&R repFr, , W a w Publishing praduce area of the bodvwork from beltln 'bealedsut".
a book called "The Gar Bodywork Repair shouw tk pa in a -&h d the
'Whval". Thls tncorpomres fnrwmaton on bodywork which has a double skin. or some
such asp& as rusttrmtmt, p a i d ~ gand oth& factor makhg It inaccessible. from
g ~ - M f+@ite as &I as W(son mDm behtnd. a dlffmnt technique fs called for. Drill
ambitious &pdm Wolw'ngwetdIng and panel several smaU tbmKHI&
mg met91 Ineib
m?firrQC -
thaarea partrcuhty In'Yhe deeper W o n .
Then m W long d-bppblg wxbws.inta the
Repaim of minor scratches in hob, just auNdantiy Wr them ta gain a g a d
badVwo* purdha;sEtIn the meM. Nnw Wdwtcan be
H the scratch Is very suphdat, and dbm pullad out by puUlm on the piumlklg- W
not pfielmtb to We m l > o the f bpdwork, of the mews with a pair of pO ml .
repair O very simple. Lightly rub Re m a of The next stage of the mf Is the m o v a l of
We &r&Oh @h 9 palntwark mrator, or XI ~~paint-.fnsmihm dawdarea, and h a n
vsry f l w &ng paste, to m v e-1 pdnt l n ~ hor sah;o:d the' sumunditig o ~ ~
from the scratch,and to clear the sy~~undlngbodywork Thii is acuornplbhedmost d y by
bodywork of wax polish. Rinse the area with using a wlm brush or abwlve pad on a power.
 Bodywork and fittings 11~3

by hand, d n g &a& of W v e paper. So Many typw of ofdyfHIerars wllable, but to one body panel, mask off the m u n d i n g
mplde the p r e p d o n for fitllrtg, s*o~xg-@e ganertty speakin$, those pbbprl@tfdtS m pfwls; this wilt help to minimise the &ffectsof
' ~ ~ f t h e ~ ~ w l t whh i aemtaln $ atin
~ pf l l w rp ~ t ~ m@b
~ f l~ d af a-&ght mbrnatkh irl wlnt anw. Bodywork
&king of a file, at dhmaplwiy, ddl -dl W n hardener are bekt for this'* d repa&. H h g p (eg chrome strips, d&f handle dd
&I@ h t h M&d~ p~. T h l ~will m a A wide, flexible plqstioar nylon appli* will dll d b d d to b m i r e d off. W.p*
@y goad %ef' forthsi7lIa msW he found InvaluabL~for irnpaxtlng 'a $hW ~~Q bps, and metal thi&irW& of
~9~ l w t r , see~th@ Ssmneon a d wU-m*mred ~ fig& ta .the surface &the n@@j%ip$r, wW K m k i # g g o ~ m a
Mlna - and rmb~avinn~
. - - ftlk, p o r e eommclng to spray, am#@ We
M1x up.a Imla filler on a ~lean p W d mrd wroihl $an h m q h l y , then sptay a bat wea
-
or h a r d mwurm the h a f d w catevful~ (an '~ld:tIh, or similar] until the &ehn!quq Is
W..pker'a instnlctlerxs an the ~ 4 ~,& @ f i @ v e @eyr@afr r a m with a thick
m i fh$ flll*r will m3~ widiy or too
e &~$m&h@#@&.~&outci m bqm
SIowJy. Using the applleatM, a p m the fiber Up uBTq1~$aal'?Tah Iayem.cd pain4 rather
Y SsW ~ ~ ~ ~ n g m & W aia p d tb the prepmatt area; draw Bhe than
e r paste ~E~li&&.&@i MOg @ . W d -
w i r ~brush on a power d l l . IftliesEl am nrrt ap'plI~or.acm#the surlwe d ther flller ta dry ffib domihe w h m d the primer
a v a l ~ ~ few . &shak d &ash$ Wper will acMwe?ti%c o i i oomgur and to level the until U 15 ~lfywnmth.Whlls,dofnQ thk, h h
ta
$.the job. m a t eH~~tW1y. With the paint s u m e . Ars qorr as a Gootour that work are@,W-@Qr&, Hmrq~gIdydoused wtth
. r g q d , . y q u will b a b b to judge hwew a&rblinlcxs Xo The correct qm Is aghisved ~ , a n d t h ~ & & WW~ly
of the corrosion, and thaiefpre d s i d b stop wafihg.'th - If you & on tm d n d in ws*r, now ~p& am ~1~
wtb,v,r to 3qew the whole paml(1 this ie ion& fttai &34.tivlll b e o m and -in on mom pal&
(&mbieJ,or to *if the affmed wek New to % i ~ k - u psn 2ha appkatoi-. Coiltklie'to Spray on ths Tap ~e~ak.,aga@ bullidhgy(p#%
,body gmdg are not as axpensive as mast add MWI faem of filker 8t ,20-minute t h ~ c h a sby udndaa&dl&t W l ~ f j @ M .
'
~IeIhthWk, &d tt' is OM q u W r and mre In.bmal~,untll the h e 1 af the 'fiiter k juqt mrt m - n g in the ~ - P P
S ? i & ~ - t o ~ nstnew panel than to attempt pioud df We * o u n @ ~ palywwk.
%"-m.m
and theh, uslng a ~Sr~ular' ri3;qrl,$ni y q k
b mpak tarq~are+$ of ob-n. Once the'flll6r hhras hardend, the ems3 outwards untl the whole q ~ k ' ~ ~ , @ d
-Rytmow_allfitfin@ *om the-affwtdarb, 'can bre#&d m&l p l w o r file- about 2 Inche? of the surrouhding gd@d
~ t ) r mwhich e wlll act # a g@de&'the From the13t j n , ~ ~ d v e l y I-~fB g F @if@ .af paintwork is ~ovwed.Remove dl nqsk'hfg
mlhd s h w of the damaged badyl;Vbili @Q @ ~ - D W y & $ Y Pu & W n g vlsifh a mabrIal10 to 16 minutes after sprayi~lgon
hgadtamg-sheils wj. l'hm. uslng ttrj snips ar 4Oqde produdlion&perS and flMshlng wlth ilpfinafobatofpaiat.
h R%~@w Mad& ?moveall lmse IN&M d 400-grade w&q&dy w.AW- m p Aftow the new Mnt N I* twa weeks to
any oiher,m&d badly a f l m by co&b the abraslve p q x r around a flaf rubber, wrk, ha-, the& using a pdntwrok rsnwawar e
Hammer the edges of Vls hale bwuds,% or wdodqn Mack - othsm* the surface of very fins cutting paste, blond the &gss of the
Wtb t ; S e a dighf&mdon Tor the Rllw thq<fllerwtll not.bsAchpbtely flat. Dul.lrrgthe paint into the exlatin9 paintwok Rnatly, apply
Pm+ arnmthhg qf the fltbr sida~er,the wed-and- Wax palish.
Wlra-btrpsh the aff- arwto mm#,tha dry p p r shouM be pbriodlcdly rlnsed In
powdery r ptfrMn the whter. This will ensure that a very smooth PIastTc eomponsnts
surface of the ~mainlngmehi. Palnt $e f i s h Is irnpwbd.b.ihefiller at the final stage. Wfth the use of mote and hbre pi;tstFc bcdy
'
&b%d meq with rust-j-lnhlbitingpa'nt; if the At this qbge, the. 'dent" should k mmpownts by fiewhbsrnanufaetum (eg
I a
back of tdle rusted ate& Is a w s i b l e , treat surrounded by iing df k e W l , wh59 tn bumpers. spoilers, atld In some mas major
thkab, tutn should &B encirdwd by the fimly body panels), rdibation ofmore wdcus
Before fiinng qaan take pkm, it will be 'featherd? edge of the go?d paintwor9r. dmaga to mh t m 5 has bgmrne a mt?er

'
I
n w t~umkthe hole In w e way. Thlq ~nw.the
mesh, or aluminium tape.
~#umilniurn'w pl&stit>m+h, or glass-fibre
ratthgis p r
o wU1.M met-
+r
omtion &gone.
area with Clem d,

8pi-ay the whole are$ w M a Ijght W t af - ulffll all

aan be achieved b9 the use of durniniom or of t h i dm.produced 'by W thebb-mg-down In this VeM, or refialing prnp!&e
~@m% cmpsfie~ts.RrPpaIr of suoh damage by
DM owner Is not W l y -ble.
b WB for this will &w up any trnputsahs in the cplst of h e oqulpmmt and maWah reqttlred
drtg ia the

i
a lam h a k -Gut a pie& to thwapproxfmab suvfacg Q F W NRw, l3w@rfh~JmpIrfWoras for &ecBng wch rebalm. The bask h~hlque
Wmd &ape of the h o b to k Rlied, th'en with fresh, filler paste or hody&o&br, and inw.making,a groove aiongbe I& atW
mitian It In the hole Sa that its edges ar8 once we 'mthe,surfa,@ w& abrasive ~ w in -&e k plattb, qslngB , g @ y WIT In a
&dy.tk<lmel a h s u u r o u n d h g . It~ p p r . . If Y ~ & s t o p pIs~M,ft em be pow* dd11;The dqrvag@lp+:ia .Wn welded
( an her mMnFld In pogItlqnby several #&s d wRh cdlUj~get!ilnnq% .p +ama r@ly thin back&$Wikd Fing g&@pgg~ Po up
b r ~ a ~ u h d ~ w h~i h 1s Ideal fdr filltng Bwl kt%. q d fypp%p!$q&
~ paste tiller md ,hb the grkove.
Almitnium tape shwld be d f o r s&l or Ri3pe~tthis sp@y-fld-rdpalr -procedure until Piny %&&,pTastkIBW n rem~ved,and the
SWQ namw holes. Pulla pi&q,qfi &0 toll, Wrn you are sdktisd @'%QSU- of mp.flHq, a m sqbb@.dom to a 33qtosth finbh, tt Es
d($ :
& $
!% mymew md s h p q u i d , eiid tM f &$h , & # e . p @ m t
en ptlll off ihe bkfrrg'p@ W u r n a@ p w b A Qean4bs*$ati-.W,Mh,elW WaWr, is,u@?wbcj4y'mmponMscan be
h ImImpW$rit-flRer red of the GO&
we
plastic
qf
%&jtp tape aver the hd$; tt mi^ M and dlaw u dry$&. a W@& m M W [eS P O ~ Y G * ~ ~ ,
pqr@prsd Cf the thlckne& 6f @-I& ~f*e,k Tha mpaK &e& is now, M W ' fpr anal A&S; ~dypwYene),
JRiM&$eht:Bumr& down the e&es af tha spmyln'g. Pairst lspta@hgm@ bik.mif[ biir ~ a q & of i -1 M@OYS Mure [abrasIons,
a 6 , ' ~ hthe . mdla OT a scr~Wdriveror ~n a warm, df$, wlndj&e wu $pt-W minor cfWks &c) aZvl b rBp@kd&p We
'81rnIw;t~ w r w t h a t the tsps ie securely Hrnai)phete. TMq condition aan be cr&$@d owmer mg a fm-pwle p w y dl& repal?.
.@%bedfa* met& underneath. adaUy Ef YOU,heye<-,@ $ lwlndaor 051QB mixed h ~qual,thiq is u s N In $Mllar
&&work repaim
flillng and nespmying
- workbg,aea, but 'If you rn f m d tb
ae qw,
ih WMoh to t h i ~ l ; b $ner
yw +dl ha* to @R-puf day very paMs. Thsfflter 1s u o d y aqm '10bpWy $
w usd &

earsfully. If p u am working indoom, & d n g tblily m l n w , m y for.8anclln$eh#'dMng,

Before udng thls Sectlpn, +the SsGZTons the dodr hthe work ma with Water MI help If the owner Is mnewlng a mmpleb
on ,dent,deep scmtr~h,rust tides and gash to ssttle the dust which wdud otknnrb be lli cornpanant hlmself, w If he has repaFred It
WWh. the a h ~ ~ pIf.hthe~repak . W h.eodlEd with e p r y filler, he Wtll b'e left wRh the
I 11e4 Bodywork and fittMgs

- --Aka frontbumpar IrDnt

nut-"Phase in md
a
k FroM'bu~-sawringarceQllR(2)
a n d b u r n p w i ~ o n P S M - ~ ~
P modezs splash S h W r e m e v a d r o a ~
~ ~ ~ b T ~ d iwltabie,pint
n g . a f wfltikhirg o n l y b e ~ w p t ~ by<aFprS!
I y dealer 7 Carefully pill tH splash &ldd Back
$&hb mmpatibre wifh @e type hi piastT6 *I& s .J@If ib +dy is Mt rri'ilgn&, the bupwr @rWe tu W bumper sldeand
@,PAt'Bri&+mg, the use qP a unlv* pdnt It k pdliarlly dpnggrba, as tH& q r wlll ndt lowc1rfbitngs,
w mt w t e , owing to thecom$e%range haidle u@.3Jy, and ssondly, un* B Unscrew the bump@ ?Id,8 m r h g m m r
,
$&C
IG enoaqntqrg in b d y lyornpon~nt smsm whl Uia lingo~don tM $tQe@g, ~ e ri l l ~ l m ) .
and r ~ w l ? ~ % , w & (aea
a$&teatibns. ' W d a r d pains, barkrgly $ugglenslg~ pl psslbly transmhlon, a Lauqkn t h i bhmpw IQW@ssurihg nu)
fmd;"'&g band f0 p k k Or NW cmlngabnohnd w k r , ar Frnglete fajlure, [them t. no peed to remove ItJ (see
BUTMBMrWft~
veEh any partrcUWlv.toa h itemsm the Wm. iiIddoQ,
l o Rwqh,gp .behindtha splash shiatd* md
locate fh~hntmgh,$?ma
t c b n w (e
i w r n ] . Se- fie b o balm Of the
----. .
ooonednr
tl M s sd
l the prw@c1re eriw 111
d ' d ue Is b first apply the fi-pfiniw
ta ~~3 $bi?i&btit w n m J mcl alloh it to Fbnt Bumpef - *
g b 9 on the left-hand lilds'M.fhdcar.
Have an as~st@tt,-$ypp.wth e hrnpwb
or up w SOnjnutw. men t h e p t i w i s PaM U ~ 2 " ~ m~tat @-€he
then.p~!l
. tront'wings & *~ , o f . t h h h b ~ ~ ~ m t
~mwlngCUP
zipp'Hetfr and €&I %f~
m ! a mij~
dry for abrlut m b u r
~ ~ J ~ l ~ ~
top' bat. I%e.WuFlais a a~ry@ly-plnured
,~ ~ ' fitted
s ~
13 -?fully
with ~ymt ~ bgflgfi~
- e car>
with&w+he bltrnper'from'the
? ~ ~ ~ ~ ~
oprnponenfAw h w th.psln MIf1.9.yvlrnth?
@+tf&Gk +&br, t y stanmd
a ~ ~ q p e t #at
d-m
Qb
qebattery ~.pefiuel&.
" ~mdhtor grille pawl,
v
14,9 h w@ a w e d Of removal.
paint + not normally POW@. d $ m b d in Becttml X
3 R a m w e W-frnmtnuMbBr ~tm. If the num- Fmmt bumper -
bk tl.aie IS iwiur+i IWsse6tapping s c w s , VP- 9"made18
~ ~ ~ d t o 8 t r l p lthe h MmW:
a ~ h
4 RGtrnbtsa the n4w-@psed bumper' kmvJ
securing nut, and recover the washer (see W Remove t b bonnet as de$~rib& in
tlluetra~~n). WQi 9.
I
h r e sriaus darnage has O C M U T E ~ ~or
, 6 TO h p r o m ~ e s s , Jmkup the front aft% I 6 .Working each $ids d the bumpwln
l ' i a?&s nied qenewql duq to neglect, f anr and su+ort it securely on ale stands iiwh pull oirt-ths p I W cllp and Ismove the
m&ns that complete n& panels v~tltnmd ($. daJ~cW and~vellidemppfiq. &rBBw securing We wheel arch tihw tu kh&
W&ng-lrt, aria th18 b best hfl to 6 Wofklng under TI-@ rbht-hand side of the bumper-
~~ If $he d-6
W ~ I I ~:, n~ q a s at~y
1s due to IrirpaM, c<m,mm-the,mcurMgm
completeIy dicmb I& w t y t ~h s
w arid ntot: &?d
e
p s ~~ M m e be~
17 Untrcrew fb, now-exposed bumper
eecurihg b d h (two on 88;dh stdg af the
&e, -,..,
aJ@hmenfof the b+hell. aild Xhlq can bumper (see lllustmtbn). b
umw {seam m M o n ) ,

- ham [M
(arrowed) "Phase ln
"Phase 2" rnod6Is
and (armwed) -wheel arch splash shield
removedfor clarity
8.37
- 'Phasa
ddm~uring
3" modets
 - -2-

P
Bodywurk and fittings 1l * 5

+€I W~rWng,under fie car, unscrw **.two

io& bumper erscurhg nuts, whiah Mo
p&r@,w.spjashieldssh -t BIW@n).
W' U&mw,&s,two u p w bumpar mamh'g
: t e&:$lusttatran).
za ~ w ,w,m'h y side of the bumpar
h . t l i e Iw@ingclip, pull the bumper
"i&@a frpm the vehicle (W iUp&W~Wirl.
Wte that .pn some model$r a shgk bumper
&irth&nq is fitted behind the nmberpla5p
Mw1% numbs @I& fof,awgq]-yMe
a@kab~$~F~VB M a nut b h f 4 'pullin0the
b u m p foh'ards;
tSn mdels htd with front 'drivlHg/ fi& h-<&~ rea'r w M arch sptssh
fbgtights, disconnect Mte battw)r negWe shield s u r S n g 8 c W S {-wad)
leiid, tfim dk$,mnect the drlwlh&i/f@llgb
wlhg csnnddr +torn&a dgfnt-bd side af support It seqwdy on axle stands [a& 2Q Wwklng under'fhe car,remove the e m
'h !i&lde. Wlthdraw the bumper. '3rlcIdflgand vehic1 supp?"). nu&- (louruppetand them lower) ~ ~ u n 'the
rq
bumpe to the bady (wemust+iy).
25 Working on the ti$iM-hmdSide of the Far,
RdMm remaw the securing sqrhw and nut, and W Have an assistant suppofi the $ump,ea,
pefirtlng is a m e r d of rmval, but reffr the wheel arch eplagh shkld. then PUB me aid= dflti-ieb u m 0th wm ths
.tbe.&.nW vlrR refermmtta SsCtim 9. HIRemove th n o w - e bumper raar win* ta.relep the lo&ng dips (888
~ ~ side
*fig $@we$ ~ ~ f . OmdW1.
1,bwer 'the b m fmm the w.
.W bfawriihg pn'-tkM-hWidside of the car, 31
rem& t b :two eftcuriqg screwri and i h e Locate;'th&r& $1- light WlYlpg
wmimal d n l j ,and r&mov&.!b byheel arEh oohi$~,w;%&Wis dp@ to ttre,bW pan&
2$ t'Plscanned We bawry neg&lWd. #*&&Id *amons). beto* the y ~ @at light
- oIw&, ~ and~
@:TO improve aqcaas, Writ $I8 ~ b r n ~ th,a.n@w*~sed
v6 h m p m slde m hl-!m.&~
&a&. of% b n m o r 4 w
dbds, then j a ~ ku !the
~ rear of the ccar:and sqirlng sc,w:and -W.

6.29 Rear bumper mo+d,Shewing sacurlhg nut locations

(-we1
114 Bodywork and fittings
6.31 Separating the two halves of the rear
number plate light wiring connector
32 Withdraw the t~umpetftorr~tlie car.
Refitting
33 Refitting is a reversal of rernoval.
Rear bumper - panel from the body (see illustration).
"Phase 3" models
34 The procedure IS as described previorlsly
fur "Phase 1 " and "Phase 2" ~nodels,except
that there are four nuts (two upper and two
lower) instead of seven, under the car securing
the bumper to the body (see illustrations).
7 Radiator grille panel
removal and refitt~ng
- :i$,
:;
% rerncvcd, 1t is p~eferableto remove :he t w u
Removal
1 Open the bonnel.
2 Carefully prise t h e covers frorn t h e grille
panel securing screws. then remove the
7.2a Prise out the covers. ..
8.3 Two of the windscreen cowl panel
securing screws (arrowed)
6.34a Rear bumper upper securing nut 6.34b Rear bumper lower securing nut
(arrowed) - "Phase 3" models (arrowed) - "Phase 3" models
screws (see illustrations). 2 Remove the w~ndscreanwiper arms, as
3 Using a s u ~ t n b l e screwdriver, c a r e f ~ ~ l l y descr~hedill Chaplei- 12.
release the plastic securing clips (two at each 3 Remove the tlve cowl panel securlny
end, and one in the centre), and pull the grille screws (see illustration).
4 Carefully rekease the cowl panel securlng
c l ~ p s(located at the base of the windscreen) by
Refitting pullir~ythr! panels upwards (see illustration).
4 R e f ~ t t ~ nisg a reversal of renloval. 5 Release the weatherseal from the front
edge of thrr panels, nut~nyhow it IS located
8 Windscreen cowl panels -
.>q\
: \
(see illustration), then wilhdraw the
assen,blv. D~sconnecithe washer fluld hose
removal and refitting
Note: There are two wt~ldscreerrcowl pariels
*
.>
.-A connectof as the assembly is w~ttldrawn.
6 If desired, the two halves of the assen~blv
can be unclipped from each other after
rcmovrtl.
{one each sfde).Everi if only otle pal~elis tn be
Refitting
par?els as arl asserfibly. a f l d then separate l/ie 7 Refltt~ngIS a reversal of ~ r e ~ i ~ o vbear~ng
al, In
two pat-ts. mind ~IE following points
8 I1 the two ha!ves of Ihe asserntiy have been
Removal separated, ensure Ihal they are securely
1 Open the bonnet. cl~ppedtogether before r e f ~ t i ~ n q .
7.2b . . . and remove the front grille panel 7.3 Front grille panel securing clip ( 1 )
securing screws released from headlight (2)
8.4 Windscreen cowl panel securing d i p 8.5 Releasing the weatherseal from the
(1) released from body (2) windscreen cowl panels
 Bodywork and .Flttin$js 1-l.7

9 Ejlsurp thet tthq weetherseal is c-IY amnot I@ striker

w t e d over the front df the panels, @,,%a . dna m n n d loch. M W k? flw
to the
$pa r C
~ ~ Y , W W @ ~ ber sem~veddr diw-
5 @ b raw,~pnnc3t
A

$0
h-
rn ~

the wirrdqr~mwiper s~tlw

it, Phnater 12.
~ ~ . ~ ~

Bonnet lock release c a b I d @ m

asse!nb&
Removal
'.
C-I
0 R@nQpihem e f s 3kYe taw- pmd,
~&d3&$j6&]~ S@on P.Mote that, where
app1MJ -.@em is w meed to remve,the
h*Bajbfi?*:4jum.mt &*9t~h and Vie
4-x
-. &om&&*Timry ftain w Wd.
'Wwal (rl-
10 WOW@{ ib r tm esgiw m-perrknent,
remove the smurfm$.'dlpJand the
j;,Hwa
n asMant iuppbit the bqnwt in the
mark
adjusted by did^ the posltlan of the brrnmt
tcrcic wwmbb an the b ( r I W ~ d r& the
e w Ut'holePpmvidsd
she m,Nejaet
,,
31 ~ m & , f i q m d , g $ k
a1fmm the Zb.& o
1 m >tevw.
*
rdwe

W@wf 12 Working Inslds the c&, mWlly pull We

hnr~d,
to ald dgnment an m n g . cabk thw& the bulkhead into W
nuts securing the bonnetto the a The brim Mngm are welded to the body, pa'utiai:.
&each side], mBn ~~i'ehllhj and cannot -1iy be i%rnd. =,,,ang
Refitting
13 Refitking Is a revem! af bH
mmw ensum that the bulkhead & m t liS
~ - b f i t @ g a wyer$al of retrnml,beadng in lacated ~nme bhlkhead,.and rode t h e e
$)?hdtkfgllowtng poi*. asnoid ddng removal.
a mete appiiws align the hinges wkh the
(m@m&h on the h n e t befoM m o W .
bh1088 h e bomet (m&lty. in caw it fouls Bonmt lock asrembb
&e fxeurroundlnp badyworlrl, and check W Remo\lal
isP@mmwith the sumdlw $bodypanels.
7,ifn w a r y , thealignment df the Wnt and 1 the
wpfwbann&m be by ~ ~ t e m gI Mark the position of the lock on the
t ~ wp o n of ms ftam edge Ule bnnst on bulkhead, ta sld curteCt alignment *en
the hb?g&, usingthe dmptd holes p m M . refmMg1. mt3W
w d i m m Q+ m e m a f w e m a t cw be 3 U m m w the twp s w f i n g bolts and re-
Removal
eovwhe washers, then lift W lo& a s m b i y
from we bulkhead f@eewwstratton). 1 TQm r n m a ~QW
, it fulbmdmpport
4 Remove the wuring clip, and relea& the lower q b & ~6 e & y i k h
cable sheath frsm the lock pads& fagn*
5 Dls~orlIlBott b b bonnet r@ieme
of t 2 Whmw appllcabl& dlmr)nslda the b-w
able froin ~ d q~ mkt l n g hver, then negafkh m, wnn&Ke~dr,~rm~
withdraw the I Q C assembly.
~ ed~tmgtcqh m the doar'piltw.,TodW#fW@
t h e . m . & ~@ide
, ~ cliprup,t
*
~ ~ M g
6 ~ e f i ~agwed ot ,Ir- b u t d i n wll M m f l m r fmnt le'm
the assembly wlih the rnA@ madd.on ths i1-1~~
bulkhead mre moval. ~='hyg$&h ~ m ~ b uf fn, w We-dapr
7 on cocampMion, If nmes$W edjusf the & & w ~ m z h p @& 1uwan1.
a$lgnme?t of the rear of the bonnet 4 AQsbM@ a SW~WBTOIX WI QIo mthe
dul mg*umn&w by altering 1w6 hlrige pi" from the hinges, but do no1
@ m d n g dib UP -- me mrilim oftfle
pn&
assembly, using the remove the pins at thk stage
elongated bolt h o b prpvud.

jisconnm tne aoot wlrlng r -, ,heck strap se~urlw

screw P' sening afront door hinge
connector ( m w d , .
11*8 Bodywork and fillings

5 Ham an assidant support the d b ~fkgn ~ , $2 Wwklng at the outer front d g e of the securing cllp and d i m n n ~ thet
m o w the hlnge pins anCl withdraw the dew door, unscrew the twa nut3 securing the handle ape-g
m car.
Refitting
6 ftefltting Is a w e i d ofrernwd.
Adjusbnent
T The dmr hinses are welded onto the door
9 Open the door fully.
10 Using a suitablb 'Pam bit, unscmw ttre
door heck strap from Wte $a*.
11 Renteve the dam Inner trim panel, as
described in SeEtion 27.
Front dmr Mn* w r i n a
nuts (amwed)
checkstrap ta the door.
13 Withdraw the check strap through the, nuts from fnslde the door, then tlll the handle
InsWe of the d m .
R-g
14 RefitIk~gIs a raversd of ramoval.
mar Imdor handle
the d m
1 F h o v e the slngls m w ~ X r i n g
Interlor handle to the dam, then withdraw the
handle and disconnect ttte operating md RMn
the rear bf the handle by r&$lng
securing clip (mIlhrstratim~].
i theM
~ e ftilt e and rafiwve from o&i&
the door.
R-1
7 RMing la a mmal Of m w d , but mT~t
tho door inner trim panel aa d e s m b d iin
Section 27.
Renrr door exfmrbrhandle
Removal
8 Rsmova the duqr inner Bin? p a d
d c m i b d in M i o n 27,
g Remove fhs door Imk a d e & W later h
ms&Aion.
l o Cat.9fUuy primthe two pl*
&* fm
the door skin far acess to the W@Whandle
wurlng nu$ [willustratron).
11 Worklnq inside the door, release the
extam
&from the handle.
1p Unscrew the two exterkr handle seWrinQ
and rarnove k fwm outside the M r .
R m g
13 R e M w Is a reveml of rmovd, rd~tting
ma door, lock as described later in thL
SWFon, anif the dapr hner trim panel as
d w b e d in W l w 2?.
Fmnt dear to&
Ftemwal
14 Remove We dmr Inner Mm prtnd as
deswbed In Section 27.
15 Wgrklng Inside h a door, release aha
securing clips and dlsmnosct the wbrjw
handle, Imk cylinder and bcK button
the operating mds from -the lack. Lift the I&
W o n and aper8tlng redWarn the d m .
fb Qrn-m*& & with c~nWW w r
R&@
Eornrl@tmebdhy *atiu~'lW,Ifnot m @Y
*
<dd&%hid d-nm the wiFing plugIs1 frbm
,w~IdvpWAngdat;Pr @i-)*
i P W~&rew,th&thtea Lock 86swihg &mews
,m,the . edge of the dow, an@WpW
rem
~W%$@lrn.
38 Working insids ?he daor, WltHdr? be
lack a-bly, wmplete with the lnterib~
bride operatln'g, , ~ d thrgugb
, the door
Wmn (sae Illu@sW).
R&ttln$
19 ReYiWng is -am%Esa
alf m e a l , rdOth7g
the door kher.Mm panel as descliW h
Sectlor

12.10 ear &or exkedrrr ~~~~ Dtriiaonwcihgt b pmfiom

nut l o d o n s (m~weB) t h e ' w s dW1T IOOII-ng motor
 Bodywork and fittings 11*9

lw ~ ~ a . n e s r . d @ r l a o k W m
me door

trim panel,, as

dwr, release the

wrl~gdlpq and dI8r;onnect the exMrfar
"l$bdk.arid trwk ~ A Q I aI ~ m t l n Q
r~d.gTm

Iamn ...aiSd-*&w Wm lock wilnder

34 To wmws WE SWW, sjmpiy m k q w the 2 Fully tower the window. On models wkth
I Werklna i M d e the doai: wlthdmw th,w w h g screw wing a s u k k Torx'blt. eledf'ci'cwfndows, tempararily reconnect the
~ ~ . $ s a e G t r ~~arnDletr~
y, with the interior battery negative lead, and rehnnecf th*
4qdk operating rod, thr~ugh the dbor R d l n g wlrlng phug to the el~ctriewindow operating
*re (we on). 35 Refitting i s a: rwwssl of rfrmwa!, but tf switch, ta.wablathe window, to be lowered.
RAtlHlng n e c @ m ,adjud
, t4e poskW ofthe Wker to 3 Ceuefully prtm the weatheweal from the
achieve Msfgdfaw W ng 05 the d m . Inner lower edge of the wlndow apwturs.
B Rcafrttlhsr Is a reversal of r e f r ~ v a reflttinia,
!~
4 W o M w aIA3hqrear of the window gl-
r e l e a the securhg l u g and remw the'
grlastlc dip ssyyihg me wfndow g h to the
mf&or lack cylinder
* gu* Mwk B~tlon)).
~~ 5 GamhIIy pull the qulde b l ~ &hack t~
dkengage the lug from fhe h@eIn @.glass,
%-Rmovetho door inner trim panel, as then s'yppari the glass.
m mm 27. 6 Working inside the reat @gf):pf the o r ,
' ., e-W W nr+g lnstde
;-tig
the &or, d i m n e t t the
%om me l+k cylinder.
cwefully triserlgage tho guide pl&(h&!d tQ
Fmnf door ~lms the tear upper iige of ttla g!ass) Jrpq the
St[& the metal ctlp koni the lock lover end of t!m w~themeUgplde.&an MI
yllot&, f h withdraw the Iwk gItln&r from
osrfallie this door (tase Illuddons).
R6mwaI fmkb tt& ,d&x m. i11mtf@oqI4
-1 Remove, the dwr inner WIm panel, as 7 Ca+flly,.p#h fhe,gltirss_rrpwards,ilil the
hfm d m ' M In B e d o n ,27. wr edge faMl@@%.~@ manlpuk the glss

@ ,men rMttlrtg the 'look ctytlndt ensure

I 'Whb thk asorrib?y engage w(th the
8 WjWpUMiw cut-outs in the door p a r d
$f ~ @ f dodr ifiner trim panst s
&@ylw:ip em*27.
m-
g*wal
e>.pe,
tp$ .$ker .ls amwed ido the -doof
~Mon-the
budy.
L h f ~mrnuving
n the Qtriker, mark its
posltio6, & &at 1t&7 b$ refitted In e>eaetky the window giam m the Wde block -
assembly remouedfor chMy
 I Bodywork and fMii\gs
11*0

t3:X Kemwlng the Wont tim~winclow 13.30 7 1 t e E u G o u t m r ~ a . ~ o ~

0 m button larrowgd) should be W - h e d af

ldih ~emovethe upper T& scmw .,. -id& .-..lower

-
out through tkie inside We window apeitttr~
mulwal.
R a w
8 R&fiMng1 sa.rgvqsl of mwal, bearing In
mlnd ,W,@llmvingpaw.
s <Ensure.thattheguide plate at the r&r.wrp~
Q@ sf%the glass is c o ~ I e $ &a@'w We
dW doop-
h a t h s d g d d e charid I
10 When rdftlng the weathmml to We
lower dge'of the wlndow apertup, ensure
;th# the seal is mr&iy oriemed, with fha
:&mut far the lqck -rating button at the
resrtsee n l u ~ o n ) .
ii B d d rMcting the door inner trim panel,
chreck tha spstation of the wlndw
mechanism, m ~ o n W n the
g bait* and ths
eboiric windows tlpw@"hgswitch, or r&ttlng
the whdw wind# hamile, @ applIc&k.
12 R& the door Inner trim panel as
deedbed In Sftctlan 27:
-
--
the mgde bdtp) and thg ISl8c ...&*wthe~etadow.
nut (2). ..
s e e rail
Rear dwr fixed wlndow gtass gu[@ rall to the door. Suppart the W d
RertiWl
wlntl~wglass, and carefully withdraw the
gul* Br.wgh the window *'Mure M e
13 Remove the door Inner trim pan&, as m u m .
dmcrib€idin Wlon 27. .tg Caieflrlly slide the f w d wlndow glW
$4 Fully lower q e slldlrlg window g!m. fmm.its tocattbn (sm~ ~ )
15 Garefully p r M the inner and outer wittlw
w~,&hersealsWorn the ffcrwef eggs af the 20 Refmhg 1s a r e v W of r&mw#,M & q
window aperture.
In &d the foNwing poim
18 Temporarily refit the window winder Z l When refitting the wlndow fixed ghsa,
hmdle. Ralm the wfndow until 7he wmw6 ensure that WB glass g a g e s corredly w h !
&durln~ the windcwv g b s to the r q w l ~ n r We aeJ8 ~rrundthe rulges of the wfRdow
bracket aw acc%@M -a
57 It the oHg!nal sudhrg glass Is to be reW, Z2 Where applicable, refit th@ w r m
mark the p&ofis of the s q wudng ~ the~ sacwhg the slidjng window g b s io th%
wlndaw glass to the regulator fSPaok@$then regulator brackat In the posltlons mrnrked
w o v e the wrews and carefully tower the More rmdW.
window @a$sInto the dmr (see nlus&a:ttonl. 23 Make Sure that the w ~ ~ ~ & s ~are @!s
18 Remove the upper fwk screw, mi* mrrec4y bated on the.tower,edgsof the
bait and lower nut ~ c u r l n gthe windw t'erar wlndow aperture (seeilbtmUms).
 Bodywork and fitking6 111
' 1

rail

'War door olldlng window glass Rear dWr window regulator

I
1
1

*
1

I
I f 12 Bodywork and fitkings

4'D.pnnecthwri-ihg fmthe h em y
@dnw, tajlgf e wtper mator, and d ~ l d t d
lo&ng, +or, as appueble. D+nn& % o I%?ie'rew the nuts,wna mrelully wiihdraw Rmwal
washer fltdd h w , where appiiW~I.W ther@~efim the vehicle. 1 O m &e f#Ugata, then carefully pull tha
prepared for fluid qpinagk RaiiiIp- inwtl.lm~hrsIkmp w e . If n ,-
q; Rg&$ the- wJn'ng loam h d S t4 .Ofi%tlhgis a r a v p t of removal, ,6uf r e b w the [tim dips udnQa -witablerforW
g r ~ r n i i @ ; h mthe e d g ~
of the taiuats, l7a wbhqptltable, fit ther M ~ , w r l gnub , td.
gAg$q9th: wiring Iwm snd ha$& (andWJ! in tfielr grlghal ,wtittontl, as noted hefore I U n m w ?JIBt w < ~ k d ts Q
c , v qnd
thaMi thmgh thb.Fg'e wf 3ha Miwe, Lea*! remval. Da nat fully Qhfcan the faikgi+e rm&r the Wh- (SW B l w i r l r ) . .
@@@@g .in podtion in' fhe tallgale, to arcl Mmdraw t k Lwk Ofonl ite mldwtI~n
in the
@urllfrg nttts until the Sap ~f the tailg€itei~
&&ingr correctly whh &e rdgV panel wd %ts tailgate. Turn thy Iwk as quired i~
$.,Qve an assistan1 support the td(@te: alIgpci rsar body pMia?. dbmnneot dw oprpflng W.
DMqnmzt the hupprt st- frum
h t
.ti On ersrnpleflon, .If adjuflment of *he
b .

@lde by, prlsing aut the rntahlmdp ~$IRQ, Remhg

t@a& r w r edge alignmm ts nquhYld, 8 RefWng k a warsat of moval.
9 '*riv,er,
remom the ktcuflng clip m d undip thb'
fj~ccov~-fPr~acl;.ess t~ the lock Wbr oh KO& Batmi qmmbly
?hel o w bwy @and.
12 the @on dtha lack &ks an t11q Rrnbvat
by$(by maan3 afihe crew hpleg3 4 ~ t h ~ F n n e r t F F n p a n d a s d ~ ~
to gt@ capct allgnmmt dffhe- b m r ecQ&of W d P h 1-
me bfi~'wlth m . ~ p u n d j n $ba$y panets 6 ~ h ~ u thetallgtatbaperture,
p ~ h @
[seeil*on). retease khe sec~ringell@[$). Dk,cotmat the
13 On& the YaZ!gafd ts cwlmc$y aligned; if. ld~legpgp~tlm rod, and whm applkabk the,
newssay adjust. the d~sllreusing t h ~ l-ng tnotdr apW@~g l p d r frdm t k m
adjtwtRient.~crew. lack barre1 m b b .
0 Dis~t'ted the W&H drain ftom the
Hhges sput at %ha lower edged the tailgaWp
34 The tallgaie hlQ@ am weld$ to #he 7 Remove the .i-n&tilsWudng dip from fhs
tal I$@@ md;th&hiq@ pins arean intarfmrw rear Qfzhp l o ~ ~ k t , . ~ ' W l f h the d ~look
~ w
fit IPthe hinges, The tiir~es~anmrtthepfore ba'nel mwnbly from wtsdde the W a t e W
&ly be remaved. nrwatp~n~).
 Bodywork and fittings 71.1 3

15.10a Remove the secrpdng clip (notethe

useof storkedtod) ...
rn mmWry acgust th$ posltlon of the striker @y
mean& of the elongated screw holes) to
8:Rdmjhg 1s a reversal of rmovd, E n w e
achieve sktisfiitiry alignment of fbMm Removal
4t%tfhrr water drain hose Is securely recon- of the tllgate with the aurroundl~gbody 6 Pull the W t r a y and kpwlng from the
TJmMat both ehds, ~entreconsole [see ~Ih&i&bnl. Workim
pan&.
13 On wimpletion, # necessaq, m wrlbr through tjle Bwftu-, pu* the dli~ette
;rdj&m&k .aWW to achlev~ MisfaFtury I$hter/swltch mollntfhfj@dIW -w$WWe
Fiermolrrtl of thet@&h(9ets lIl&Wh~14-32). &sob.
4 The lock strlk8Y is atwhed fa the towy 7 Disconnect the WtHng pl- fmrn Ure
badypaneL swW, thm push thPr swltoh oiit thmgh tha
10 Flmow the w w i n g dlp (usin@a fwked top of the @and IllustWon).
h l If naceqry), and withdraw the pladc R a
paver from the lock strlker -assemMy (see 8 Wt by reversing the removal apwatlorrs.
iwtwm).
t i Fmm~vsthe two seewing &crews now
qw,c e W V 8 l the ~ h mWId, w-[
Fmnf door lock apemtiw-
hbkk~tdw
m b l y . RemwaI
g
-, 9 Rmovs the door lock, as tS&@d'ln
t0 RefitfIng ia a reversal of removal, but If won 1%.Remove the clip d r i n g the la&
Rentoval qaemtlng rod to the mPtQr op@n$ rod and
I h c o n m d fhe bMay n m v e Isad. the lo& W @B illuamtlon).
10 Remove tRe.simle 3mw s&yrlng Zhe
2 f&f@lly grip !he front of the W v e r unit,
and pull Itfrom li8 ImaMnIn the roof mnsdte motprto&lo&WmblyI wWWthe
Mar.
{wi i l m r r ~ 1 1 .
3 Diymnnwt the wMng plug aid temov$the ReMng
wilt. 19 Refitting I$a &al trf-hm~vsl.Rm l h ~
n-e door lokk,css &@Mbwi In Wtian l z
4 BtRth$ka m m ~ auf
l remuiral. r mpkmdng motor
Reai d ~ ulock
DdItwP* d m 0@mting m-feh
5 The swltrh is MkgCal with the.mator am-
mbly, and c h d b m o I m~ W ~W

16.9 Fbtre* the chp sea&-&'lj646k!t'

-.
ooer;ating md to the mator o p e m t k ~
and Lolaktwer.'MMorWuws*
rod
~
11014 Bodywork and fittings
16.13 Driving out the roll pin securlng the
rear door central locking motor to the lock
assembly
13 Using a suitable pln punch, drive out the
roll pin securing the motor to the lock
assembly (see Illustration).
34 Disconnect the motor operating arm from
the lock, then carefully slide the motor from
the locatlng mll on the lock assembly.
Refitting
15 Refitting is a reversal of removal. Refrt the
door lock as deserlbed in Section 32.
Tailgate lack operafing motor
Removal
16 Disconnect the battery negative lead.
17 Open the tailgate. Release the securing
ctlps {preferably using a suitable forked tool)
and remove the tallgate interior trim panel.
18 Reach up through the tailgate aperture,
and dlsconnect the motor operating rod from
the lock.
17.2 Withdrawing the door packet from
the door
18.2 Removing the mirror trim panel
56.19 Removingthe tailgate central
locking operating motor securing s m - locking operating motor
star-cllp arrowed
19 Remove the single screw securing the
motor to the tailgate. Prlse off the securing
star-clip, taklng care not to damage the motor
nr the hilgafe (see illustration).
20 Withdraw tho motor from the tallgate, and
dlsconnect the wlring plug (see iHustration).
Rding
21 Refitting Is a reversal of removal.
17 Elecjrlc window components
-
r&hvC3L ahd tB3tting.
Operating switches
Removal
1 Disconnect the battery negative lead.
2 Unscrew t h e four securing screws, and
17.3 Disconnecting an elecirlc window
swltch wirlng plug
1 8 3 Unscrewing an adjuster housing
-
securing scmw manually-adjustablemirror
18.20 Removing the tailgate cantrel
withdraw the door pocket from the doar (see
illustration).
3 Reach behind the door pocket, release the
securtng clips, and push the swltch assembiy
out through the top of the door pocket (see
fllustratiort). L
4 Disconnect the wiring plug(s) and withdraw
the switch assembly.
5 Refitting is a reversal of removal.
Operating mofors
6 The motors are an Integral part of the
window regulator assemblies, and cannot b~
renewed independently.
7 Rsrnoval and refitting of the regulator
assemblies is described In Section 13.
m
DOO~ l m
Removal
1 On models Rtted with electric mirrors,
disconnect the battery negative lead.
2 Carefully prlse the mirror trim panel from
the front edge of tho door (see Illustration).
3 On models fitted wlth rnmually-adjustabb
mirrors, unscrew the three adjuster houslng
securing screws now exposed. Unscrew the
clamp screw securlng theadjuster lever to the
houslng, and remove the houslng from the
door (seeillustrations).
18.3b Unscrewing the adjuster lever
-
clamp screw manually-adjustable mirror
t Bodywork and fmings tl*15

4 On models fitted with eldclrl6afiy-~pemted
rplm, u n s p w the two scmm seewihg the
mimr CPV& panel to the door, then unplug
"e6nriJb
the. w i ~ l n,plugjs)
~ from the mirror (see
mar tug m~the adjuster engag@ wih the slot Raflltrrrg
in the fo&ing, and fmnt of the adjuster Is 12 To wilt fhe g l m mengagethe metal cllp
ftush wlth the wd of the housin'g { d o ylth ,the lugs on .tb?'rgar of aheglrs, lhtfien
Iltwtratlont Reflt end tlghtm She Clamp push the glass into ~sMimIn the rnlm unttl
Scm. the cllp wgages s~outdy.

'
6 !3$& the plastic cover from the frm edge
&tM dow to expcpase me mlmr front $wer
p n n g ! nut ts- jflustrauon).
Daor m i m @assm e w 1
mimr wi# glass mWmd by
- Doar mPmr g l w .reRmvaI
mlrior with glass miW& &
-
B'I~K~ETPIW the &me mirror securing nuts;and
wire cfip IocMng r4ng
I yipdraw t h mirror
~
&b~mMually=ad1~8.~1e
from the &or. On models
mirrors, b e d the
Remwal Removal
9 Using>a fhln-bladed ScreWWer, carefulty 13 U ~ l n ga thk-bfaded screwdrlvw, probe
,@per cable and lever throWh We aperture probe ~lnderihe edge of the mlrrprglass, ahd through the hale p"muicbdfn the boWm of the
t
HWe d m as $hie mlrror Is r m o v d (see locate the d s off he wire cllp retaining the min'wbadl, and lo- @ #frat4 af
y@aq.tlon). glass. tRa locking rlrig secudwthe gtms.
.*i l a support the%g~w. 14 CqefulIy tuw fha b&ng rlng, MUsfilg the
'I.rm.Mgis a,rev--al of removal, but. on t1 Push ana of the ends df the cl& towards screwdrl&r, until fh8 ~~ 19 W & d ,
,m$& fitted with manually-wehd mmm, th# centre of the mjrrrror, thm back<Into the R -
,$$@ wlt$lng the ad~trste~ lever to the mimr body, to release the glass I-
h0mlqprocsed as fOiiDws. i-ns). T& care n dto drop the mlmr 15 To refit the g l a s , loe&>the hl the
i B,'PElsh the adjuster Into the hausltw untll the glms.ast b clip Is rebwd.
~
mlrm using the four guides rC*) shown W
u ~ n ~ .
16 InMrt the sgewddver tYlmugh h e hole ID
the mirror body, and turn the I d F n g dnQ,In
the opp~site~dl~siion fo that w d for
removal, €olook the glass In rnitlon,
EIeEMc m@mropemt&?.-
17 The-swihh ls IocMed In fhe-drh,e?~dwr
arm-, wlth tfw @w%rioJndow.swItdY@s.
I& the p r o d u r a is a$ deWb8d fur the
et&frk wlndQwswitches h w o n 17.

1&8 ~ n w r a U i d f t S I i ~ i u @ [ a ~ o n
the Muster engages wlth the slot hr the
hwdm

la46 D w r mirror glms components

mirror with g h s retained & W
-
w rlng
18.1I b ..,and .rthe gl-
viitk~;rai*l
11el 6 Bodywork and Trftings
- - -

5 Hdve an a s s m suppart the windy ReRttiw

r n e bqr,
, g l ~ ~ f mM a The p y m d u ~iq 9 b a d b e d for the
7 Using a blunt RBt&ta+d screwdriver,
mmfillly p m tl5e *&a, back f r h the
ffar@ 6h !h?,t&&ee Cithdraw he glass
Pallpate .In'Ed~w.* in W o n 19.
0 C h ~ ~ t t t E . g ~ ~
w + m Ik ~G$W,-W*@a
mil.o"ubwmgm: tr3tedbrWm, pmats.
R W ; Ofiedng ~ ' r l f t a H b I : ~ ~ l e
8 Pk Zhe d & - bthe 4~dthe g~
9 Etige$k 6 c2i,rd in iW grp-W.a In the Rlemcrwat
we~thqml,as shown, so,that th+ends df 7 O Q $ ?he ~ wlndow ,then m v a : % e screw
be~&#f.:&@ii%.~ !he-i @-tfre<p@w securing the window g l k b t h e ~ h .
oi h e j33ttdfi idge 611 fhl @& (4 8 Have Bn a&sistant s u p w the glaSs.
'

%Q,@ Grrrss-section of the CallgaWwhrdOw

m ~ d m ~ 1~ j .1 4thepends 05 the cod by Gadulty unsmw itte twa ?chw~spkrlng,
\ # i t a t h a t wtkh wtd I n W for rdHW appl~mmly 200 mm. the.* to the hingas, and IHt the g W frMn
10 W #a @assup to U ~ Q hitgate, passjng the bar.
the mde of the G D P ~fhmigh tmiCL$ the
Utgate. Refitting
11 ,Slowly pull maofthaends o f t h e m b 9 ReMffrtgIsa~&ufrernorpal.
EbWonrPcrrrrrnatw seat ?hewmthersqt over the Range on tlie
ID The motor k not aGallahJesep8mW Ptam t q a t e . Openin$ mar M e window
the mhar. If It Is fauw, the complete mirror I F Havg +n ansistanf apply getltle pressure caw?
~Iyrnustbemewd, to ths g k s from oubide thti car, to aH
lnterbr m l m r mdmval dthe cord. 10 Open 4ha wlndow, and remover the .sdrew
fa Wen the wrd m c h s ' t m centre af the &ctlilng ths cat:& to thegIrh5@.
Removal uppet @ge of the gJms,WWthe opedon
11 Remove the two -acmw8 securlhg iM
20 The m i m can be, removed by carerfully with the rmatm'ngend OT the cord. ' e h ti3:the body, then withdraw the catch.
pulling it from ttw balljofnt on the mbunting 14 @hmkthat the ~ I a las secure and that
tn& aftached te the d n & , w the wkathewal is $orwtLy .sWed, then RMng
2d The rnauniinq bracket Is f f ~ e i dto the' ncmnscf:the h& rear window wlrlng, and 12 M Wt a ~ m ofdm v D .
whl&Grwnmuatng a s ~ i a adhedue,
1 and Mil t h Q . t a i l ~ ' W mMet.
should nat be dhturbed u n b aalufety
rimy N.q# that them ie a risk d &rtg
the W i n d a m glass if an aWn@ k ti!sdB tp
m , a sw~rlnelylbm,Mi-rromhg b*W.
R
-
22 Remffng L a revmal d refidVal. Y
;n- the&cld adhesiverequlredtof k
the mauntln& trmMat to thd Wxkresn can m d mf quarter MR&W
b dWrt&%ma Renault dealer, Rblmw 1 O m the sunroof, and m o v e the screw(s)
1 The W R ~ O3g1as~
W is SBCU~& by W& serouring the han& assembly to the . -
clampphq &lqn pf the weathemeal. piir@L -
2 Remom WCI B-pltlar trim pA&el,the r q d 2 hold the panel in the Bpen ,positIbn, th&
$de tilm pl, a d Me rev aide t r h band, viirthidve the plastic coygrs b m We screw8
as d w c r b d in S e d b 27. sawring t h ~pariel ta the hit&@ &&
3 Have ,an asgshnt support the w i n d m N u m h ] .
mndm gtaas from Qutsldethew. 3 M o v e the hlnp s&w, and tii fhemfl
4 l% uyinds- IS bondd in p i t i o n udng 4 Using a blunt flat-bhded actewch.iw, fro6 Me w.
a special a d M w . carefuCy priw the wlndow we#Ierseal bapk
2W T wts?&wive5 and experti88 are from theflaryle on the bady, then withdraw RefWng
a
re$trsd WsuwessPu1 fimoU;rE and refitting thi glass from outsid+ the 'wr. 4 RdMng I a a ~ E i f m a u d .
#:gw.flxed ky %Is method. Such work mu&
~ @ r e f 9 ~ , ~ ~to~a ~RenW a t etiger,
d a Su~mhmdh9
im&&.w drwns.@~lss~d
-
w h d ~ q &peclailst,
p or #her m m p h t
p ~ 1 r S ~ . Ramam1
glaw
Eai4We.wW~w s ope31ths WW, an@- thewmy&'
Removed w u d p g the k n d f e a-ly tci tfia
-1-
8 The tailgate window glass Is sexred by the $ Remoxa the hw s e m f l q i q ran#
clamping action ofthe weethem&. wIthdmwtfw hamile trim p l from &e
4 f b r&mov%the qlas~,flmt f e m ~ v 0t b (seelIlu&@on}:
bllglate trim p-1; pull the pabq deph to 7 *r?%ote tb thW screw8 seouFlng tt-$
rdeaset h ~ecuring>
~ dipst or usa 1 dli&bie handle mmbly to VwW,?Ken wIWW
w e d tbol. thd'&blgc ( S W a ~ o n ) .
5 Di.scorm& the battery nq&# lead, thm
dismnnaEt the w7~,ng~plugs from the, heated 21'2 Rbmkhg the Wer from a sunroof hama
mar wlndow elemnt. glass pmekto-hingesecuring screw 8 Fbefittlng la a reversal 6f r e m d :
I' Bodywork and fittings 11017
1:' M I I d e mmmof twrnp~nemh
I
7 9 This type d (8 a c o ~ > p Wfie
equipme& ~on$lstingof s IWQS nurnber'of
/. mmpanentai, it IS wndy r8oomtnendd *it
the sunroof rnachanlm Is not dl8lurbM
u n l w &sgluY~ly vcms+ty. H the sunmdf
ib faul'ty, or i&@fws mSrha~1.

b
mg&&$
*$$t a Kmault d,mler'for WIW.

14 ,(;arefully r @ W B . the spoiler from its

m a d wheel a d epla8h w n i n g .dips by dn'dhb'It-u ftm
ZfdB Remwal MtpaW4srartlng+'@<en&
1 VwWs plastic shields mzpy he fitted to tho 8 b & b a ~ w ~ w l t h a a d h ~ s t Refltking
whdm esand W i w engiM camwne@ ~ . T o m W M, e ekhwsoftm theadhesive 15 Commence reflttlng by c h h g
tujmt#V@nst mad dlrt and maistun. using a h&'& ar halrdry4r @MtQ W . b mafnlng adhesive t a p from #FI tdlg*,
3 me shteb are w i e d by a w,m,WngtiPnof &old &amageto-thepalntworl4, or separate taklng rnnQt to damage thq pint.
p J a Wdips, w.nuts and pop-Wets Isw the W g a from h e M y $y,"saWlqWthwgh 16 If the originalspollg is 0 b+@ftlW, 4-
hatrdon). R m d and refmlng should be t h e m v e usrnga length of nylon wH. off dl old adhadhblve tape,and @ply new h@
.-B< Take m ar care not to bra?$ -ng to therre!mnf a~?ag.
e t l c dip when @ W n g them. Renew any 3 Chat? off dl t
rw OJ adhesib(8,u s i q .white f t R&no\c6the p m t d v a backing from the
@bp-Mson where necessary. adh@lwe tape, then slide tho spolW IH6
spirit, then w e the area with y m soapy
v
bwrr mbbImg &s witerro e r n a~w t m df sW,and allow pitEoh b i b r&@nlng ~llp.
ro,$ry. Ensure that the surfwe tb wbtch the 18 Press ,the spallw snta the tailgat@,
Remm new b a d e ta tD b fmemd,is wrnptetely enswhg that the adhyke tape holds
3 the door, antl m o v e the p!Mc mer ckm, and fm from grease and drt. spoiler-TtrmlyIn pasltidn.
from .We rear edge of t i e door to .mp- I 0 Use t h ho3
~ dr g q t? ~ p f t e nthe adhM{m 19 R a t theqwllller:s a i d q serws.
nlbbhg StXip mlrgs m w @m-lllusbation)+ an & new ba+e, then pr~aa~tt flrmly into Bonnet alp duct
R w w e the s m . p'sitiion, pf 6-valvemmod&$)
4 ~grklng ou@e thw door, uncllp tho
pbblng M b 4purrhlrrg It toward3 m par nf Remod
*.
ti tf &sM,the rubbirlg M p s w r l n q dips
20 Open the bonnet. and uhswow thq five
Removal nuts'sedurlngthm.wy&m d the dud.
Hn 'bemmo~@from fie dow by tumirig
I? Am& &h&W tape t~ the tallgae & r e 21 Unsmw the sihgf&,securJn~nut, and
i a * n ~ e q ~ ~ a t ~ m t ~ - ~ t a chm;d
~ w !h~e w ~ tofhthe apoler, to p r o w the
edges wlthdraw thb maih grills assembly f?Qm
btrsrs* pdnt during me following .prowdurn outsidr\khthe-&:
R
- iuudk): RaMng
8 Todita Wbbln$Wp, iLJlgnme hob3 In .h 42 M g a shw blad&\c&dUly cut wgd 22 PrntIhg is a wed of femavd.
I@@ w&h &e mrr+pMldim iltpa in thkdoar. tho edge of the s p d y to deasethe doable-
? t d m t o sld& adheahre, tap6 'seewhQthe spoiler to
. P u $ l ' t h e s @ 3 ~ ~ 4 f i @ Wofthe
<PWPMelrW thetail*!
'7 an compIMon, reaf th6securk-g screw and 13 Remove theW@IW WQudmSCWW
WpWbcow. [one undereach ~ n pfd lhe&kI.

22.1 1 +ldh-*e
tall-
appiitdtb FUW
when tamwing %palter
l[i-vahr~models
-
11*I8 Bodwork and fittings

yourself # the exhaust is st111hati FmRt sea€ Mfi

4 Carefully iffthe s@ fmm the vehicle.
Removal
ReMng
I Remove the front fodwell ,siddsill vim
6 ReMting ls a rwmerlof ~ ~ 1 .
pamel,as d p ~ i b a dh . W m27.
Rear seat cushbn 2 Prise ofl rhe coyw wd u n s w ths sgat
belt uppea.W M i w bolt (sas illuSimtlOn~).
RemM S ' U n m w the rno,uundng Pelt, mtnd w M d w
8 Tib me seat. cudililon forwards, thw IIR it la the Inertia mei -6mbly from the door pllk
dbefqqq ~ , @ q ~1ugp q fqpm
, the hole&In (see Illu9tratlonE Remove the &at beit
fhe floaf. assemblyfrom the,car.
m Refitting
4 ReWlng is a revenal of removal. TIgMen
-w!.*m-lnn* "- 7 w n g . is a r s v m l of removal.
-
(amwe4 note exHaustsystem Re8fS43at b&
the 4belt mountfng bolts to Re lspecrffied
torque,

Removal Front s a t be# h e i g h t ~ u s @ r

RUHtWUt
wmlh$: On mod@&flw with
A seat bett -timsInnem, betom
pmm3dng, d e d a t e the p m
~w.sryptemrssdescrYbadBr~~
Remod
1 If deslM, remove the seat aide birn panels
for Improved access.
2 'Working Wide ~e car, remove the two
3 Worklng undmedh the car, unscrew t h
two nuts sscurhg the s&t inner MU $0,tftPf
ftmr,(seeIllmWaU~n).@pmdtng q whlch
~ s : ~ mn og ~ dw , ' w e not to bum
8 Release smyring catches &,the top of
the seat bdlrs. Fold the s a t boksfa ward.^. RWnWd
9 Wnrkln~pt ihe tower edgm 0 f tha seat 6 Remva thd B-plllar trim pans!, aa
b a k , mhse the catch& W n g the seat dewbed in Swtlm 27.
Wcks !a €he body, then withdraw tha 8 Unsgrw rhe two, m c u T 1 ~bolts, and
assembly from W car. wlthdraw the adjuster from the pllai (see
m g
10 R&@ng la a r 8 d of remoual.
Ihsmhn),
Refftthr~l4
x R m m g i s a a ~ D f r n o ~ . ~ l t ?
ther B+lhr trlin pqd h a w colrectfy uvwthe
door W W W weathem&&. RghM thdt -1
bet?rricwntlq to tlw sp%d toque.
Rear irneMa mal d W f
mmitag: M the ~ c r l e u n -&
A
stat
In a-t In whkh s t a d d
damage was +talnad, all fhe
rompwrents musf be
8 PHse ofi ffBHe"mvW, md unscrew h e 8eat
belt upper mountlmg b R . h t e the W o n , of
the s+r rlng an bott (see a l w o n s ) .
 Bodywork ahd fittings 1 1.1

a,.Remove fhe rear seat ~lr&Im,with Warning: If m a w p t has btwn

made ta t o 1 fhw~vehkle,If the
mt~s@bl2i3,bT-wo.ahs$&
&t lower rnountltq baR Unscrew *&ho'Yr.
YO U d p thesaatb~ltaurmundfmmWr+
V€44&!8-has hem +*, *
a? orff
vbhlde has bssn i r r v o l ~ dIn an Impact
q~~ panel. whkh did mf mgqer the #y?n JB~YB~%
4j w m g in the luggage com-mt. pull thepRt*fe&mergysPem shoWk tested
~ h k l wside trim f0 expose the kWFa @I w i r i g ~ u k ~ t m ~ f ~ a
p@m% bdt (see lflu-1.
'jp:4tMtb~We l W r i n g bott snd WWdYaw I
$bhy@afrgm :lbloWcati ~ d * t h e d
>fjt\th@bgh*e bob in the. w qWW Wm
, m e
--
~S~7fie'W&bMk:I8'mwunhl~d~m
&-14bq ~M;omp@h& ~mi
the h r , aftw h g the Wr seat m i o n pulled backto lexpase =at betwrtia reel
fur.pee&s, mouMlne hit i a m w d
,m The etectronic: control unit Is mounfed
34 Refftting 'Is-aY&AW
of rmovd. llghtw un&r t b bnW"m@ole,and Inwrporatea a
.$a. wgt b ~ l tmwntRgs to the spedfi5d decdmtbn sensor and a triggar unlt. If the
'*. mnsw dnses s WBration m Pert h n a
preddermined Imn,the trigpbr unit sends
Rear lap seat belt sigrmls to W i@kI?n maWt& lrl both seat
Removal beit fenelon@ wrrlts. Note that an host
mdelq, the b a t belt Qndener elgcazonic
I$ me belt cornponerita can be control unit' la intqgrated with the Pibag
I@bW,aft& w i n g the raw seat cushion e l w n l c coatrolunk.
* m s to the m n g kk. 6 When a tenstoner ignlfion module Is
&Mm Mggw@ 8 mall W I e e w & d , whlch B To YE-~MM- the pre-tgnslgner system
10 IWMw Isma of ?OW. T!@en rapjdly reteasew gas Into the tensioner iW carying aut w#k, p m W a S ~ l l ~ .
~ ~ ~ t b ~ , b ~o ~b t Of i brquk
e d tylin*. As the p is rdwsd, the plpton Is
farced dong tb,cyElndkr, pulling h e oable 4 B&re
M
m n g out mpfudherwork,,
m r n m W w f if@ opehtjQr1W
and hence the seat b& &dk, which in turn tie &$stern 4s dmkeri uslng R m M
rem6vk ariy sick from thws&at bdf, pulllw vial test Wl YRMQ (&. 1288).
the belt tisM,agamsithe wearer, 61 Reconned @ p r 6 - W r n p ~ h g '
6 On@ 1 seat belt tensloner h
c b n m m under the wts.
trlggwd, Lt must be m w d . J Re# the p i e n s h e r fuse.
Warhbg: Do not expose the pm-
Benerd hformation
iSki'beh pre-tmrbners are fm& W later A h*k
fensionw system to ex~assfw
W m i n g f f m y w m k t ~ f o Removal
~
W l s "fa rernoye any shck Tmm thg f~ant
a frontal Impact. Th%
~ ~ i n . i t w ' t w e ofi %
*ucm B e W w s af
front seat pa&-@@ in
A
Tonsfone?
W t ~ d h e W ~ f e & a x h e r r s9t Deactivate the pre-tenstoner system as
n#rew~~kI~vi&?&t3f~pm
'sy'sm
deacrlbed
- previoulsly in this Sbdbn.
eomponeMs which I 0 Remove the seat 8s described in 5 s -
@ m ~ $ ~ f a n d duetotheseatbelts
d ~ t h ~ i n i p a u b w ~ e H & & n a m o w t hWone 23.
*d&t* p*Monw wm@ fuse (see -11 Unscrew 'the seeurinq bolt and r m w a
Tfle systam conshts of two specid $eat hmheF**-- &en Walt the pr+ten&ner a9sembl)r and trim pand
f~hlonw~stalk Assembile$ mounted t $ r a t W ~ from ~ the~mat (see~ Ulustrations).
a
34 Warning: When hstalling any 12 U k r n n e thm wMng plilg i rom the tqp of
W4 untt.
on the ffont W,and an M r o n i e
3 @h tensfofonerrtstalk assimbly eansll d a A deefd~ala-SO*
i o u d ~ k e ar
(SU& the pre-tensianmr assembly, and feed the
e dlhm 8ystmsI wlrlnb fhto&h &e him pand Berm the w#ng
$$&&t.bucKki,attwMd to a cabk. Th$ end of wisIIch emif s magnetic field, the clipped in place under tha m t ) , then
th+&le la attached to a plStan inslde'the- cwrnjhnwi* must no? L fitfed near the w M & w thg tensloner assdmbly [see
m b r cylinder. w ~ s l o u ~cwrfrol
s r unit. ilustrafton).
11*20 Bodywork and fittings
I

2&lib .aswWyandtrbnpanet
..and m m w f f i e gre-t$naioner 25.12 DLsronnee#ngZhe wMg.plug from
thetop ofthe we-tensl~lerassmbly seoraingmtts larmw%S)
warnins: ~ not
i i 'Wja& 'We pre- 29 Re-&ivde the preLbnslonorsystem a ofd, broakf:blad~4 'scl~~~driver
wHh the d@
t d o n w asembfy to s h o e or &crib& p~evIwslyin this%c#lm. h . W r n gw MI
e ~ . > d
heet rr
m ma gowd a u W %
Z B w - n 8 p* ~
5 The following Ssctlbn gnu. the . :

A
be<w$pmd
~ r ~ w h m h s p n o t
b w W P ~
ttm appn&ate Rpwult
I m ~ m ~
accompmylng IllusfWl?ns>and phMqmphs
deecribe m o \ m l and tefkhg Q? 811 the majbr -
trlm pat&. Note fhat at t p md n d m b ~ d
fan
qeaaqu#m~-m ~w* fa@emrs wed offgn ~r3rl& .d.~Tingthg
produaon nm af a particular m o h i , sb
Refittrns dIHemnm~may be noted t o the #medurfta.
3s Fee13the p%-tensbn'w wmg Wqugh ~ , eR e m d provided.fat mrMn u&i+3.
siof h ' Weqt'tdrn @el, and m n r a e c t &B 6 When removing a pmd, never -uLpB
wring mnnacior to fhe fop of the pre- i Thb prwiar trim. panels are at1 secured ~~sxasssl$oTow, or the1 panel may be
tendonet unlt. ~b79&th* SCWWS M WOUS fYP13~Of
damaged. Atways ehwk car,Eafufiy that dal
-I4 hefitst h ternloner-and
~ the trim wd tu taster@@ h ~ v ebeen removal or re!-84 ,
~e mat, >.enSurln$that the prerLrensioMr is ~ ~ ~ $'Fan*.
b s f i w e ,: a:-.t t Witf3dmw
corrwtly located, then &It and tlghbn the notinghow it Is muredm,W P?m or
andillary ~bmp~lrenfs (such as seat heft WWng
ma-,
b&'a *I&
grab landb, d4)must bB m o v e d
pahdGW be wlthhwn.
9 Q w p any such compo~&nw have been
7 Men remlgg?swure the
-Ing
dbtwbed wwnmb are m=tly =MUM,
fasehem by
them firmly i r h plEioef Enwe that d
w m w d , ch'& that fiefeara nu other paet* to prevent W t b . If adhem W fafoundd
E l e ~ t m ~w Inc tmI unit oy@pprng.fhe w e to be mm~Ve.rX.W l v , ah9 pot13,&qq remod, use white *&It
Hob: On d&Ua wWi ,a "wnW",Bi&w ths: s~gu~n'm, to bg followed wfll bmrrie xernmb:W,dld a d h e s l ~ b ~ t W, Wn p h fM.
system, *e,pm:tensr"omr system the &lops an-dmInsgs&nI G&nire @ngng WWI US
a n %m t m / UM@i the systm, B tbe 2 R'%bve a! Q ~ V ~ . Ufasten&,
S ~ ~ w b h~ m . ~ u h e (e.Renauk
sl~e s e l d b4#b
c m w u n ~ ibs 4erem~vadanarrwWwtqa wwsCmanyofwt-il~hritay ~veph+tIC & f&rnmn'd a pr-opWw pro?luetl@-
mrnblned pre-tensi~nerfairb~g control unH, fM,If the pFupalW cSOt be fteed, It b bkmb V b Y .
betom p m d I n g , d e - a c ~ the~ #i@Q
~ secured by h!ddsndlipk ~#WiWne*ron
-S as &h& in Chapter 14 S d g n 28. afthe pml.'~mh-$FS am trstta1b srtu?@ -b
w w d th&geAof.tHtt.papJl and mbe pPised 8, Tha passenger c n r n p ~ ~ "f mr
~ l GEapFP
t
Removal > up to te@@s m.Note that $WGoli@ Eafl rksik-onthe fl&r, gyd b hdd in ~pslth~' bj!
17 D-ate the pre-tefisimw aySfem break qubW1Iy, so It b advkahle Ya h& a Ptls sill tiirn panels and othbr airrrouJ&p
d m b d pYwiuSly M thk*tiwl. Tw WWement c11w of ths C D Wpe ~ panelsand m p o n f m k
is pmwe the m t m a o r n v pesotibed mHabtefbr Mlirrg. GenMdy, the W m y 6f Q cmst sem~vat~ and W f m g is
W i n n 28. a@ng& C I I IS~ to'use a SCLWle W e d straightfwa~d,but very tlms-Qonmrirlq$
.fa Discam& the cbntfdl unit wirjng twl fwe ilhmwio* lf thkj Is &d9,ai;l due tcr the fact that many afthe adjolninq W$
CO~~&QB. . pands must b ~ remowed
, P M . it H I alsO @
fig sersws t~Q8ssw
w ~ ~ M!W&. M .
,QD&O~ Unk &:&.V@r~unttq@, t h w m ~
A*,

Hrnrn'W
21 .
i~f~ unit lhto witkm,m g fp @ b d [ n i q is d p g d Xo
thau'fhk 6eLy6jw .g.d t h ua
~ b nust a c e
towwthe.f~d F"
'hi&Me, t h ~ n ,the
sewring &l'M$;p~@~ gydtiQWm
&,W~st!!!myCr,*>4t W v such
grab handles,, mn'v M & stprod*
securely. M)HOTbI%anne%ahYYW4hpwltfflg pIl& Mrn panqlsJ-3uZer tdm
. mreMmhavS
connector3 unfil ,tW88cUrt~g .
weatbemai~~, el&, W d Lb m ram
b m trghtened. ,pWd &W*
a Remnnwt the mnbl wit- '~Idng ,sf r-lp@ thak hwart-dfig rem,wd
~conrwtors. &%*die sklil and path~crIt! l
23 Refit the centre eomla as descriW fn 28;4 Suitable forked tool for r h w h w wried out wlthbut d'ktWe, and ts
M o n 28. plastic Ylm panel %curingclips k@ entrusted to an axpert;
 Bodywork and fittings 11*21

272 wng a f a r e fpol ta release the 27:8 PrM tk&m fmm the door grab
window -r handle handle to exposethe securing screws
? P ~ c l 0 ~ M
7 R m a the ssurim~acr* q d wlQt%raw
the doar @ock@Pfrom the door. On model&
fitted with e l d k ind do^^, reach Up W n d
dodr pock&, and d i s c o n ~ c the
t wirlng
plugs %m We & a c , window Swltehm.
gfIsecmnnect the wlrfng plug from the electrl~
Front door inner trim panel m T m 'aWch,.wh'W,atmH&lele
8 Where applicable, remove the four
Remd screws $nd withdraw the I p u d & m &cpla;-
1 dn madels fttted with c e n t 4 locking, l~udsp$aEcerand k u d s p d e r housing frbm
dbmin~&thsbattry de@tlve W. the d w . If r i m y , mave,the mirrortrim
2 On mod& fltted with manuallpopented pya1and adjqste~houslng @mSation 18).
windows, note Be pd~tirrnof t hm d a w 9 CariWly rel&se the sawhg c l i p around
wjPiri hand10 wlih the w i d a w fully open, the d g e of thg f T hpanel, W m W uSmg a
WFIWasa the securing dlp and rernoNtKe forked fool.,Putl the.Wrir we1f r p the dew, withdraw *e tray from the armrest (see
hat* To please the w r i n g <el@, make up noting, fMt it is sewred with ~ d n gillitstmfhn).
.a ' b r b d teal almllar to thgt shewn (sea compound arwnd itk erne (5ee l-). 13 On $nod& fitted with a door bin, u h r n
d l m o n ) : altematl~ely,Insert s length of Refitting ftw thtQe secutlng screws md remove Wm
with a h o w end batween the handle
and the trim panett and m i p u w Jt ta frw 10 ReMng k a revel@ d M I I o V ~ I ,W W doorbin.
T
In mhd the fdWm 16 On mo,deIs fW,d wfth an ashtray, pull the
the m d n g clip from the handle. Take &tray from the' hatlhg?h e n mi- the
irot Z&&mge the trim pand. 11 When refitting the panel-ta tha door;
.ensurbthat the swhrg m p o u d pro\did= a hawino secyrlng dlp%".&We# a$Me bottom
8 ~ m w t hsingle e dw u w g W door goad seal between the doaw and the pandaIf of the housln@ J&d,g a mrdw'dr'dw M a
rnfertor hor@le to the &arb -raw the
&Iy w sdlng compound of's ill-won). P ~ &I-I Rwslfig fmthe
hqydk anb.disoonnecf the op- bd from .n-sary,
sutkzble*w(avahble from a Ranauk (Id@ door.
.
the &? of lthe handle by rakasinq the the seourW dips
12 Whist$ eppltcable, refR ffie window Wmdw f7 CBrefuIly,
e n a d!P. handle in the pasition noted before remhverl. m n d . t R e : v e'Of ihs fdm Wl,pr-1~
ig &&&wthe NIP ftarirzlte dpar. us@'g,fp- %ob Pult the trim panel frdm
5 -?he m d m gr&b handC Rear door inner trim panel
cover f ~ tha, thedobr, notht$,tb&ft L semkd with d h g
fo *p&e Wm two swrm e b w s (sm cmpounqwnd its*$.
Removal
i ~ [ ~ r ) ) b
Refitting
C M-noMs'thewurlng s c r ~ and
s withdraw 13 P r o d as &rib& In paragraphs1to4
$e grab handle f~om the door (see (mem m o n l . 18 Proceed as des~rtbclfn pamgml5hs 70
Remove the securln$ smewj r h m to 12: . +
$lustration)* 14 ..-

- .-

27.t4 Reinowing the tray m i w e w~ housingse&G dwz naYe the. bf

from ?herear doaf armrest tam40 ptmte&.B~e- panel
11 *22 Bodywork and fittings

Carefully manipulate the rail 'to release the

-7y - WqdmtflemweL
br& -R&&ng &-kont'bat belt lower a irn 5-dkr madek unbolt ths' f w i seat
morvrting wt -
,-
madel wlt low* ~ u n q n (scre
g mstmioml.
n c&eful&pull .ttie.panel fbm the te-dy t o
W e ' h ~ecurlqdip&,and withdraw the Removal
Rmwalm pan& h r n tM sill (&m lustration). 28 Remove sewrirrg a m w fpm 'the
19 On 3-door miodd& pkl* off the phStiC RtPAtting I-&@ of the,*I,t h m m & puU.th~!
w r d unser~wthecboHs m r h q the mht 22 R e W m Is a reversal d ramvat. Ensure pan& Worn the pltlar b I'elmse€he.$curing
belt rnriundhg MI l&e aumad~ln).
Nae the
@siJosr uf any w & h m Wfor spac-&s.
m,
that ththa s&ittifig 'cltps are mrrectly ctlps, aha withdraw thepane!.
md t l g m the -at $ett mounting hl% totfi&
e R m
~@f&dt a w . 28 ~ & l n g I&a mersat of removal.

-bS-dwr!
a r po&vm&! ddeMI $dmpanJ
models
Remwal
23 Rbmdve W,e r e y seat wshlon, w p
refmoe to Sealhri28. h &move the footwe31 aEdd8lll Vrn wn,&,
24 Uhcilp the rWPfW front footwell s i W as de%rlbed pwIbusty in fie; S&on,
trlm panel fo expose thrt rear W e l l SfWllI 81 Prim off tha ~ovar,and unbPlt the ypmj
trim panel &&ng w w . f Pemm* a m , . seat bpR rnounth~.
25 U n M the W seat Wt lowe?~IWnthq. 32 Where applbab1.8, prM tW G ~ W % %
28 Garefully pull the *el f m the body to from fha seat belt hetght &Jwtmmt
rde- the sacurlng dp,and WI?&#W .W 4 h n pull ~tie'knubTmm the adjuster [s&
'w*l {See iIlu-1, 'n1-w).
 Bodywork and fittings I 1*23

me#&
$gW:MHm2rng
a u r t n g lug
33 CmtuIiy pull the pand from the body to RPrfittirig r18 Working in the luggage aomparhent,
@lamethe ,a&udn~dipq and w M m the Refitting is a m a l d twaval. fighbn unscrew the w,:w&r Mtn , pmal v w l g
-panel, the mat belt mouhtItlng8 to the spwified screws fram tt)s.a@r lhe panel . p e
Rating torque. illu~on).
4Q Pull bactc the trlm Yrom thp s i d ~of the
34 R M I n g i a reversal of removal. Ensure Rbordde tdm penel lugga~e~mpartntenttb' the WO
the-pane)~oaates&rnW over the door lower Wurlng s W (W RIutMlItonI,
aperture w e a t h e r d s , anel tighten the seat Removal
mwmw to tb ppwiftcd torque. fhat one of the screws m y alao Wmhe
40 RmOv$ the B-pillar trim panel, as lug@g% &rnpartMrlt light s!##W. R ~ w
d%crlW mIrIws&Irl thls Section. ths scmw.
41 Carefutly pull the roaf side trim panel from 50 Unscrew the retwalhin~ trlm p&d
the body tb rele&e the securing clip@,and a&tdhg screw, whfch is amessibb through
withdraw *pad @e ilkrrrtr$tkn). the hole exposed by r e m d of theseat belt
3S Pracmd a5 rtescrlbed In paragraphs 30 Rdtting WtpUnd (seaBmmtbn).
to 32. 42 R m n g A a #versa! of Woval. Refit the 51 irawib pit11the and from the bodY'to
b Remove the rear seat .cushion, wiih B-pillar irlm panel as dwfibed pmviausly in release the bpwr secvr?ng clip, and wfthdraw
Wtmw to WAloh 23. thb Section. the panel from the car (swillustration).
S7 Unbolt the m r &belt lower mauding.
gs 'We'fillly r e t ~ Mthe s-unng Q I F ~ s Rear qu-r trim panel m g
around tfm &ge ofthe trim pami, preferably 52 Reftmng Is a reversal d rem~vfl.TrgMen
uslng-a~fwWYPOl,then withdraw thb panel. Removal the seat belt nwuntlng bolt to the speclfiad
45 PPlm off the plastk da@r and wbdt the torque.
mr. .seat belt uppar rnountlng. Mote tha
p&tlon of+m
*>\9FT fheWlt
4$ b W k & ~ ~ E i a a t ~
4.5 4-$41@4%wteW bk WPW thetw Removal
#at ~ ) t s e ~ ~ g , I u g , [ & ~ U u s t W o ~ ) ,
M ~9W~~~.$wurni~rnff@ g a r the hrteri~rIW a$aeiVlP% :@s
6Sf RBmolte
quaW Wlm pInn&:#tmnfdthe &at W
thmmtt tWhoI"$l"t& In@Ph9 Iuwg
cow&.
47
drscohne3hkvdifM'
hq
a
~mpmmi,,@ &"IQ&B+,
tq@h8I@@,t h y
w Ma.lpq&ji6ak,
as applicabtc

27.m hmwing the mar ~ a r f eMm

t 2 7 s Rernwing a roof console panel
pane1 securing screw
f 1e24 Bodywork and fittings

ReWtrfqJ
B R W n g Is-areversal of removal.
P i contpartment ~m
@a-
57 m e Iwgw tmnmrbnent #im parrek we Warning On mod& 4IfUad 'wfh
dipped and glued ln p h . The edges of the
pqnets can bs wcl.IpW fW -To
COrnpohents,
InWt A seat Reh p m - t e n s i ~ ~ e f %
m i n g , cle-adimte tha prrt-
~ ~ a s ~ h s e c l l o n *
won4

Tailgate aFPm patIeE

6b fie pan01 Is & w e d by pIesti~,clips. 1 D i e & the Wtely n w i m h d ,
2 W h w applicable, u n e w th8 tya
Gdrdully pull the panfrl from the tailgaie to
release thi ctm (me Illustrsrtlom), or &easesecurtng x k w s and ramwethe f o M koh
theclb,susing a suItabImrotkd her. th9 flqw nbxt to the oenjre c w w l s (see
lflusfr%Xlon),
Ftm#reat trim pansls 3 w u r e hat the h a n e k e Isfqlly applied.
W ism& 'trim pakls are dlpped in pm 4 Qn madeta .fitted with 'a manual gmrbox,
l
6xwpt @r:thg mar ouiv trim pw~l, Which I;s unelip t h gear lever gaibr fmm h centre
w~ursd .by &ngk awaw thraugh Ws aansote {see Illustration).
rwI,-pemq@ aod reWq xe++.vkirant. 6 On rn~dels fitted with automatic

28.4 Undlppt?gthe g e a h g@ar $om

the centre console
 Bodywork -and fitYtngs 1I*25

'8W~rking under the H ~ r i t l aG ~ . U V , headlight-atmaq+,tnterdt control. cerefiilly

-Q ahre smurtng ~ r e w s zthen ~ pt~llthe knob from t 6 i cbrWJ, uMb a pilr p
&r&& 'pull the tbw'er sHroud dpw' to plkn and a plwe 'Df lhjck paper 'Ot c&d to
F##&*>Wrrg,~l@. W l m w u i e lower prated the knobi dm-aWfhe%wdltimci
&p,#d Ul-oIls1. aecudng .the cbnir#l ?rimM , a pand Ime
I, fh; A h a%.&g wheal as nmes3w for .1-1
-, m d ~ B ~ Q ~the twb upp& '&md
V B 11 Take &Wfulh f f s d the rbqlng of my
~ &kom the fmnt, ofthe shmud. ~ 'cabs md hpses, then u~cJIP WB bdnnef
#Hdr&w *per s8rbFrfl [W release lever ass8WhIyl the e w e mntrqi
UlW4ta8J, Rema* Werllbly. alid the hadljgM a h a d j j b $ l
-n$: ~7Pull -the,,bonnet release lever .dmn t D switch, a8 aappllmbFe, from the r@r af .It@
dr&dttfng I a ieversaf ' ~ r#h)4yf14
f
expw&ihh,GT* kq& m & h @ I yaf&umg p a d (seeHlusWabdnsl. W d r a w #Iwpa&.
v q e bolt, . h nummw W',bolt,
applrqble, @btm the radioi6wfte playatf applicable, .ds&nne& ,tha:.6hQke Refi'wa
'&m& ,cantrot switch ~Xmpwrew ~ftcr q8 bWhew k from the carburattor with mf%k@ncrata $2 RsflWn~is a rWw%l d remoiml, murhrg
refittingthb &muds. hhapter 4A that any ~&8~s..andhosesare @uWas rioted
~ ~ ~ f r l m 9 Removethe
~ l two wing scr&,from the 13 wore removal.
upper edge af t*" panet, t k n cmfully lower Ware applicable, nn wmplaffan, ofleek
Removal the (8- mwtmtlon). the a'djh~hnerrt of t b chke M l e as
6 Remove the five-sw~tirtgl=raws fihree I D Qn madals f M d &ith g ffacla-maunted dmcribed In Chapiw 4A
 11e 2 6 Bodywork and fittings
29.7la Releasing the headlight aim
adjustment control from the panel
Radiohassette player housing
Removal
14 Remove the radio/cassette player as
described in Chapter 12.
15 Remove the two upper and two lower
securing screws. Withdraw the radlo/cassette
player housing from the facia, feeding the
wiring plugs and aerial cable through the rear
uf the housing as It Is withdrawn (see
Illustrations).
Refitting
16 Refitting is a reversal of removal. Reflt the
radiohassette player with reference to
II Chapter 12.
Heater ducts and vents
17 Refer to Chapter 3, Section 13.
Glovebox lock
Removal
18 The lock striker mounted on the facla also
incorporates the glovebox light switch (where
applicable). To remove the striker assembly,
remove the single securing screw. Withdraw
the strlker and, where applicable, disconnect
the wlring plugs (see illustration).
$9 Two types of lock may be fltted t o the
glovebox lid. The first type is operated by
pushing a button at the top of the lid. This
type of lock can be removed after removing
the single securing screw.
2Q The second type of lock is operated by
squeezing two buttons located on the front of
the tld. This type of lock is secured by a metal
cllp on the rear of the lock. Remove the clip
29.18 Removing the glovebox lock strlker
29.11b Bonnet release lever securing clips
(arrowed)
I
I
29*1Sb ... lower
u
screws.
and pull the lock out from the front of the
glovehx lid.
Refitting
21 R d t t n g is a reversal of removal.
Complete facia assembly
Note: This Is an involved procedum, which is
likely to take some time. It IS advisable to make
carsful notes as the procedure progrssses. to
ensure correct refitting of all components, and
correct routing of all wiring, etc. Specific
details of fixings and components may vary
from model to model, but the following will
serve as a guide. Provided plenty of time is
allowed, removai of the facia assembly should
not present any problems.
Removal
22 Disconnect the battery negative lead.
23 Remove the steering wheel as described
in Chapter 10.
29.27 Facia wiring harness earth lead
seeurlng bolt (awowed)
29.15a Remove the upper ...
.. =.lac ...an9 wlururuw ulu l a u l u r
I
cassette player housing from the faeia
24 Remove the centre console as described
in Section 28.
25 Remove both front footwell slde/slll trim
panets, as dsscribed in Section 27.
26 Remove the steering column shrouds,
uppw faciatrim panel, driver's side lower facla
panel, and radidcassette player houslng, as
described previously in this Section.
27 Working In the footwells, unscrew the
securing botts (one on each side), and
disconnect the facla wiring harness earth
leads (see illustration).
28 Where applicable, disconnect the door
wiring connectors from the door pillars. To
release a connector, slide the securing clip
up, then pull the connector from As socket.
29 Pull the connector securing clips from the
wiring sockets, then unscrew the two securing
screws in each case, and detach the door
wiring sockets from the door plllars (see
illustrations).
=.ma Pull the connector securing clip
from the wirlng socket.. . I
 Bodywork and fittings 1la27

'B.#R ~ m m eW , WF='~WB!wewing 29;m RBrn6w'b~ ~ ~ ~ f L ~ r h

the faaia assembly to We rrteerlm column
housing aperture, remove .the two screws
doodng We Path essembly to >Wernsral
maunthg bracket (5- O l ~ o n ) .
ewttgA*mbly, then withdraw the swltch, 37 Llnbllp *he rado/aa'ssette pla96r wlrlng
$&@ the
j wiring t h w g h the facia. Note the mnnechr from tha m&al mwptlng bra&&,
r6wiJn6 dthe wirlng as it is withdrawn. &.ld =paw&the Wo h e l mofrtle 'iqhr~~?of.
3$m8!q&:et& c b r a p ~ esteerhg column 98 Remove the t w sewing
~ screws fmm the
$dk" j@M~h
t&s@ly, as described in lower Wga of tha Water cMtral pa@.
Withdraw tha h ~ t w control panel from Iha
.Wmd Uip, f&% dlsconnmt the k l a , md dkbnnltct fhe wlrlng pug,
the W to the r n m r t h bmkert.
~ Note
connwtors must now b e & w n n W ,
42 Note thzk mst of ..,tneqmnly,tors ate
dipped to the b u l W or the -ell pan&.
In cdrtahn cam& the two halves of the
cgnndor are fastend tcgehr by metal or
plhlstib c l l b Note the rbutirrg of ail wirtw gs
V I ~uontractors are dfs~onn&ted'
Ifi~gons). 4

SQ Workhing mtbrough the radfdassetke player 43 Rmove tM large plastic swudng cup
Ir,ouslng apeiCure, r'srnove' thg two s c m fmm the tapwitre d ths m a m b l y (sea
W
~&?ibY$ ilTB sting calumn (ee w u d n g the heater duetlhg to the facla (a* .
-
l
rlll&wn). illmtlan). 44 Workin$ d each otSrmr of the fada
36 R m ~ ethe instrum~nt panel as 40 LOG& the rivet sscwlng the facia assambiy, Lmrew the four murjng nuts
M b B d lil GhapYer 12, assembly to the meal bracket on the (one nut at each mer)(sac illustrations).
36 On U1 &valven models, m o v e the paasanger's dde ofthe heater control panel 45 MaKe a final check to ensure that aH WIT,
mxlltaty gauges, as dwcrlbd R Chapter 14, hbusitig. Using a truitable dlam+ter dY111, .cables and hoses am disconnected and
W o n 74. carefully drill otlf the rivet moved dekr of the M a .
38 W m h g through the mdidmwtte player 41 The, rernalning fact? pid wiring ham- 4B With the dd of an assistant, tarefully

... ...and d i n n e 6 t i n g bulkhead

1 a* ~ ~
-(-gd)
~ S e C r a i n g R~gaplasficctlp 29-
wiring cannews

I 28.4% -D
l a bulkhead MPI
wlting ~ o n n e ~ W
2@&d Fad= footvrreil w M g oon~~?&~ra 29.43 R~movh~g
WOW@ (&OW)
the plastic: mmlng dip
from the tap of W faoia
 I
1*28 BOdywark and-5tkIrtgs

& 1 W t h ' 6 c t a ~ b ~ f r o ~ n ~ 3 w ~ dEnsum

, Wat dl1 wirlng Wnn&Wb are
qjd.w#hdmw it from t h e ~ vm'd ~ h' d bt.aI1m w & r
h , s q c m i y r p n n ~ apd
%$t 4wm (--Maration). H t b *la Zs ~ e c & ti ell pet^ InpweI whem,app~W~a
-
diHmkbmw$do n d m e x e ~ f o r d e 5tJ Use sl ?qw pop. rivet, or alternathrely a
-&6%Wt $I1 WCBW$ wlRng kw,h e n sultah1;e -nM\,and bolt, tp mcure thq fads
dls~wlmted,md-tfratfHe l-tmwwars not -isY$tt$iy ?fO, ib m&aI bra&& an the
*mi&sumdlwmmta passm&Fs, M e a f The bqaXBp w t m ! me1
tlQwJ@jJ- SUdon).
Rang SmtWm'ap$1~mbI4 do not fulh QJ-IWthe
-47 ReWdlng 1s a fww~1 oY' rsm~val.W n a rad#d&&
-,- p l a y remols
~ control MtCh
~~'In'@x$ tfr~&Itawinggpalnts- ~damp,&& r r the
~ Hewing p&mn
I WIRd s m b l y Is off@realt~ the &&q&-fpye been m M .
.trpl,@eqdlenhiur? that none ~K.thewlring 52 Qn f vhiplsflah, check $hat J1 swRches,
-, :pU%,&I%.& h m - q w d . lights and instrumentsfunction m M y .
12.2 Body electrical sys€em

F& -m (M*): C~MS)

p ~ & '
9 6 ................................., ................. R w e W g . K ~ , - # a i k
2 $5 ..........‘ .........."..... .......................
; ; ~ ! ~ h @k@&~td . ,dl* m iq d W l i g h t ~ & d d k e
3: i q.... .....................................
. , ~&ar;&Mt@~ appwd-bm
Q
4,
+r:'.."
20. ..ii..........,.,.... ..........................F~Rt,fqali@b
. .

:?@ .................................................-.... Englna bbQlk@ fan

'

8: aD .. ............................................... El$l~fun@b~
f$,, .... ....,............,..;..;............... ' , R @ h t - h a n d h at!plpe~l~b;aam,
:,:..

7 ?
- ,
~mi! wastdwtpg
madlight
.-'t;ofusefuseNo 2)
s:
g.
:2b .........,......... ;. .......*.--................-...
1............................
;l5 ............................
,HQ~
:J+tt-Rand hdllght d p p d ' b m ~ a l t ~ i ~fusib:.W4)
e ~ t o
1.0 '25............................. : .................. En$fri&fim'btbnS
11 5 ; ...*......'............................
! .................. ~ m a t f E ~ m 1 s s a b n
I:! ...............................................
?5 ,;..;, .. . .
~FtlgM-h.mdh+d~kg~m~n~,,
.I$ 15 . .,..
............................................. be&
20 ....
r..,,,.... .......-....................-.-...bF&lk PhUdFheiidllQhtnialn
. , . i.!.. . .,
~

w mW
wrinh~ ~ f he mwon,s.
5 To-ftrrdthesqyq &WY intwmkkrilddw
dwtripal component, any switche8, relays, fa& (usually dlre i d rt mm ar dlw
m o m , f w , fuslble Unks or circuit br-ers cphnW n , w + m q d - wking Insdatl~n], a
related to thgt wrnponent, and the wiring and "wt&1ed lest oan be W the WfTin!J,
Wamlm,Befom out any connerctw whleh Ilnk the component to both

A w r k on th# bfeMcd system, the battery a d the chassrs, To help tu

tmad &roughmthe pre~alrtbm pinpolfi 6 prdbhm In &I @&troircui% ia It should b pnrrsslhls to mnow d o h the
h LLBefe&4T@IFfat the WImnlkr~of WIfhgdlag~amsare ipcluded& fhemd nf this mufoe d the fault to a pdwlwswttan d
~ ~ ~ 7 7 W A l l i cha*. ~ wiring. Thb mcsthad of t d n g can be used in
eB I M qam
~ is .of ~d-vott mgpitve 2 &#fareathtpting to dkgnase an W f i c l conjunction wifh any of the teats. &stxibed In
%yea.: Pb\liiBr bt M Hghts and all fault, Wt Study tfi$ i3ppppfMewiring dqmm the f ~ l ~ o ~ n g ~ s u ~ l u m .
eIect?ladt B c ~ % 6 O r l 8 ~is supplied by B to o h m a mwe complete underslandlrrg of S Apart €ram plpblgfns due ta Vbar
hBU/a~i4type btittqy, whluh Is charged by the comrronmts,lnc!uqeti fn thw partkular c,mneMlatx. tw,b @ ~typw af fault can
the alternator. ' cI& concerned. Tha aosslble souV~-es-ofa aewr in an &&la&wIt 1 -o'pbn-dlrw'it,at
This Chapter cov- mprtlr and #dm fault can narrowed dawn by noting whether w*-m.
prmdtlms fdf 'khe variws efectfkal other components related to the circuR are 7 Opm-circulf faults are caused by a br&
. seved mponents or sqmewhwe in the circuit, whlfh ptwefits
C O # ~ O t l ~ l snor ~ o t r i a k dwlth engine, opeqng i r o p e ~ l y It
Informaifon on the batie'ry, alterfigfor and circuits fall at me ifme, the pmblem 1ll&y Yo p e n t fram flwng. An *~~dmlt IaCtlt MI
&or can h faundlh Chapter 54. be taa &aedh%or eq%h w n n d i prevmt a ~Mnponentfrom woitcing, but wttl
It'&iheuld b nated &that, piror to WMng on 3 . 8 e c I w I problems uwaily stein frob not cause We r s t m ' t crrmdt to Maw,
my component in *e.eIwtriwl $@ten%,the s!mpl& caus&, such as lo* or .corroded 8 8M-cwultfayhs w~,musedby a '&I&
b&wy nagatl+~temlnal @olrId first be connections, a faulty ,a#h ~Qnnricthmn,a gomewhere In thm circuit, whlah aJldws tha
ttlsconns~ted,to pravent the possiblHty of Mown fuse, a melted firalble Ilnk, or8 fauw oumv.n~rrn m thsqrrcu~tto " w p e *a l o y
e W r W ahort-circuit$ and/or fires. relay {refer la S e d o h 4 W"dll8ils.Mtegting an tnlternafiive route, usually to &h. Short-
Cautbm B e t h &onn&na the batten. relays& Visylly inspect the condition of all drcult tqllt& afe normally qwed by a
&* to &the informwioi g~ven in fuses, wires and kOittfeFfiOn~In a p~oblsm breakdown in wlrhg Imlrifi~1, vrihlchdlonrs'a
m s D ~ n n ~ E t i tha n g bm&ru;* In the eir~ylt'b&are-68 the components. Use f e d w l a ta touch'e'Wq #other wire, or an
&don of th& manuel. the \Irirlhg disgfams to detmjne M(6h .earthed component s ~ a$hm bbdyyshe A
iwminal cam-teGtlonswlll need to& c h d i L . qhblt-clreuit, fauit Wll normally cause 41%
ln girl& to pbpolnt Ihq Wub!+spt. re1wwt CireuftWac to b h .
4 The baglc tools requlmd f& e1euti-Fkal fault,
finding IhcWe~a~ c u ftesiq t w volt mete^ (a Hnding an op~n-eiU3t
12-volt bulb with a & of rest IW'malso. 9 f o ~ h & kfor an opm4imult, connect one
be used for cmain tests); a wlf-powemiteBt lead of rr ckwR tm~c or vd#?ter-tu either
Note: R&r ,to the precautions &rimin light (sometlinesknown as a continuity WtN; the ~ B f l vbaftery e tmlm1or a k7lown g o d
%fetf%~%tl*and i f the Wnriina WCh@y &I &hmm~tw(ta measure wds&nce]; -a e m .
5A befare starting work, The foilonrln~tats battery and aet of test Leads; ' a ~ da Jumper f 0 G o n n e t h e other lead tv a wncectar in
M& to W M vf 8cl8 6ikiMW deu& Mre, .pc&rably w k a circuit breaker or Lse the c h l t behq terrttd, p-r netrrm to
and should not ba used to test &/I& incotparaled, Whfctt wn be used to bypaw the baPtery or fuse,
cimh [wch as mti-~myrbra~iq suspect wires or de~tricalcornponeMs. 11 Swrt6h:on' the elt-citlt, b y l n g m mind th@
systemsJ, partIw&ty where an et~ctranic B&fohatteraptih'$ to locgte p problsm wlth some muit? are the mly when the ignlti~n
mntt~1rn&ufe IS us&, test"lnstrummts,use the w l r i g diagram fa &Wls m e d to a mtiqdar pdsttlq.

I 2 I$M ~ Q B L pfewnt (indicated ,eM~tbx- con~etlqnmating sutface. Be careful to
,W't&mbulb IfgMlngor a dtnl&Mw
and j h t h e - Is~ prc);Biewha
~
18 Continue to check the rmalrrdw of fhd
d#l&lo ttis*o t4ipKi~n.
14 Whem a paint is reached at whloh ,no 8hd W7&ykhell, to ensure e clean an?
voltage is phsent, W problem must b secure mnectlm. When the cannecffon la
that point and @mpr&lou$,t& pdd &I&,
WI y o h g ~MOSI
. prdblGWban b Y m @, flrture;biapplying a cod of petmiam jelly or
a'brobn, cwradd nr l&>~rihsbbat
md cannwt a circuit t&er w v0Hmeterto the
km m n tbm
PI Swdyn the olmm,bearing in mlnd that
dbme clrGuE are five mly when thq tgr)[#on
s w k h Is mwwd toa pwtkdar pmitbn.
T8q tf voltage Is present-(hd&af eimer by
tb l&w b& IlQf~Ungdra voltrnetw mdfng,
as applioabl&, this M a n s tlwt them IS a
&wtclrctlH.
I@.If no voCtaga Is P m t but tho Wse +ill
Nwa with t b lodf9) conneetd, this
IndWem liltm,al faut In the loads.
Rn$& an eadh fault
The.* nqatlve termitiat ia cortmW
-
to *earthn f h rn? af the engindtrane-
-
,ir&st~nunit a(rb the car body irnd mast-
q 5 m s 8m w w so Zhat-theyonly WIW a
qasitlte-f&, Wn cdenr refurnlng via fhe
'mbl~of ltb t
w badv. Thks means that the
m; &-ha &~p$nt is In operwofl,
'm+m ~ W r or
wiper n fhe radjafor
mMirr) M y fun 'Slowly, and fie.
Win@.Tm
o m d o n -of >one cfmlt may have an.
appc&ly+unr&t8d Maot.'on aiioner. Note
&&on .m&y vehickw, earth straps we used
RWW-Wt&d ,
disconnect the Battery, and
mnned pne, bad sf an ohmmeter to a known
wod earth point. Comaot the other lead to
c o n w n M g Wtd. the
tnewlre w ~ i - t h
r@#tm$a W i n g &auld be zero;if not,
&&Itjtwim n i d o n Lfolltm.
?2 Riw @rthyonrwctir~nis thought to be
Flitllty, dlhanP1a! tfie gnn+tWn, a d .ctean
b a q k & . h ~ a txo*t fhe bdphetl and the
wlrs tarrilinal or 4he' component earth
.rmom dJ alltraces of dirt and corrosion, then
umq'hb toirim w a y any paint, so t 1 4 a
aw tn$khl-ta-rrtstal joint Is: mads:
, a h t e n the joint faenem
~
Wire feminal b bTng r-,
um;s.mt+ washers between the tem1ml
Meat the mat ofeomlon m th&
slllcanpb&ed grease, or by spcaying q n
eer~ularWm&) a proprietary IgMen ,miere
Removal
3 Disconnect 'the battery irwathe I d .
8. Reaah up underthn facia, and tmamw the
Wa securing $crews fmni the rear af B e
fu-bax-{we us^^,
3 Worki~gat<thfi bcithm of the- fusebox,
unslcrew tb-~emalnlng twa securjng smWs.
4 camf fully lower,thti fUS6bo)Efrom me, L C I a ,
Disconnect dlt relevant wlrlng plup to mable
the j u i b a x to b@wRh'cilrawn, noting Wr
la&br~s if nmessary,
Refitting
6 W n g la a rqe& of rernoval.
Body electrical system 2
.
3
(q
3.2 Fusebox upper securing sc-
Iarrowed) viewed with Pads removed
Any exc'essiye qmnt.tiow will be.due ta n
fault In 430 tir&iit,uhm1ty i k M I d l r k ~ R[$&
u
ne
rf l w f a d a : m . t h e t ~ n p f sside.
3 for a M tb-th6f*, NQSSthb WQ
plaatic securlng tab, then iomr the fusebox
panel from the facla The drw7tg-p by
the fuses are mark4 on a etl&&r at the
bottom of the fusebax m e1 @a
illustration).
4 Addieonat fus'efl ark l q t d In Bn qjli3p
f u h x under the bonnet,,h m f i t f i & h l f l g ~
nap lit ths wlndarm cowl md sd thrrkip
hand dde. FW ace& to ~ S iilsas, P tlhae
cowl panel flap, then uncllp the , q e r from the
fusebox. The clrcub protected by the fuse
$re marfuexf on the hie of the-panel covet;
The fuse far the radto&wWtib pkyYr l s
mbonaed on the tear of 'the unit ( a w
illushltms).
5 A M v n fuse can be remgnbd fram it8
mdtedarbmkeri wlm
6 To remove .a fuse, f# ensure that the
r e l e n t c i w k tS WchBti QfJ,
7 Using the glastic tad pr0vlW in the
~ w W xpull , W'fWW m Ib'cgljqn.
. - -
8 Soare fuses a m mvldadca! the tower It-
hanb side of the main fuse&~,and at the I&-
handside of the avxlliary fusebox.
 I I - I

A4a AukiRary fus&ox locatSon Inw i n e sornpmt- w x i I @ y ~ - d y ~ &

44b Fuse lmatiow~In
4 Flap s ~ r f n dip
g 3 "&V&S&&~ W Fur cihbp-W, m h r t~ sti~kwunfusebox Ild

9 Before wnwng a blown fuse, trace and use ofI&htergwp mflgand & 13 C s M n mod& have a klay b X- 1
MIfy the muse, and always use a .fuse of W co- In the engine ~~mpasbnenk, rn itw left-hand
correct rating. Newr substitute a tusa of a b) A M y C B w~ i v e more than m e WRtrd sldht,In front of the 8uqemsIm turf&. The bOX,
highding, or cw!#tsmpmy &palm uslng hgd, unlike a qd?WWW W . wntalns days. far *e fuel i n j a n system
wfrh OX netd 'foe mom serlous damage, or c) A relay can have a VmeP4functhn- for mdlgr p r r h *g&im pump. F U ~ W
wen fire, muld muit. exernph* bCle infmitmt wiper d d y . d@X& be found in Chapters 4 and 18
j0 Note W th@,.fupeEl e g l o ~ ~ ~ o casb d 12 Most of the r&ys are lacated In the r ssw*.
follows. Rder to the Sp&W&ians for decallhi fuwhx. Note that en .some modeis, the $4 If a dmu'imd~~lled by a d a y d w t a p a
of the fuse ~WI@.W #8 C ~ , W pU~ e a ~mwipd#a y IS ! a d mind €ha f~ui?,a&thrt lay ISS M 0p~m4 ~ the
COIOW * WM to the left of tt~e f u w b ~ x (see drau~t:~fthe m t q ISfun~tioning,R should b
QmRP &
10.4
I illustmtions). * hea th4 relw c l i ~ kas # k
pa&blii.'t@:
R&
Blm 5A
Yellow 25A
*
Qm
or wm 2%
30A
rZ
-.t

RaIap
1 4 A reJay is an electrle-op4rated switch,
whpth Is w d f~ Yhe b l h i n g reasons:
4 Adaycanswitehal?eW~md~
femotdy ftwn the dmit In whi& the
w m t & fbwlng, thwbm allowInrgthe

fha r@ of
4 . 4 ~Removing fit#fusefusefro';"m
fhemdw-player
 Body electrid sy-stefi TD-5

wwglsd,If thbCZhe case, W fault IW with Torx key, m o v e mug& screw sawring the
the mli.onws 6r wMng in Msy~tem.If the shlih ~ y . t b I J m : e & f i &lurnn'
g (tw
refay is nnf baing mergised, then either the on).
rd@ 1m nat.,r&celv!+fg a qwltbhing voltage, oi 6 UsiM a aGFaWQflvbF;p@i'W tha 'WWng
the d a y iisd'is faulty [do not swleak the dip located at .the batt6m &'$he swlbih
rel&.l&ii$.t €amtlnaIk w b n tradna faultsl. admbly, then pull .fl~:a'$mb Jyth8
7frQm
Tesflng Is by the sutPstItutlon Of a known good stewing d u m n using he key. Feed the
unR, hu€9F1 careful; whlle some plays m Removal wclor
iw
i thrwgb S t y &Gprfnq~~l,umn:€@ .%b
Idmbd In appearance and in operation, switch b withdrawn (seaillmtmhml.
o t h q look drnIrar, but pWom affereril t Dlscmned W M e r y n d v e lid- t To separate the swtr& from .ttw IB&
funcfldns. 2 Remave the. +wing o~lurnnshruuds as assmbly, m o v e H e two samrlq s k W $
desc&& in C&&er11 S&Im 2% from th? T ~ Wof the houslq, and IR.&..the
3 Follow the swbh wiring behind the fa&, mr W .TheswM ean now bewith-
~ withe ~ o r i 3 b d o
and d i s w n h ttle ~
(see from the I& ( s e e ~ i u s ~ o n s ) .
Hlustration). Y nece&my, lower the driver's
side Qcia fiend far &ms& as d@oribad ln
Remlrig
Chapter I?, h ~ t i a n29. Take note of the 8 W n g Is a wmal of removal, beartng In
routing of ,hewirk!. rnindlhe bllcrwing palnb.
1 The'llglrts on' warning buner is Imted In 4 Ins& She ignition key tnto the swltoh, and 9 Wtin retittrhg the: switch tho b ~ b
the M e & % along wIfh the relays {age Wn It to posttton " M (akn3''). assembly, makeaus th? the lugs on the lwk
I l l m f l o n 4.1%) S Reach up behiid the switch, and using a ngage the ~ut-outsinthe switch. Not$
that the switch wilt only fit In one mltlon.

Removal
11 D&mnmet the batt&y nwettm bad.
12 Wv6 ihe stewing c d m shrouds as
q*~lh*ch@tw t*I;Smolt2& '
13 w~rktngunder the $Web, umcfew f h l
hrvo sew& screws and Ilft the swlteh %om
the steering column (see Blustrabion).
34 O i s ~ $ n w +e wlrlng> plugs, md
withdmw fie switdh (8- i l l i ~ ~ t m t l ~ n ~ .

&?a ReMdngthe QnTaion sWitEh r&r 9.7b ...and WithMnQ-thewhch'frorn

COW.,. the lock
 I

II

,I

-- -
:.aG-
&:at,;
. m!FMa!@m
and whhdrarv th.8 stelk switch WfwY
wm@ withdraw the asketmbly from the swring
column [ ~ ~ I l ~ i O n s ) .
RefWng
T5 RMlrig1s a reversal oT movaI. 28 M ~ I s ~ W W d d m ~ , W w
RefWng in mi~mWfollowlhg pnrnt%.
W m W p e stalk 9-h a
~9fftbng ISa af mw.*frt the $9M t the ~ { O / - = B Q Pla.W with
3 6 P r d w d as, just wcrltred. ,fdr the M~~ whml h s c d w lnChagtBf fa, referehm-teW e n 24.
Qhtln$dMon indie~~rltvom etdk witch. 90 EnSure that the,Jring Ls muted as noted
RadWarssefte pIaW tema€e during mvad.
g0mp/& &/k SWH&iwzwmblY mntd sw&h 3-t Da no3 fuUy tighten the switch damp
aomw mil dw stmlng wfumn h~ve
&moual Removal been @w.
$7- &noye %e steering whwl as described 28 Diswnn&'Che bmery ne@tiva k d .
h~~ IOh 24 Remove the mdhhssetet pla@r as Fsols-mounted M r ~Whhehes
TS Pr~cwd as dewibad In paragmphs 11 dmcflbeled 1n Sect;trm 2rl. M,scmnec! 'the Removal
and 12. remotwwntrd switch wldng pbg frbm the
19 Dismnnwt the wiring Nu@. from .the rear of the Wljtjw Llltl-dm). Sl DIsmnnecl,the b p y mgatkre'leEid.
~~~
.S Wme appIiaabla, slide the rad(b/&&ttb
25 ~ W *ha O-Lng
de2pfibedh G h a W 1I,
mIwmn shrouds,*
'SeCtj0n 29.
33 U&W sMdrlvoFs,W l V p r l s h l the
mwitch3a'd~#Wgm* e W €&ng mre
l$rhW~ n t r oBWIIM
l from the:bracket 26 Slide the swltch from tfre bra&@ on the not d a ~ & ths*ja:~m (8- mu.-
a& switch~rtswmbly. &talk sdtctl a ~ m M [me
y indmtton), 34 Pull the' ,shvitrrk Vr~m the fada and
;W@kTng Y tM I p of the switch 27 Fwd the wiring thmugh M bmbd the d ~ ~"8. ~
b~mnnthe cI&p ,W&W, thm trim notim Its w m !8d hw R c ~ . R-0
35 Refiitim Isa r m d ofr~movad.
m?@,r*&w-mw
y The ,packt$bt aim sid]meot anml,
hmas h
a
nd a&Mtor;s fpm a cofnplMa
nu pa* we avdiMkseparatBEy.
~ ~ ~ ~ 1 8 , ~ ~ '
Jm.m@ntmmb ?/Iumfmtidn
ija*l
I
Removal
37 M m n & f h s $ a t t e r y q W I& L
b using a scra~ldrl~ai, s&uIty prl* the
sw&h wMng from We rear pf the phm
8.28 Rmovlnd the ra~rRol~ilssette a l the fad.faking care not to
~ ~ M r tfrom
radIo/casmtte ptawr remote control swm
i damage W W8 ttim teee IlIustdaal.
 Body elwtrical systmi 12.7
h
r

&$q' P W R ~ ~-r ~ &

rrbmWWe 8d6 ....them p u U ~ ~ ~ dmr
m t &
b & Dl-cti.~
~ I the wiring Rwnthe
s a ~ y itch...
~ w luggage compartment light switch
39 ~ u l thk
l Wtrpl from the facia, and tha body f o r a w @ tofie mar oFfhe4wRch. 3 ~ ~ & k r n S r u cf o4n w 6 @ h
d l s m w t h e $ring plug (s- Hlmrationl.. 50 Drswmned the wlrlng plug from me hdder (as.9 p I I d l e J . &JwW BW @
swltch ~ ~ U l ~ o n ) . dm me~-to-m@,.m~ct b h m fhe
m n p l bulb confads and th&pomtacts &I @
W Push thw swltch altlt thmujdh tM rear
40 RefMng is a rewersal of mwd. quartcir, trim parid, and remove it (sea mdEor M , m d h.k&J
C*gCIQ%tl hm47 ommtw U1-I. plug. ck3m &my cqtwrn w \dirt
L A
I
S-m
41 ~prt~CEhapbrll,%cfionl6.
R-hg t$
bebm mfig a new bulb.
i%shthat the new bulb& dthaaumf
52 RefIttinQisatwew1of removal. -4 and tkt it fs comple&c)een
E W B Whdow 0mffh3 Q~QWBWlight SWM kh$ &f7Q; fhihls zjtp~ues~ W@ R
smi$ms n d i g h t W'@.
S Tha glovebok light SYvitctl is incorporated
42 R e f e r f ~ C h ~ Y t . ~ n l d . In the gh~eboxIwk.str1k~.Far derafis see Headlight
Chapter 11, W b n 28.
Coumsy light s w M e s Removal
Rmwd Map mading fight @&h 2 Wohh,~In the engine ~dmpiutrnent,
~ h . s0 & b wz l e d h t h $tom door W The map W h g light switch \&lntwnrl s q u e m the reMhlrjg bHp[3] Wig. m O V Q the
. wlth the rqpf @r~!@l~,'ard cannat be rmovbd plastic Wer fFcnn the rear of the k d H @ t .
pillars.
44 DImomegt the battery n-va l&d- 58pamtJ)r. R e r m ~ ~aitd
a I rerfifting d roof 3 Pull the wlrlnd dug from the FW af the
46 Pull the rubb-efcoverffom She switah [see canshfe @anelk dsscrlbed in Chaptef 14. h&Ul@ht b.ulb(Se8 HIu&&M1]-
secdion 27. 4 Release the bulb retming spring clip.
EUw-uw. Grasp the bulb by ib madts a d
4 9 Carefirlly pvlse l h <$~ e h from Zhe daor
qlq!and di~wnneettho wiring plug b e withdraw It - from the Wadlight .i#I(W li
iIw&sWn).Takci c&pnpl to allow th@ wlrIng r ~ ~ ~ .
xo:qr!rop @awninto the door pillar while ther Refitting
swim i~ -
mW tape R to tbe door plllar If 6 Whm hartJtlrr~Ms new bulb w4 tkwe
.n- o r . o h cl?h to mld'fw~hif g the$- 4th
Ra!- mmm1 h r n @ m ; m o p m and g m fp ths*n
1 ~ ~ ~ E s ~ ~ v 1~
Q ~e v ~>a ~ Y or e w ev d , not@
wbulb ~ the
~ .
L
4 .*
cap - + , ..b l d m i i g andl 4&r
A I!uppfpfb

Rmorral
48 D M p m i W the hf?w n q d k Id.
49 d'pen the taItgat&. Pull the \ w a g e
cimqwrtment right-hand f de trim away from
12*8 Body electrical system

%1 W&Wr$gWsiideK'#tl buIbbotd& 7,1& ~ o ~ ~ ~bulb from

~ the
~ &7.t4 Rsmwhg
# f at PMlrt'BireMbnwadleatPr
bulbhdd~ Eght bulb- 5" niodet
hdhflm is a rewrsd af'movaf. Mote thai the brrlbholdsr Is in p d m d l t i ~ nand 1s Front.d f r e h n I n d l w . s l c d s
?&WIEght cover is r8Tittw with .mM-oldt WtrWtfyW: ~ ~ r I j y h 4
%&k~lflhgmt the bottom. I S W the M l $ h t muer .with Wout-out ~~~~~l
F&tdde~igh l fw €heW h g at tns &OW.
18 Carefully pTl$e yB light unit from the wrn
Remov?3f Front direciion hdcator light m m ofithe h n t (rfm the wing m d
mrnoval Ftselflas ap~Il@blaI& RlustMqn),
It %rkfr)hl lcl the m g i n ~mmpmmf, f 9 Twlst €hebulbhotder antI-ctadmIse,id
Qw< the retaining.ctids)and m y %€tie I 4 Dn rnijdela where the bubhaldar Is w l m w # from we w of !he Ught unit
p W c CQW ram #B rear af the hmdllgM. acce~iblefrom the ,engine 6?mpaytm4nt,
8 Pull the' amg plug ,fioh the rear of the twist fhs bulbholder antf-clockwise *mu@ a
sWQMputbhIder.
zz!:!b
quartet of a turn, t h wlmdraw tha (sae tlfustratlorr).
lla a push-flt in the b l b h b l w
r
s T.M@pe buIMrdldw~an~-docK~e,
and bulhhald&rl t i ~ r eiliwfmtbn).
r m e it from the mar d the head&# t 5 On s o w rn*I's> acm.to the b.ulk- R-g
m b t y (seit nlusmmnt is mtp8blble m'b mlnemgaxlh 21 bfitting L a wwd of revnovat.
I b %'bulb is a push-lit In the bulbholder mnt. W o v g the light unit as d@ddb-M In F#nt W g g M
ilIusWlan). Se:1;t1M E3, then W the bulbholdsr -etntl- ~ $ ~ ~ d
-hg cl- rerncwe# IS& ni.-
96 mebulb hamon& fitb&@, &jut~l~l&~, U ~ S ~ Wthe SecutW,s ~ m w s and
,
I t RaflkIng is a rev- d movalf b d n g I'.mwethe ItgW fPgm thq Wont bu-r Isw
h'yWt?wb l b w i n ~m. R a w ulusmton).
12 Ensure&& therubbw seal an -rear of 47 Refitting is a of q - 9 ~ 4 . 0 W-nW~eHrinsplWcseFt~,

?.I6 - front W o n ~ndlcator 7 . 3 ~h - t h e - w o " idj*& ' .its.* .r;em* .-.,:-. ~ b h ~ i & ...
liIJltbulb -"'Phm '
1 mdd repeater lightTmm trim *-.
.1

7.m ...and*rawthe tsub 7 2 U ~ l n g . a f r W t t f o g b M ~ r r g 7.23 PIBCm-n 8 frorrt'foallmwiring

 Body electrical system 12.8

7A?QUnswewfw.a~ ~ l l g f t t d ~
seourtns nut

- --
7 ~ ..b,mid r e r n ~ p p + r
m.4~er 7 . ~ 4P&Q the high-level sb~pIIQM and&4e-tke~h-l&&bE&t -
brdbhbldW access colrer from tha tallgate trim pami bulbhbldsr
24 Twht the plasfic mver mtFcJockwlse, 50 W&khg 0utBIde the kar, tllt the Imt M The twree NIP&are 3 push-flt In the
@w3th$r@wItfram !t~e.rearafthe lQhL ctusW.and lllt H M m the r&hfngAh!gs on the bulbholder &a8 illustmilm].
.28 Dhsonnect the,Whg from % mr df; €he body, DiSmhnecI 4hewirifig plug. Refitting
wlti., 81 Squeeze the. seurdryy dlps towards ihe 37 Rewtrga buttak?
2b Release the b d b M n R $ sfirings tip, then centre of the. bubhddw, and IjUH ttla
grgsp the bnl b by It$mntacis qnd-camfully Pul bho!der fiom the rear ~f the Hght duster
, to ?ge tht3 butbs ,he
b ~ o l d $ Is
r I$fltYed.
&#&ahfrom the lightunit (emlllustratim). (see l l l m n s ) .
32 The bulbs ara a bayonet M in thet R88r H U - ~ lchf
m m troldek.
q When handllm the new hub, w a Wu8 RemQval
&aleair clath fb wold toW~lhgthe glass wiBl Rmg 38 Ualng a gcrew~jdvar~ Galafulty priSe.tb
the,l%g~ r ~ I o l ~and
# from the skin j3 Refrmng is a reversal of removal. number Ugh! W b l y f@m'b31'&W
m cause Maolierhg and q d faihlre of this Hlsh-,EIFI Otop lmt qIqg
In -the bu-ypy.,Dlg'con~cf.,~,,wI~~xf!.
(meil~3mtim).
of bylb'. If the glass Is a~cidentdly
foucfied, wipe It dean d n g mkhyl9ded spirit. R m o v d $9 R e l a m thp wwh-9tabs and undfp @
W Mttfng &amvet.sal ofreyovat. lensfrom the IigMmearibly (mi& M d r d 6 i 1 ) ~
w O P $ ~the W1g-j and v@ aam*s a mpulj tb,bylt)lftom itsme*
, R M IEght
~ dptw cover hvrm the t a ~ ~ g ~ trim
t e panet (see
I I J ~ o A ) . Refimng
Re#mVd 35 Deprass the Wo mewing eLps, and 41 R e f i m I8 a Wve&id,of m w a , M s U E
2B Opm the Wlgate, and unscraw the rear release the bulbholdw from tb rear of the ?hatthe rubber seat Is c o w l y katd when
Ilght c ~ s m r i n nut g (see Illustratbn). light unit (seefllustmthn). reWh'6lthe MS.
12.1 0 Body electrical system

M 6fanaouetha cower from the courbsy 8.3 ...for access to the bulb &6 Removing4M g l o v h x light
llght ...

:@mw
I M r 8 a Section 'l.w g w h 1,
*$ttWy /&ti€
? .WUp thb -\rep fmm the roof wsnsde for
W-ZD the Nth[rree I l l ~ o n ) .
? Is w push-flt Ih its contacts (see
#TiePulb
IptWfon).
.1%,Pull the ashtray and hwdng frbm ths
i&%am~e. Worldrig ~ 1 w fhs
>m &TmoamJ6 [see Illu&man].
13 Djsconm~
h ~ ~ r
panel
push the clgar&e l i @ ~ t w m ~ t l n g fmm
+hewlring fmm the ctgtdte
light*, and d m any wik- mounted In the
panel (seeV l I M o n ) .
14 Wotklngat the r ~ ?of t h e c l g p Ilgh&r,,
-
a ,
m m,$th"$w& e --*
Removal
pa- ,

1 R m e h e d W o n indlcatw Ilght unit, as

UwirbM law In thk W@p,n?
& M h g 1s a revemat of removal. pull the plastic uover from tba bulb (&
B'Rernove the radiator gtille pane4 as
IllustMonJ. desew1rt@kafm,rll, "
16 Ustng a small screwdrlrrer Inserted 3 Workfng at mr of the headlight,
thmugh'he rear of the bulbhot&, push the squeeze the ~ a l n t n gcllpls) and remove the
Ita cantad%
bulb f f ~ m plastic Mvesfrom themar of the hmdllght
I% Push the new bulb h b the bubholder, 4 M a c g ~ m the wMrq plugs from the mar of
IjWp-Wsht Ohen'memWe & ~ l the ci@Me ii$W the h d i g h t and sidelight bJbs.
refit
4?Ad& -My from R
k k i w b n irl &n@ a m v w of €he morn1pror;e$um
0
X.*
p@&-q 0- U-nJ.
~ l b - 1apusti-flt
s In b cantacta. AaMmy iUumInaffm bulb
5 On models fitted wlth a remote headlbht
ah adiudmmt control, free the actuator from
the r8;u of tk% hdiight, by twisting the
-@: Is,arqmal of r4movd. 17 fhtf *@ray sWw xhb q s Hlminatlon m a w ivltfrcl0~kWhand pulling it slaarply
bulb as the ~1weWeIIgMei. R&r ta IQ the ball@!&.
B
- comflcdment light pa~@raphs 14 to 7tk.WdeWh 6 U&c$ew the three upper s&rg Ww,
~ $ h $ r ~ - d u m is as dmrlbed prev(ausly and the slngle fwnt woyring m e w , then
~ P * E ~ ~ X ~ < ~ S M . C l W inurnlnation bulb
~wl~hdmw~.headllght &m BlwiWMi~ns).
18 Rembve the dock, as des,crlbed lh
I--t p n e l HIumination Se~tron15.
.an9'1#arnkngMght bulbs 19 Twlsi the tKllbholaer anti-chkwlsq aNd 7 Retittrngkamed oj,rermwal,bgtwtrena
pull It from the mar d the dock, apa!l&le, take cafe not to daritagb' thb

.- I

8.12 Push the cigarette lighter rnouriiing 8.13 ...and disconnect the wiring plugs 8.14 Pull off h e plastic cover to expose
panel from the centre console. .. the cigarette lighter bulb

i'i
optical &himequlpm~lt.This & ~ k@fl b
h w l g h t dm aqustment actuator baltiolnt
when r & n d n g it to We h&lbM. card& out by a Renaultdml~or a wiWbly-
e, ulppd g d q e . The b y ~ m@ignrnent is
rn,rnIaakn't +!justsci usihg *the two r m w s provided
8 00: aar&hn, the headlight beam the FqTit unB IS& Wmtmtions).
6rgm& ~Fhutdbe ch&6d, Ideflly usins
Removal
g Rembve the bennet and 1ha:fWt bumper
as m b e d ' h Ghapter 11.
10 'Unw6w' a d h~??rrye the t h w upper
fiq+ltghtlfrent dlredbn Indieator unit
mWfrFg W k (seaIllu~gtlon).
11 U w w the kdlighUdimtlan Indidafot
trorrt 7&rin~ Wit lsrhe lllrrstmthn).
12 Squeeze the locatins allp tang% then
loher t h h$adllam/dlt@on
~ Indicatorunit to
allow the upper locatingdpeto fi&s thmgh
Body electrical s j r a m 1241
panel,
4 8 Where applicable, disconnect the wihw
plug from thq h~rnimt dm qdjudq motor
(seeUIuWatlon),
-14 Dlsdofinsct the WjrinQ piu' ffam 'tk?3
dire& indicator bulbhold& 266 & ~ * u B
the pl&tfc cowl, grid dkGW$$F
h'@dlight and sidetight bulb ~l*.$,'flug@,
wtthdrariv the headRgtiVdlWan Indiq@r
(wiU l l I s t r ~ ~ n ) ,
Refitking
1I5 Rel'Ming1s a mwd of remwab
eganx alipment
38 Refertaparagraph4.The beam adjW
med WMS me shown Tn W -mprrnyiQ
Illuemions (Ilu-1181.
12r12 Body de~M'mI
system

R4m0Vd
a4 Own the bonnet and disconnect the
moml b- nqathtelead.
17 O p n the b+onneiand dlsmhnwt the % Unmrw m t t w o ssauring mews fm
Wev m t l w lead. tliefmht of ttnr faglight, then pull the light from
tha Qwnper, and Cfkconn^e@tthe wliin$ plug
(tmIltuSmhn).
-R-F~
.
28 Fl&tllng is 4 p a r 9 1 of rernovhf. If
We WM
!mma~safy,~ alignmt of the beam
wiring plug from the b,adjuqI4d by ttlrrring the.atl1Wment
WMWer &wAlustWh), m w ,
-
5
20 hefitthg Is a rmmal d rema*. Ensure
the, W B & ~ B T k~ ~C O ~ ~I & RmovA
O ICYB ~ ~ of the light-dqsterw . 4 - e n p g e d wfth
tatidywrl the $5 unit@ t h w ~y. the cami3psiYdlm.IdesIn the body.
27 O w mihe bonnet and disconnect tfm 34 Make. s m , that the wfhersgal Is
batrsry nmatlvel a d . mhW@~ ~ ~ W , M s l6 l W g mMd
28 Open the tailgate and u m thahe-placltlc the body.
nur *mi m*.D theffight clustar.
mimw 28 W@hdrawthe llgM cluster from outside
a , ~ a o o n a w & e wnegatiw t ~ . the car, M n g k&e not to the Rhm09l
2Z: Gmif~Ilypfise'kh~tight unit from '&Wm rdalrrg lyga a€ Mhn ofthe tigm then
36r,Ofpenib tailgate, and p r b the acceas
#ate on the front wing, w lfom Yhe Mrg dBmq&d.fh&'wl+IngW 6- I h s t m o n ) .
b e ti;im p&hel.
m, aa apdkabla bee ~ l f W o i r l , 50 Wereapp1Wte,dwd the wiring thwgh
~ W m mW
.& bqress the two securing dips, and
fha'grOrirm@th V14bottorh of the light 6IWbr.
,

Withdraw theawmtrly from the car. the bulbho#dwfrom ithe,rW bf the

univ @aillusmion 7.35).
Rwng ST Working !mId.ethe WalirgW,et ,p& tower
31 Re4Mhg'fs a mveW ~f fmm~d, W g &fge-pPthe light unit,d m the twa pt-c
Ih mlnd the bltowing poine. m n f n g dips. Push $e Mght unk out pf the
Where appl!cit@kmkke sure that tha tall&& sllgMly, then depress fhe .two rnef J
WMng grommet is cormtly p d o d In W retaining dips, and *dray the ltghr unit
bottom bf W e , M t dustw. frnm outside tha tag& (seeilludWons).

$25 hitYoIfllgM d h q -.# lv;& DkmndhgaWtfng-plug from a @.37a Dbpwa?hetluo ptystie rebmhg
and h a m Wjwlment:sww (B) ~W~HQMUIIR ~ w M W . . .
 Bady electrical system 12 4 3
II
I

I
I

b
...
I

I Q.Wb Wen depress t?mtwr,meW r u a R&eazMg B co- fiWassmiW I& 8~-.m-mw "i6 WIWW lbhl
I r&lnkrg.@IM[ m w d and withdraw lhe m m g lug witha ptus
high-levsl stap light
Retittlng 3 Pull the adjuster -hose grommet from the
& <~eitttIngis a reversat of remuval, but
bulkhead irrta tfw c;arrInterIor,Menmanipkllata
Map reading IIgM the actuators and the hoses thrwgh t b hole
m e auq the plast1~W'nfng clips are 5 The map mdlng light Is Infqral with, w e In the bulkhead lrito the inside of thaw T'al4e
oonslFtIy mg&ed. courtesy &$it as&^&!$^ Aemwal and rdMIng no@dtha routing of t h e m
mar number phte light mrwd~atlbed@wv3oudy In this Sedan. 4 Withdraw the assembly hoh' th'6.q.
delrtlawal QJ~ebox
!&hi
WUsing s screwdriver, ramfully prlw theB OiscPnnW b b b&ew nwative W.
laght unithm its location R the bhmper,7 Pdse the light from #s loeation, afid
99' Mf~onnect
the wWng and vyithdraw the djwnnact ih&wltfng. plug.. 6 Route the hoses h n o w during removal.
a ~t&rdng~ s a r ~ . o f m m w B t 7 Take m e not t6 damage 8-te Wtllator MI-
ldints w b r t mannechg then9 b, the
Luggage comprrrknent IMbf hmdllghts.
B Pim&d as described pmVIoyely for '!he- 8 Make sure %at the bulkhead grammet Is
gtaveetox tight s d $ ~ ~ .
9 RMt .the W a r ' s sidetoy fads p a d dth
refarmto Chapter 11, &dbn29,

Wdmy light
1 Dimnnad$hhMwy nqqiiw la@.
2 On models with, a separate courtesy light
,Mae the
end ,no map reading light, fiwefu~~y
Ilght assembly from its locedian in the roof
p&, mddismflri9ctthe wlrlng pluqs. Removal
3 On models with a map readlng ljght, batte'ly nBg&IVB I@,
1 M$&mWt>tb@
mefully pike the. cavar from the light 1 U&we thq d r l i e h $It@lower fa+ ~ d 2,Rmave Meshwing c o h n shmuds and
fqsmbly. Using a mwwdrlver, release the a d w b d h~ chapter 11, Section 2% the faole up6~r'fi;impd#el, 'a@tlemlbd in
sekudii ,lugs dnd pull the light 8ssernMy 2 Workfng In fh@ wngine c o m p q m t , Chapter 11,'SWon 20.
(camdeb with map readmi d
m and switch) r e l a w the 80tuaer ,fMpeach headl$ht in 3 Unscrw the T a r %cMim sctew @o
kprn'~er&f caned8 b i s o n the
~ turn by tdstinb m 2 1 - ~ ~ u ~ h epultihg upper and two lower) (see tllustratl~s).
and,
wiring phg.and wjthdew the Ilght-unit (me sharply to re- the ballfoidt [h 4 Pull the instrummt panel- f fCpm the
illustration). fstcta, at the same time dlscon&lng the
 1\244 Body electrical system
I

1aAb ...andthe~ometerQaMefmm lll4#mlQ%I).

the rear of -the hmmentpmel 4 Raoh crp behind the pand and d~~
Ww'plwand the speBdometerr rnb from fnsfftrments the wlrhg @u@,Wnwtthd~awthawel from
YhMH $the assembly (see IUusmtima). the facia.
,, ~ ~ p W b l dmnnw&
e , the wiclng Dhfg Remohl 6 To m o v e -ffie Qo?yranents f m the
fm the sw& wmr m the end of the 5 Pull Ohe trip meter aset buttefi from t h a
+ernam *a. frpntr Wth@'$hsf~fnetIttrpamII
insthnnenl panel, proceed as dmkribed 'h
,Wlm13 far the main m mmw.
S W d ! ths.mml;fromt ~ l e k b . 8 Wurkirtg at Wmar off he tnsmrnm panel,,
rsmQQva th@f&cgrifigscrews, or 1'61- mmm,
securing dips, as appIIcaM0. Withdrew, ?he B 'WlhgIsa wversd of removal.
8 Refl- is a seversal af m v a l , ensuling I ~ ~ d o v assembly
er from 9 6 front of-?he
t#@ all uvirhg plugs anel the spaedarneter I r l r n e n t panel.
7.Redowthe apprciprlate sdacutlng screw
.db not filly tlgyen h
tmg \frbm the rear of the padel, then wehdm fhe
~ p s e t t e , p l a y e remob
r wntd swlbh W&ument fm tlw front of the panel (see
@amp.scrw untA thb sth~riii'gmlumn i l l ~ n ) .
$h@ds haw been Mmd.
Reittfrns
8 Mtting is a rave@ oj:rmval. Aower'Ma-rno~nbU
dock
Pdhted ~ I m iht a d Rem-I
Note: M m pt ,shauId @<,*,i~
m V e I Dhcmnwith8lxit-b~ wative I d .
the @fed &cult board uhlW k8ib&Wi t& 2 R O ~ O Y B *fie r&~lwssetfe player, a8
1 Wpi Zh6 i m m e n t panel remayd as bg faulty, md b m&.mw. -d In W o n 24,
tksdbedin S y o n l.2~ - Rmoval w ~ 3 bmorie tha radrdhwte play# hwsthi3,
9 M o v e the lllumlnation md rv@nlrt$ tight wmdin Chapter 11, gectlonS,
b
Ria%ti ~lIrrrnhW&n 4 ~ea&-u~'b&lncithe d&&,and push R m k
e>mns Jlulbs Irnf bulbs, and the Instruments, asdescribed
gwkrusly in this+3&an. #rouWW.lrqnt ot the fack
8 mgannadt the wtrinQ plug and wi#draw
!mwral 10 The drcuit board can v w be uncllpped
2 Twist the appropriate bulbholder anil- from the re8r d this IrrstrurnW Mml, nPtingo the clwk
cki$Wt%, and Madray It from We plnted how H 3s located. R'effttfng
klrmlf b&d an the mar,of the'l~trurndnt R a m g 8 RifMin@&a rewskd oYPermW,
panel Ws Wusmon).
8 The-,bulbs kannlrt be weparatea from f he 11 Reflttim is a Wm,S&J of r&f@v+l,
r e m W M g thaf the dmuR h t d Is mile. Upper i9damouM clbck
bulbMWm Ensure that It Is located as- -n, b e f m 7 No i n f m o n yas ad&!@ +lng tha
Refrmng removal, and that It fits earreetly ov<r the removal aiid refitfig of. tba upper fsrcia-
4m g Is I ri5vElrS~t0 T ramoval. wlfmSWnII+t~[B at the tqp afthe' pmd. mount& clock at the l m e nl M n g .

isz mamwinqn -I ,ja3 &bw,h@i@&a,m-

bulb --wd- smWs(aro~-"~~ualW~
8QGdwm W B (8)
 Body elwtriml system 12*15

-w--
73 for ttf6
I f i e - e d e w i b & . l n .&d&
\

6. Working thraugb the cig&e IIgMw bulhead Jnto f he p m g s r jmmpartmmt,

amturn damesfhe m&inh has, and DW f i ~ n gW ~-l!$t!3mA@3.
- th
$ . - ~ w n w j mwnw
a in the bottom of the the&I hAuslng from the G&&sun&nd. 5T ~ n & o f t h e 8 ~ ~ r o f h ~ e h h h d
I&-M,Worrnhror. Pwh the huslna out thrnugh the front of €he We kia,,theit fedd thp
q?b@,thr.g,~~iF
4P 3 - n W v 8 . ld. ,*.blI~ -4 ~ieoni7- M a end wlthdmw It %rn the Mk ',WMrb
$&&if, a d ~ 1 u f l y prlse tm 6 : R e w the myilng luge; antl push the ~ppdlcaMe,take cam 'not. to. damage<the
n&$p%khr ,panel from tbs fmnf edge of the p J ~ ~ ~ u *my&~ ~the ~front. .of~theu speed
t sensor unit on the~spWometwend of
&;,\-, - ' memiling,pern&isee.nfWon). fiie able.
-w mmw #
7 Retirng Bs si xewsd.PffemvaI. 6 FWtt3ng k P dr ~ ~ ~
mi$ ffi&fOUowing.po&
,asn
r - h u r a k i :w'wI@wi&mecl
~ w
8 Fkthove the Mngle securing screw, and bdore removal, mi bs dnot to M d $ r
wlthdraw the sensor from the m h r , feeding twist R trstwaan we bulkhepd &the rear@
WMne throw the mirror bu&. the hstrumeat p e t .
-w 8 Ensure that the bulkhead gFqft'q@t 18
cmectiy located.

Removal 4
m rr~ a l 4 W&nb& W wlr?ngf@mthe horn. I The wiper mbtor should ge -In the parkwi
6 Unscmw the secudng nut, and withdraw
1 W W n M the W&ry n-e led.
ihorn from its tsau@lMWket.
podtton before mouhgWwlw arm. Maik
2 Pull the wMrav and h~usinsrfrom the t k the, podiitpn pf the blade en the glass with
m&e &e. warkingmrnugtt t i e r afserture, MWng a$heerlera~,as gguide to.t&kllng.
wsht h e d e U g h t e r m o M i n $pmel 8 R d l t t f ~ a -rsd dm m d , 2 If both wlndscrein wiper arms-areto be
the am c@hme. removed, ldentlfy them so .that they can be
B Eli~ccmnedthe wiring plugs from tha mfRtqd In theit mind p~$lons@e arms eue
cigarette Ughter, an& f r m any switche~ N dlffwmt hngths]:
m m W in the pawl. 3 Lift the hinged cover, and remove the nut
4 Remavs the dg-tb lighter from 5 k sm~rir!~ the am to the splndk (see
iHustratlm).

1 Withdraw the Instrqrnmt p e i from the

facia.and disconnect tM 'W&&ebr cable
from' W@ r W B t h e r @ ~ i ,; @ J ~ @ o T ~ in
B~
W I b n It
2 WorWng in the e n g l p compartment, uncllp
or u m the end of t b i spWomgter &I&
from Phe g-x or transmission wslog.
Where a p p l W e ,me how Me secming dip
t431- :an #ig@rboxiftta~18~0~i
@ ~k&
seV@ d #mQp ot'ctib:
;* are !@dm
a Wyttl~,~behind t hleft-hml side .at he
uIemsd,fKun fatil~,'tww6spspwoln&r cabk\@mme%
arch splash in,tho buIWd.
4 WI i h e g m m e t and the cab19thr~u* tte
1 2.1 6 Body dectrical system

- $73 D* iink pns&ned%'r e-@f

as.L..," -., ,,,,
.....
2,%&:-&@tm --&#$ht
W l ~ ~ * , v bnkage
~ ~ d HtIJI*
mofor I*plug *nib& matar tower smurlng bolt
4 PuU~otprTbthem from therspindtb, using 9 N ~ h w t h ~ a W m w y B m o u n b e
und? h ~
a.aprewdrlvep A qm85@fy.Take m e A a t h body brackets, bight-hand dnw models,
a&
- i+a Q E i % l 0 m w ~ r k h-tighhand 6nU of Ihem@rnMyi ~ m W
under the bra&d on the bo*, a%d 4% f&-
4'%- hand end Is nlountedWMp &bbw!d)
8 'Rdth'rggts e reversal af remat. PasltSon 10 If r&-W. sar8flrlIi remove the
~ ~ ~ ~ ~ b a l ' t h a bdl5nl a wm
d e th
s mpp Windscreen qwl bane1sewriia cnps from the
applid to the glass M o m removal. body to Wovlde additionald m m .
I 1 -k&pulate t b -mb@ out p " g h U@
rlght-hand slde d the scutU~,Wi#g ckre not
te damage surmundigg atrrnpnmts {b
ru-n).

l e W~tting5s rsveisald removal, B M ~

,Rt,inb~al In tiiindt b followind POW. 5 unscrew the^^^^^
4' Makg sum #at the wipb am park& 13 Emure that the assembly Is i+~~ufit#d on mmekeit tow ~ ~w@dtl!ytfie
8 .
2 a.mnm.tRebmiy n69atks lead. the kbdy ,mIie? as
& n p d b e f y ,y w a i , motor and bracket@@s
a Rmtjve t h s windecresn w@er wme, bs I 4 Bekra reflttlng the mrlndscr&n CONR 8 m n #
a@wh.W@n $0.. p- _twmt W drive link and the,spJndles by
4 R W b he rhrlrl&W.N! gmd~k hami to he parkd @wi!bn. 8 ~nlglsam~klrwnoval.
C1wwdm . am~<lil: 1% Refit "the Fin+creen wiper a m with
5 R O W i the $murin$i$p (full U ~ M W S ) ~refmnca to m l b n 20.
Mgmect the wl@;$u&from fh0 @or
(- -1.
b U m m the aeCum,w,and remove the
car jack from it6 M i s n on the right-hand
sldaafkeS@kk Ruid mmir
7 To prwldeiImproved dearance fw remW+l,
Removal
y the motor and the spindles by
~ W l l turn
@&tho thq drive.%%@nn@tng)the Removal b. .
1 Dtsmnneat the Mtkmy,nqcativ@.-I
mwr,to the drive aw8)~approdmatety110" 1D m d W * neiJative I* g Rewve Yb windwpp wiper m s as
Worn Its parkid mition {a& UlWriali~n]. 2 Remove the tallgate wSpw ,m, as d&w#Bd h4wtioii 20.
8. Unscrew the rnot~rllinkage assembly &&bd R S&th 20. 9 Remom k e wirrdsc~reencow4 panels as
~~ d .or 3 O p l l f i e t d l ~ a bthen
bplb tune at.earn end, ~ r r orle
two lower bolts+d~pendtwon model),.and imtei-iortrlrnma,
, move t hWgab W#lb$d hCfiaprsr31.
4 .Unscrew the fluid reseruotr securing brrlt
w v CW-WaS.h@ WlU-m). 4 D i s c o m d th8 motor widn$ plug. 0 s iI[u&atl-onl,
~ thm lift thp m!r s@W
 Body dectflcal system 1%I7

- --- --. - -
a OW ttw a ~ & the win-n
ii 25.118. ~ e m w t a g
~-n~88har S M ~ I . R e r n W w t h e washer
n d mmle

I
B c&kfully pull the appropriate pump ffom
ths Wwpir, qlwl fl,*wwthe m w plug
and the h w . Beprepred fw ff uld 8pime.
-Ing

t l ,'Grsfully prke the nozzle From Its

mbhfhg, th& disconnect the fluid hbset
@!Gwona)?
m 24.8 &&as1
tfre:mdio/eaase#w
$P.Refiffln'g h a r e v m l of remevat. Tho
nbUle @ukbe a#&ted by hlm?rthlga pln Inti3 ~ l e y ~ w r l k rMugs
g
th6 ]&, and svjfveltlng it to .the re&lfed ffacla. DIscmwct ,$hewiring plqs and the 2 R m w a the four p m r b screws, then
pwiaon. aerial cable fim the bear of the unit (ses wlthdiaw tW Ioud#p&er .cover and the
-fl. twdspmkr from the housing In t h door, ~
Note' that @te'loudbpeak& Musing i&a l ~ o
S€wred by the four6wew (Epeailmmtlma,
8 l3pynnet.t me wirlng plugs gnd the erkl 3 Disconnab€ the wldm and femve tho
cable ta the rear of the unit. laudspeaker.
7 W h thg wltt Tn'ta Its haudrrg in the facia
tmtil the retathlq lups snap lnto plat%.
-g
8 Where,applie&l& mfit the wvas b the 4 R@itUnq Is a rwepal of rmoval. E M m
1 All the m~ldcawetteplayers hued to the sictes of theunit, then rmnnadt the batt* that t h p~h t k h&aing is corm&& poSttioRBd
GYcf ran& ham DIN standard flkhg8. A pair af n Intlm 440r b e f w rditdngth@k ~ d s m b -
w I?@.
r"Ovd~ellps, +t&able from in& ant&ain-
, m $ i < @ w l i i , wlH be k s m d for fqoval.
# Dkcmnej the b@hy negative bad.
-3:W h w applb@&, prirlsgt the M C :
c ~ lm
Removal
ftbmtheslk of the mdlal*aswtbplay#. B D i s o ~ n n the
d battery nagNw t a d ,
+;
-
I*, thq dl@Into the ha@ ,at Wb $id&b 8 Rmovethethws~n.gswewbO Imer
the unR until they snap into placs. Pul ihe screws,'aqd m s~rew'atatAddeneawst it^
'gps warwa~gs(away 'from 'the hcta). to
F n m t d o m m M ~ do@,~and withdraw t4-m ~ I &Is B went
WmeYha unit (we Illusbmhn). Removal 7 U n w e w the four 'loudqp~&er emuring
1 D i n m c t the b;tttwy negatlvm bad, Isee fllu-rl).
 Body electric4 system 12. t9

W m i W Etofa that the a m & -

must no;f be 8ubJectd b - .
_r- mw Fs
&@ dI that ~t c m g a _ W d
,errsum

WjsrgW agW&PwMact the

a ~ w m w m b t %ny
h must b 5 $lrj the airbag In a safe place, the wwet
way up, with M-paddedsurface uppermwt
pb k @ d ~ ~ p b k , l h e s j + ~ +

A Mairtiig: ff tTra -g
fo be
airbe ki
&ev&
whIIstst#eE#&$&v*&&
'*
whwt 'k
lo 9qt.W fie
k&erd
Is WOW& irs
the wshm mw'h~W&tW
Refitting
Warnin@ Do not re& the airbag
h unH 40 the steering wheel once
the W r f h g wheel has &en
mwmrlae-.
6 Where appllcabte, rewnnect the
wktng anneetor, ant! F h M trat We alrM$
wmning fight h fhe sb&$ M flab.
7 hntlbcf the R m l y dummy Jgnifion
bftw

Warnins:Po not attempt to test rnoduie "He. i 2 W to tjh @m;g wiring

the a m # d8chWl &miltusing cbnne~W,anyl check that the @rb@ -1ng
except fha Renmit
anything lIgM goes ouP,
-&,I test foah LMng a e~nwentionai 8 Dlww thp 9 m ignition ~ d u l eand ,
n r U r ~ o r o h ~ L ~W
Waw
t o reoonncsCt me'airbAg wlrfna connector tb @&
the
Warns:.H the el- has,
-
3 Dtscorlne& the wlrlng mn&w from Ule @ifbag rn*e wre that the m n w r ie
rear of he drbag unit, holing that the d r b g pshd firmly home. Ctkck that the shag
trfggemd, the w n t d upR must warning IlgM will dash onoe the wlrlpg wamlng Ilg!$bsnot wmew oncehaibig
mnwor has been discannWed (see hais Wan r m m & d . ;lT thb wming. ICMt
Warning: If the airbag is to b ramtion).
A renewad, the confro1 un# land
-*on mows wiw9th a *set&
~wr@MiraP".il~Mustalso be m n e W
4 )% prevent Qkin on the .alrb;rg system
bdtedes, Renautt remmm~dthat the a*%ag
drinp cannec* shauld be w n W e d to
comeot4,hWmmw4beWIngW
Redull s#;lal airbag test Wl )(RBAG.
9 Mit #w aifbag to fhe -st- wheel, then
r e f f i t h i m wLlrlrq.bolts, and tightan tu
Wmming; On mod& atred w f i a
A
4-
ae&mtahred airbag,
bettwbs mud be m d every
Thiswo~shww~lemrwstedtoa
the
Renqult dummy ignitlcn module "El&, 1Q88"
w w w twqm,
#CentmIR@bag ub#
M o w when R3fimg the *cwid"
dtbg unit,
Reaeult de8iW- Remuit motn&d that sped81 arb&h$t
fad %RBAO, w
y inwr@of+tes a dummy
fanitson rnirbilk El& 12%83 is used. H is
advJabb not to attempt the fdlovuh~
pm&dure.lf Ws q,@&nt Is not a@&kif@.
'Removal
10 Disconnect the b a t t q negative lead, then
Note: TO m o u e my' of the sirbag system *;ist fa). 5 minutes m r g carry~h~ out my
cornpa*& mnbult s~ea'al W tool further work.
XR&AGrwMch Imrpomfes adurn@ Ignltm 1Y Working at Me rear of m.-ng yd~&,
pdule ('TI&. 1288"1, will be t-@qulW.DO unswew the two both sewring the aItbag unit
NOT attempt any of the d o w l pmsdurss
~ p me stwrlng wheal. It may be neGessaqt~
if MI5 Gqxlwmd 1'8 qdt@dm. tLm bs stwing w f W f o r a & s s t ~ thwhak
[see illusbation).
*wnbhedR ahbag unit
Note: To @moue the W l f w : n @Wvg "
unit h a u l f recgmmend that +d a k ~
fest: tot?/ XRBAB, rirhlch fplcorporstes
dummy rpftlon module PBe. #Ha"), 1s EM,
It Is-&v(i@/eCpf to atte,mpt the followfng
promdumHth/s squlpmnt Is not a~f!&ble.
Removal
7 Working at the rear elf the a t d n a whed,
I I
u m a w t b t w a bits smurm fhadtbag unil
to the steering -1. It may be necessary to @
29.4 u W f - ~ n t a l n ~ A a i r b ag
turn the steering wheel for access to the bob. ~p0m~~WithSenauItdum-m
2 Carefully lm the airbag unit from the i&ion module "Be. 12880 conn+W
WMw whed. PA not use excessive force,
m d do not under any clrcumshnces me ZB.11 U R S ~ . .-.-..r*rp-,-rk,bdt
"~
shhp tads oP-tapthe &bag to mn-iom R - 'lcentraP alrbag unit
12*;?Q Body elgi3riCal system

kid
.-

12.lSar&rly oft me airbag mkt from the 23 Dismnngct the wiring plug 'frm'the rwr P8 RBOm?wtthemwirfng plug to t h W
~ of
$h,dng wh& (we illushti~n).Do not use of the pbntacl ring m m b l y (8- t h~unit;
exc~wiveforce, and do nDt und& ztnY ruu~on). 29 Rdit the uppafadlower'st~ngmlwnn
B W G U ~ S ~ use W ~ ~ tools o r tap ths
~ ~ sharp 24 Ushg adhasiw taps, tqpe the didlng shrouds, then'mflt ma tightq~the swu,rIng
atrbag to remow8, section d the aontact rlqg assemBly We screws
33 DlsaonnW the wfrlng ~onrlectarfrom the 30 Whbre appllaable,Terneve the a d k m
fiK:$d eptlob €0 l p k the rinq msbmbly Itl
m a 05 them,ag unR IIWtmtiwll. podtian. W J r p r ntke unit, Wing c& n d f o ma\Wma\WW
14Stwetweth Onqa~ ~ place, the &IBG
sede 25 U m m ihe three mtalnlng dews, and c~ni&& Dp NOT m o a t h @ . d% anew
way %p,with <Itspadded ayrfac~uppermost witRdraw the mntatring A&embly from the unit ie Muq*
Po not dmp or h o c k the atma@ HWiiuaIumn [ma I H u s M M ) . ar wt fh& &teem mJ wm r e f e w to
RermPna R-g $haw7 10.
82 Refst the airbag as &wf#b~I ~ t o u s l Iyn
16 ~ f l t t h g the drba , Ranauk 26 P W to t p n g * W l s n w w to mww thlh sadon.
i~,cheoked'~b1bw8:
B
m m m d that the operedhn a fh8 spWrI that the omtad unjt is mmdty m a l l s &
wlth ~ ewiilq
, conri&tot the t q af~ ihe ComtmI,Walt -mom&.*
@Rap~~eb@mvneg98ls'Uc unit. PtXiq the adbsim tape d u ~ h greriioval ' b S w W d PJ ~ B
Witch en W & n i f i q ~ d . d W &Wt the should ensure this (riew un& am fitted with a
S@ which will b & w h f i ~fe&q'R!mI
~ Rm-1
is turned fbr lhe f h t time), but If them ls any 33 R_pmmwttie akb@ unft as M d W
doubt ababaut the mntact unn pwitlon, pm'wh h $is W.
ins&& W. TZ@&*to tP1B-a&g Wng p m c d as Tallows. 34 D i ~ ~ t t a a a battwpby i ~ ~ m
mmtw,d ~ ~ ~ 4,Ratate~ +he cohtacfi
w uhit f lw m . e , l~ n dlsobnmng the d l bi&iQ-pin oonneckor
mnd;I i g h t r n q
r an intt-doo@&a d W o n d l 1 in *e gsntre of sfssr~ngwhaet.
16 SwItch off the'lgnition, then dWonneq WSfmceArn 5 Umiymv me t?rees bolts, and withdmvdthe
3
!
ths aDmmy MttIpon maduh, and reconnect b) F m ;rhis
point miate the upperw%m qmtml unftkamZhirMng whlset.
the air4q wlrlng condeetdr ta 'the a[*"- back u d i the wHkg &nn&~r t k
gositlmd at the top of the dt. R
-
m&q sure *ar WB a n d o r is p u b # bfiy 3 B Rem #ievwmmlunit SEl'fhesWf'lngw h d ,
home. 4
CohtYw WZumM,qpllwsWli In a
and tfahten the w'urlpgboltsw r e 1 y .
e to th &m*ngwhael, thm ' ~ l b ~ ldmtion
17 ~ * t t h$rb@ s e thMughwwnj3lete
thebatfay wiring mmedor.
re#A the secutlng bolts: ancl flghtpn to $he turns until the wiring eonnectop Is @n
s~ec$ed torque. #wmd at the top of the unit The unit
18 Sbrltch nn we IgniUon, gird cb&ttnnt the. is &*YoTM*, #is *ttm*
aj&g wmlng kht iflunllnates for 3 se&@, 27 E n m h t the
thsn %ilt'^tke
~~ iiiStm wtrahlW,
cpnwct unft to ilw steering
~ ~ 0 u P a n d auL ~ Y S
column, and reflt ahd lighten the t h ~ W
~wittrin0-WE. Removal p

Note: Ther aftberg $ptem share'd fh8 %W

mtibl unR as'the BW bdlf Qr&-3emtOmf
W Enmre. !hgt the afmrlng w h d ie smkn,
oentk&&%4$ih We rqaciwheei$,pointing In 6 €;iur~ that the, igrtttlo~Is switched off,
$f$& g & W @Ion. Do rSd Wk%tha +hen remove the seat tielt we,-
swtng, unUlW@mfi1b;t r?bg #apmbly hw tinston&r/almgfuse <(refwtu the vehl~te
+-
.
2Q Rdniwa 'thh alrbag ss dwcrlbed
hanpbook tor klcatton). D I m n n W 'WB
battery Maflub la,Bnd w i t 5 mlnum
prsvi~udyin *'Is hdbnp then r6Em the Wre o m g out w mer-
steering whwt with &imae% &a&r llh 40 Rehove The m'nfrg mmle ~ ( dg d t r e d I

ar Working under the stwlhg w k d , FCIW in Chaplwll.

se~rlnglsmews and WitilQpivrthe low^ 4t Cris&nti&t ftrer cpntrol unit wiring 1
steering edurnn shroud. amiledo&) (weifhrgkatf-1.
22 Remava rha ~ecuriq s c r m and 42 Uh&w ttp seculng nut?, and m mW
withdraw 'theupper &eawInq r&utim shroud. the conwl unft (sse1llmtmtk-n):
 Body electtical system 12~24

Refitting
+9 m
46 Rec&in&
r the control unit i n t ~pod ti^, c ~ n h m r 5thbn
t h e bntrol utlit wk~ng mf
~ refit the c8nM c a M . a S WIU) I -00-#&~
5;"m WHwks. mode&
-
wurjng that the arrow on the caslng p@tW d-4 m ~ ~ * -.
~ l
tow@& ttr8fmr of thkvahlcle. 4tl Refit f h e seat belt p r e - t e n s l ' o p e r 47 R m e W of Z h l '%&&re$ should be
44 RgRt and tighten th@d r f n g nu&. fum, t)ieh r&onn&Ihe k t h y n e g a t h k d . erjtmkd to rr RwwIt W"@
> <
,
12m22 Wiring diagrams

,i*fi~
-
A. 'CONNECTION DETRILS ENGINE FUSEBDX
FUSE RRTING CtRWLT
f 6R R.-- -*m
z 2Sl worpprdm%--
3 w m-ow
4 m Fe-P fP0n-t
6 tiroli fm
6 38R mina W M B
7
B 28R
m
m
9 *e
lm 25R &rptrat -w
U 6R M d k -tSrt#l
1m RHwnbsba
i3 15R CH Hahl biw
14 2BR F U pa^
is 38A l emd7&
Pk

PRSSENGER FUSaOX
FUSE RFlftAIG CIRCUIT
L 3w FPI ~lt~trr*irWlo*

--
2 1SR WFW np-
3 m IN W i c vrnBow
+ 20a hat& M
I 16R InhrW rdb, o l w m
3W1 kmssavk w+oH
7 1BA
8 IWI Wruh/n@a s.rwrt
9 16R croor-3
la s + m w

-
IeR
U im
l2 2BR w m wlnp,e l c , m m
D 2BR kTd w <dew and rnh-u-s
14 lm MWfmr + r m ~
16 ua ignHlan fe cam- W'gn
18 1cw DWjbn h d w w +orhw w*
I7 1m F W
w lm IH S w w a U lorpr;
19 lm W S W T Q B Sorp*
2e -0
a zBR Wntmr b l o m
-22 1m h d t q nlm

Notes, irrSevnd connection ctet.#ils, key Ta symbald orid w i r e r~lours

i!L \ Wiring dhgqms 12?3
12.24 Wiring diagrams
-
 Wring ,diagmn

I N I CO I Ic I 0
12.26 Wiring diagramS
 I
f

Wiring diagrams 12.27

Widng,diagrams 12*29
12.30 Wiring diagrams
12 ~ 3 2Wiring,diagram
12.34 Wiring diagrams
-- -- _- -

fl
Wiring diagrams 12.35
12.36 Wiring diagrams
Wiring diagrams 12.37
12.38 Wiring diagrams
 Reference REF.^
Dimensionsand Wights ...........................
.REF01 Disconnecting the battery........................... R E P 7
. .

,CmvmimFadow ..............-.............,...REF02
. .
: Tools and Werlbng:facilUeg ...:.....................REF08
~weral~ e p &~aoceclurm; ..*.I ...,..............REF03
I
. -
MOT Test Ctiecki ............................... .REF40
Buying Spare Parts ..............................REF*4 Fault Flnding .....................................REF44
Vehlcle-ldeMc&n .......,...................... .REF04 Glossary of Technical Terms.....................-..REF+22
.............; ... ...................REF47
;.

Engins~idmtTfieatipn .................. ...........REFm4

! II Index ;
wnd V & W ~support
~ad'tiln~ ..............
,......... REF^

/ Dimensions and Weights

: ~
~ o a e&/ 1 % 8 s r t t w & ~ , ~ & m $ M~ Y~ Y$W ~ @#&&m
-fO && w,w&st-.
Dimensions
N o w Exact dlinm3bns dqpend on mmM.
.....*....................... ..................
OveraiI length 97M to 371'6rnm
mim4 ......... ...... . ........
Overall width (excluding,- ; 1616 4 98114
~ irih
..........................
i
: ..... ........
%,

Overall height (unladen) 1365 to 1'3% ~ t Y t

Wheelbase..........,.................-............... . 247pmnl
.......................
L i i

Front tra& ,............................. ?of372 mm

Reartmk ...;....;..:.;
.................... ....;........... 11324b4&tmm
Turnlng clrde (between walls):
All except 16-valve models ..... . ............. . ...........* 10 3-metres
................... ,.,.................,...".'f 1.bm-
;; ; ; ;

l&valve models
Weights
NOW- wdgh@:w.Wb mMe1
rl Kerb weight Maxhurn gross vehlcle wefht
.t.ll~&e~,.;.;.;;A.L..i ....*............ ........,-. 810.to820~. I 2 5 0 to 12653 kg
lt&,Jki6:Wels ..... ............ ,...........................'8$5to.825 4.
-.-,..;.a

..-.,. . . l m t o 1275 kg
REFOP Conversion factors
Length (distance)
Inches (in) x 25.4 = Mlllimetrw (mm) x 0.0394 = Inches (in)
Feet (f4 x0.305 = Metres(tn) 11 3.281 = Feet (ft)
Mlles x 1.609. = Kilometres{km) x 0.621 = Mlles
Volume (capacity)
Cubic Inches (cw in; it17 x 16.387= Cublc wntlrnetres (GG; cmg) x 0.061 = Cubic Inches (cu in; In)
I ~ P PW M (Imp pt) x 0.568 = Likes (l) x 1.76 = Imperial pints (Imp pt)
Im-1 q m Omp Wj x 7.137 = L i d ) x 0.88 = Imperial quarts (Imp qt)
rmpedrJ ornp qt) x 1.201 = usq~mpsqq x 0,833 = Imperlal quarts (Imp qt)
us slue qkjw- x 0.946 = Wes fl x 1.057 = US quarts (USqt)
x 0 2 = Imperial gallons (Imp gal)
I W m gall- OW !@l x 4.546 = Wee (I)
Imperial @lons,(lmp gall x 1-201 = US gallom (ClS gal) x 0.833 = ~rnperialgallons (Imp gaQ
us@^^& x 3.785 = Litreso) x 0,264 = US gallons (US gal)

Mass (weight)
Qunw(04 x 28.35 = Grams (g) x 0.035 = Ounces (04
Pa- b) x 0.454 = Kllogtams (kg) x 2.205 = Pounds (lb)
mree = Ounces-farm (ozf; oz)
,Oun~~kfwc&{o#; x 0.278 = NewW&(N) x 3.6
~ ~ & f uW;mIb) x 4.448 = Newtons w) x 0.225 = Pounds-fo- (lbf; lb)
x 9.81 = Newtons (N)
(N) , x 0.1 I Kilograms-force (kgf; kg)

Pressure
Pounds-* per s q m ifk& x 0.070 = Kilograms-force per square x 14.223 = Pounds-form per squwe inch
(psi; I b W Ib'Wj centimetre (!@/me;
k@cmq el; Ibf/inD;iWnT
Pouncfa-fwcs per qW inch x 0.068 = Atmospheres (Wn) x 14.696 = P ~ U t & - f a r a e p S q ~ l n c h
W; ll3Mn.: Wilq (Wi; Ibfnn'; IM@j
P~u&-L~ inch x 0.069 = BPlrs x 14.5 = P.Qunp,WrngeIrqwh h
Mk IWV; MWt3 @I!bt%n?'lh@
;
Wunds-force per squaminch x 8.895 = KlIopamb &W x 0.145 = P o W f Q WW a9uw i h
(ptWe IMw W; M M Im?
-iK pa) x0,Ol = Kdog~$ma-forcepw~uare x98.1 = W l ~ l 8 ~
amtrmetrs W/GW; WmF)
Mlllbm (Warl x 100 = PasmkSpa) K 0.01 = Millibar (fnm
Millibar (mbar) x 0.0145 = humh-force per quare.lmh $ 68947 = MIlIlbar (mW
@I; WinP; IMr$)
Millibar [ m w rc 0.75 = M M l m W d mmui‘y(rnmHd x 9.333 = M i l l i b (iPrb@
Milabar (mbw . x 6.453'1 = Inotrwpf-@H,CF) x 2491 = Millibar tmbar)
MlMhefiesofmer~vy(mmHg) ~ 0 . 6 3 5= In~hegtofwer(inH~0) x 1.EN% = MIHlmetms~ f l r r r e r wbrtt+g)
In- of water (inY0) x D,0B = Pomds-famp r tmh x 27.6B = In&= ofWBT (inH20)
(p* I
W 1MN
Toque (moment of force)
Pounds-force hchw x 1.152 = Kl togriarls-fom centlmetre x 11,868 = Pounds-I- loch-
Qbfin; Ib in) &@Cm; h3w! MT In;Ib In)
Pounds-force inches x O.1t3 = Mawton m m ( h l m ) x 8.85 = Pounds-forminches
(Ibf In; Ib In)
Pauncb4orr% Irii5hsa x 0,083 - ?ounds-forcefe& (lbf Q'lb ft) x "f
OM In; bin)
= r~&-fwwtnch&
ilW;I Ih k)
-fme f d flW fk b Ib x 0.13@ - Knapmns*m metres
(Wm;ka m)
o&h; tb
x 7,233 = ~ms-fPm feet OM pr; Ib ft)

Pounds-Tor@ feet (Ibf ft IIb ft) x 1.368 = Newton metres (Mm) x a7p = ~ w u r ~ ~ l e e t ( l ~ f t ; l t r ~ y
H W nr
nm pm) x 0.102 = ICifograms-fammetres x 9.m = M w b n metre [Nm)
Wgf mi hm)
Power
Horsepower (hp) x 745.7 = Watts (W) x O.OM3 = H-er Byl)
Yelocity (speed)
Mlleg pw hour [rnlledhr: mph) x = Mlornetces p r hPur (kmmr; Wh] x 0,821 = M l b Fhour EmilBathc mphl
Fuel consumption*
Miles per gallon, Imperial (mpg)
Miles per gallon, US (mm)
x 0.354 - KIlornetPes per lltm&dl)
x D.425 = Kilometnes pbr W eun/t)
x 2.825 = Mlle rngallon, Imprial (mpg)
x 2.m =t Miles per gallon, US (mpg)
Temperature
Degrees ~ahrenheit= PC x 1.8) + 32 l ~ s Centigrade; OCI= PF - 32)x Ijfi
WFSW ~ e l ~@egrms
* I f i s o d m m w t ~ i m t o m n ~ . ~ r r r m k p ~ { m p g ) t o ~ ~ aW [) n q~p~g@~l/tMkm=%82
flW,
 General re.pairprocedures REF.3
Whenever w M n & mf& or averhaul wrtr un$hoWdeWIthe seal should be f m d with M & . ( ~ n ~ safter tong period8 d we, and
1s mrrfed wt on ihs car ar h aomponents, Itafa~~fiwh wlth the b l n g top fsrce(tlnless shddlm-i ~ren~asamedterdmurse.
ob&wa the fojlawing pfomdurea and &mlsehstrut.tac$. -Splh plns must always be replaced with
lns?wtlsn8. Thts WlII In carrying 0th tb new QF@D~We aomct stte-for: the hole.
o m t i o n efWmtll( and to a professional Wmw fhmads and,fasfmings Whm thread-lmkfnig compound Is found
stanWd of wornwhip. S e w nub, bolts md wem am mta a onha.Ww& of afasteWMkh Istobere-
common m u m e where cur- has mt used,.R shoutd be clsttned off with a wire
h h t mating faces and gaskefs In, and the weof O f m i n g oil or r&&ng brush and ~Blvent,and fresh .mpound
When s~pwatIngmmpbnents at €h&r fluld will often o v m m e this problem If the app0led on n b l y .
maflng Taces, never Inwrt screwdrivers or offending Item Is sroakd bra whlte before
similar imptern- I& a e jiht M w w n tbte attempting to celeme t rnuse of an h n p d
faces fn m e t ta pfiss thein'q%rt, This can drlver m a also provide a means of releasing Some.r~palrprvcerdUwS In thls rtWtntnu81
muse severe damag~whlch results in oil such stubburn fastwing devices, when used enW the u s e d s p l a l tools such as a ps,
leaks, & h t I d , ~ t upon c rwwmbly. in conjunction wRh the approptlats twg or three-lqgpBd pullers, sprlng born-
Separation is usually aGhieved by tappJng ~crewd~wr bit Or s&d. I f nane ai these wessors. &c. W w e ao&IBle. ~ suiWbl&
aloYtg the @jnt Wtth a 80R-facGd hammer in methods works, # may be n-wy to resort
ordu to break the seal. However, note that Yo the &I application of heat, or the use d
thls fi6thOd may Wt Be suitable wheb a hacksaw w nut wlmer deb%%. shown tn k.I ~some I ~mimms,i t w e no
dowels are used for oornponmt location. Studs are usually retmdcby 'I-0 two aHmatlve is possible, k.ha%bgenn-
W h ~ B ~ l a m % d M w m t hnuts ~ ~lagether
g on the threaded patt, and then to reart to the use &a mmufacWefa tad.
faoes of two mmonents, a new one rnust,be us1ng.a spanm OR the lower nlrt to unmew and thk has been done fw rea&i5s af safety
fitted MI~ ~ ~ ~ w T iitIitLbry
I ~u~; otherwise the&& Studsor'boltswhich haw broken off as well as the efk~entw r r p l d p n ~the t mpdr
3MW ,MIhm t r wwedwe. hWe sure that below th8 surface of the wrnpamnt In whim w r a t i o n . Unless you are h$hlp%ltlM arid
the mating fa& & #loan and dry, WWall they a p m s u W y o .*ltpe~b r r e m o d have a thorough undershndiq of the
tmm of okl gasket removed. Whm cleaning a using a stud m c t o l ' , Always erisufe that a procedures descrlbdl n o w attempt to
jdnt face, use a toot whfch Is unllbly to score blind tapped hole is completely free from 011, bypass41s use of?any.speckl took when the
or d m e the We.,and mmve any burrs of grease, water or o ~ flw utd before installing proccid'dure de$~dedlSpMfies Its use. Mat
nicks with an oilstone w flneflle. the bok or stud. Failure to do .thiscould cause only Is there a very great risk of psrsonal
Make sure that tapped holes are cleaned the housifig W crack due to the hydraulic 4njuryi: but Npwsiw damage , q U M b
wlth a plpe ~tsanw~ and k q them ~ free af action d the bolt or stud as R Isscwed in. m e d fo-them m p m t s I r w o M .
,lohtirq cumpound, If this is Mtrlg u s a , When Q g M wa,aastPIaWnut to sfwept
unt- speclf ical!y instructed o W J s a a @it pin, tighten the nut to the a p o i f l d
Ensure that J I orlflms, chmnels or p@es torque, Where a p p l W e , and Pherr t I g M %en &=sing of usad errgTne.oil, brake
are clew, end blow thmu$h them, preferably f u r t h ~ 10 h fiWt gplft hole. WdackM fluid, omlfreeee, a?c,aM,due, w ~ ~ t i to o n
uslwcornp- dr. the nut to allan the splllt pin hde, u n b s staled . q y d&rnmtal mvjranmmtal &tab.Do not,
In the &r amBtsdm for Instanog, p u r any of the ab&e tlqutds
~hen'chekklngor retlghtmtng anut or bolt d w n drains Into the wnql sewwe system,
Oil aeE118 can be removed by levering them to a s w d f k d toraue settina, stacken the nut w wtta the ground to saak away. Many h i
aut wM a>W R E a - W scwdriwer qr slmiiar or bit by a quher of turn and than counoll refuse tips provide a fZLW.li fDC waste
Im~lsment,P r l ~ m a~number ~ . of seR- ret@hten t~ the specified setthg. However, oll dlsppsal, as & msor.gmggs.E none<of
GIQJ screws m y bq"&a into the a,th5s shautd rjot be@tempfed where angular ffiese,facilitlesq e available#mmlt ~ nIml r
and tka used as a w m Totdim ps same tigWtring k& been used. Envi~ronmhntdHeath v m ! , , rn the
For wny s q e w fastenings, notably w i d ~ ~ ~ ~ . u tforh futthevadvice. o q ,
eyllnW ,h$& b&a or nuts, torquer wrench Wkh the UnlVtrtsd ,@hMni$-up ~f leak-
working location, &hwlndlv!du4lb or or,part &ngs a(e no lottter spwHI6d for the latter l a t h regarding the emkalon d e n v l m m -
d an assembly, Itshoukl lik refiw.ed. st* pfLfidhten!n&,*anal$-tlghtahg" behg wfy-Iyrni'I'ul subslaness from motat vehlclesh
T b uery fine d n g llp,of is easily c W q~m n W . Typically, afaltly low torque moat vehlcla have fFlnyrerpmd W k fmed
m a g e d , and will nat sessf Ift39 'sufface # wren& setBnQ. ulll be ' p l b d to tlm to the maln adjument points of the fuet
mnta&s Is not completely clean and free from boltdha'ln the wmct s&ence, 'hlhswad system, 7%- d & w are prjrn* &signed
wmtclm, nicks w gmov&, I ,We qnglna hy Srane',o~-mw$aQed ,of @ht@W>tfimUgt, kr prsvmt wqWfIed pemns from adjuang
d i n g surfa~erof k e mmpn&t mnnoX be q w c b d angl&, fhe iueildr mixture, whh the c m e e of a
restored, and me manufaage?has not W e conseq~qrnlIncrease In toxic emlasians. tf
wovisbn for snaht relocatlan af the s d l LO&- Iodctabs W d W8ShBIS S U F M4d.s are found dudns savibifig or
&*
h t t v e to the
shwld be mewad.
surf-, ttre,wnponsnt
~
Any fastening which will r.otgit@against a averhaul, they shhpuld. where& possible, be
cornpPnant or hwsjw durhg tlghtenlng renewed or ri,fitt@dIrr a ~ ~WW ithe
~ t !
P- the I!@ od the seal fmrn any surface sbuld always W e a washer between It and
whlch may damage €hmIn the ~oursgof the relwarkcomw1Pent or hou&m.
fittingb Use tape or a ~ ~ n i sleeve m l whem Sprlng or spli ~ a s h ~ s h o u always
ld be Now-ff Es

-
-iM& tubt5tatedfttesaal wRh ail before mew& wbn they are, used tiB lock m W m a t m d
iWfg and, on dual-lippd 4 9 , fill the space cornpwlent such as a blg-end bearing
aetwesntfTetlpsmpmasa retaining bolt or nut. Ldelchbs whkh Brd m w dump
Unless Otherwise stated, oil seals must be folded over to mtaln a nut or bolt should dl dawn fhe
Wed their spallng Ilps taward the always be fenawed.
IubricantMbe sealed. Self-locking nuts can be r&uW In non- € h e mof
Use a tubuI8r dTlWm block d w m d of the c r l W arm, provldlng resistance can be felt yovrlo#rtoH
appropriate size ta instdl tfia seal and, 8 the when the Imkim nodlon ~aaseswer the bolt h k ,
w a l housing 1%sshould6~ed,drive 4 k seal or<stud fhread.i-hwev& ll obutd be noted
down to the shoulder. If-the awl homing 4s fhat sslf-lpckln$ sfiffnuts tend to I- their
REFJ Buying spare parts
Spare part8 are available Worn many
sources, including maker's appointed
garages, accessoty shops, and mator factors.
To be sure of obtaining the correct parts, It
will sometimes be necessary to quote the
vehicle ldentiflcatlon number. H possible, it
can also be useful to take the old parts along
for pasltlvs Idenfffication. Items such ETS
starter motors and alternators m y be
avallabls under a servica exchange scheme -
any park returned should be clean.
Our advice regarding spare parts 1s as
fpllp~~.
OtHcbl& appointed garages
Thls Is the best source of parfs whleh are
pmulktr to your car, and whth ere not
othsnnlse generally availabk (eg, badges,
Intertor trim, certain body panels, ~tc).It is
also the only place at whlch you shauld buy
pwls iffhe vahlala is All under wmnty.
Accessory shops
These are very good places to buy
materials and components needed for the
maintenance of your car (011, air and fuel
filters, Ilght bulb, drivebdts, greases, brake
pads, touch-up paint, etc). Components of
this nature sold by a reputabl~shop are
usually ~f ti18 same standard as those used
by the car manufacturer.
Besides components, these shop dso sell
tools and general accessorfes, usually have
convenient opening hours, charge tower
prices, and can OM be found dose to home.
Same accessory shops have parks counters
where components needed for almost any
repair lob can be purchased or ordered.
Motor $actom
Good factors wlll stock all the more imp&-
ant componmta which wear out compar-
atively qulckly, and can sametllmers supply
Individual components needed for the
overhaul of a larger assembly (eg, brake seals
and hydraulic parts, bearing shells, pistons.
valves). f may also handle work such as
cylinder block reboring, crankshaft wrlndlng,
etc.
TLrs and exhaust specialists
S h ~ eoutlets may be Independent, or
members of a local or natbnal chain. They
frequently offer competitive prlces when
compared with a main dealer or local garage,
but it will pay to obtPlln several quotes before
making a dmlsion. When researching prices,
also ask what "extras" may be added - for
Instance fittlng a new vatve and balancingthe
wheel are both commonly charged on top of
the prie of a new lyre.
Other m u m
Beware of parts or rnatertats abtahed from
markea stalts. car boot sales or slrnilar outlets.
Such items are not invariably sub-standard,
but there is little chance of compensatlan R
they do prove unsatisfactory. in the case of
safety-crltical components such as brake
pads, there is the risk na only of financial
loss, but also of an mident causing injury or
d m .
Secmd-hand components or assemblies
obtatned from a car breekw can be a good
buy in some circurnstanc~,but this sort Of
purcha$s is best made by the experimced
DIY medwnlc.
I

Vehicle ldentification - - - -

Modlficattons are a c~ntlnulng and
unpublici~dp r o w s In vehicle manufacture,
quite apart from m4or modal changes. S p
parts manuals and ti* are compiled upon a
numerical basls, the Individual vehicle
identification numbers being essential to
correct Identification of the component
concerned.
When orddng spare parts, always glve as
much Informatton as possible, Quota the car
model, year of manufacture and fegistratlon,
chasis and engine numbers as appropriate.
The Vehicle Idwtificaflon Number WIN)
plate is riveted to the top of the front body
panel, or bonded to the body pillar behind the
driver's door, depending on -el. The plate
carries the VIN number, chassis number,
vehicle weight Information and various other
inforrnatlon, depending on territoty (we ,
illustmthns).
The chassis number Is given on the VIN
we.
The englne number Is located on a mMal
plate attached to the englna. The locatlon d
the plate varies according to englne type (see
illustmllans).

VIN @atelocation (A) on *nt body panel vlrv pare mcanon lam-) un o m y p u a r

Engine identification
Thcou*wtthis manual, englnss are referrad to by type.The following information explalns how to Identify the various t y p of
~ englne.
Enalne type Description
C-type engine ................................. 1108 cc engines (1.I lltre models)
0-type engine- ................................. 1149 cc engines (1.2[itre "Phase 3" models from May 1996)
E-type engine ................................. 1171 cc and 1390 cc englnes (1.2 litre "Phase 1 and 2*
models up to April 1996, and all 1.4 litre models)
F3P engine ................................... 1783 cc, 1794 cc engines (1,8 litre 8-valve models)
F7P engine .................................. 1764 cc engines (4.8 litre I %-valvemodels)
REF.6 Jacking and vehicle support
The ]a& supplW wkh th& car should only
be used for changing the roadwh&els- sm
"meelcft~nghrng*atme front of thls manual.
When carrying out any other kind of work,
raise the car ualng 8 hydrautic jack, and
atways supplement the jack with axle stands
padaned under the car jacking palms.
When~winga hydwulir: jack or axlestands,
alwap poaltion the jaak head or axle stand
I 1
Rgqa&ing points for u- with WIley
M k
RenauITspecfa1tool posllhed under front $ubfmm@ tO ralw
Renault spe~laltool posltlorsed under sill to r a h s i d of r wlth
front of car with lmfleyjack. Noh n M (amwed, fight) to dear
-uat PW
haad under one d ?herelevant j a c k i i points
(note that the jacking palnts far use with a
hydraulic jack are dWemnt to those for use
with the car lack). 5)0 not Jackthe mr under'
ilw sump or any of,#tra&q&ng or suqmsbn
~amponents.The jacking points and axle
stand postthm are shown In the
accompmylng illustratjons (seeWustdons).
When raising the fro* of the ,w,~ l fhgy
handbrake and chack the m ~ w?ml%.
r Use a
a u l ~ l ewooden or metal bar positiond
u n a r t b front euMmme as shewn (see
illudmti~~), &Ifion the iack hmd undw the
centre offhe bar, Note that on Wtaln W e l s
it wlll be n w w to cut a notch In the bat ta
prevent contact wlth the exhaust W m .
When raislng tha MI: of the car, chock the
fnxrt wheal$ ahd engage I st gear on mmud
gesrhx models, w select g~sltion"F on
modJs wlfh autornh transmiasion. PP&m
tb,jack head undet'one d the & f o r d m?
jacklng points provided for use with the car
m
!#hen raising the dde of the w,chock the
w h w a remaining oh the ground, w l y the
handbrake and select a gear, as described
p m v l ~ ~ s lby i. t i o n a suitable bar under the
sill b n d h the front door. The bar shouid
have a dtabk move to awmmadaie the
flange on the dl. Ensure that the slll flange Is
~~y engaged wtth 'the gmwe In the bar,
then position the lack h a d under Wm W e
af the bar (seeUlmmlm).
Axle stands s W d be posRbned under the
r e i n f w d jscklng pints provkddlor use with
bmrilnck
Wmhlg: Never work under,
A 4
~mnd,or neat a r a w ~ a r ,
Up- it b w ~ a t &
-S
~ a i l e a s t h u o ~
~a
traky jack
 REF.% TOOISand working facilities
IW#imtenam a d Repair and o-rhaul idol kit
A %leaon of tools is a fundamental minor repair t w l Wt These bols are virtuaIly sssenkial for
rwulrem~ntfor anyone dantemplatlng the anyone undeWIng any major repalm to a
The tool5 given In thls [kt should be a.

maintenanos anxi repait of a motor ~ehlcle. motor vahIcb, and are additianal to those
consIdared as s mlnlmurn reqlrlmment if
For the owner whp 4 ~ not s possess any, g l m in the Maintw6mtxt and mlnwapdr list.
routine maintenance, sewielng and minor
thslr purchase will p w e a conslderaXlte repair apm?ionsare to, be underhken. We lnduded in this list is a mmpreh6mNe set df
exgens , a W t t h g w e of the w h g s made remrnmend the pumhasa of cmbinatlon socke&. Although th8se:we expensive, they
do&-lt-~oum~.Howmr, provided that spanrim (ring One gmd, open-ended the will be found invaluable 8s t h y are s?
the WJs pun%& mest the relevant national citheq; although mork expensive bpen- -
vprsatilb particularly if vatlou6 &IV- ate
dew standardsand are of gpod quality, they ended an=, they do give the advantages of Included in b set. We e r n m e n d the half-
will last far many years and prove an both types of wadW. Inch asquare-drive type, as this mn.be m d
wtrsm@ywoPthwhlle tnv-t.. Cmblnationspanners: wkh most proprtemy torque m c h m ,
To help h a average owner to W d e w h l d Metric - 8 & 79 mm im&tsivs The to& In thls 1M will somatrmes need ta
t o m * nesdedto cam out the prtous tagks U AdIustabh m n s -
r 35 mm jaw (appmx.) be s~pdbrf!#fGd t W from the S&d He:
- detq11d In thk manual, we hewe. mmplled n S @ @ W W M W ~ ~ B T I- Q ~D Sm$@ fbrbbxspw?m~) to w&-
three If$& of toois under the f0lIWlng pefror@$ in previous,/I& (WWing Tomsocbb)
W i n g s : 'Malntmmce and minm -if, n sparkpl~gmad~~tmemm~- R m f b l e Wet d r h frw use wlth
R@randowtmvl, d d Special. Newamem peM models sc
xkw
to ~t.aaicalmeohanics should d u
f with Wwfbkmhles 0 m s h np h s , &dl mm @r use with
the' IWB~&?W~B @M mioor ~ p r s t kt, ~and C] BM h k d i#& wrrh~ &me&)
confine hemselves to the.sima!er'iDbs around Scmwdim&
' I
d Unhrseljdnt &r u& with Wsl
the vehicle. Then, as cbnfldem and Fktbkk- l O b r n m I ~ x 8 m r ndla -6 handle or ~IidingT *b#akef bar"
I sxpedwce grow, mom diPFiwlt task can be cmmds- IWrrrmIo~a6mmdJa (fob urn Wltfi w*ts)
undertaken, with W m tools being p u r c h d Tom - vatiaus s b 8 (mf dl whidel Cl TWUB w m c h &ruse wRh sock&)
as,ardwhsn, they am m e d . In this way, a ~ r n b h ~ p & p s Self-lpRggrips
Meintemnce and mimr re@ tool Mi can b m k s a w ~unW Ballpdnhmm
bum up into a -rand overfiaul tool Idt over TY= Pump Soft-faced tnaM @IWcor m b W
I a conskbab~epen4od of time, without any VmP-~mW~ n i3xi3wdm
major cash outlays. The edperlehced do-It- O N m -
Rat b M e @iw8( sturdy, short {ch'ubbfl,
youmbr dl1 have rr tuol Hi good enough for m xrml twmoval m d end m w (dmirfdm's)types
most repafr and ovarhaul procedures+and wlll Rne e m doth C~nss~-lo;ng&mrby,~&~
add tools horn the Special caiegoty when it Is W,# brush (small) @hwWt y ~ s
felt that t h e w s e Is l u M k d by the amount Funnel (medium ~liws:
of use to MI.&these tools wlll h~put. h m p drain plug key (not all Kehicles) Long-nosed
Side cunm @lectcian's)
Cjrclip ( m t m a l and e-4

Brake bieedig kit U Jack (shng trow or hyhuIIc

D Ught wltb %x&mionh M
I7 W n i v m l e l @ Wmufti-m&f

Hosedamp Angular-tlghtenlng gauge

 Tools and working facilities R E F 4
special -1s BuyJng fools Working facilities
The'to~lsIn this Nst are those whlch are not Reputable motor accessory shops and Not to be forgotten when discussing tools
used mgularly, are expansiveto buy, or which superstares oflen Mer excellent quality tools is the workshop Itself. Ifanythlng more than
need to be used In accordance with their at discount prlces, so It pays to shop around. routine maintenance is to be carrled out. a
manufecturers' Instnrctlons. Unless relatively Remember, you don't haw to buy the most suitable working area bwomes essential.
dlffhult rnechanlcal jobs are undertaken expensive items on the shelf. but It is always tt is appreciated that many an owner-
frequently, It wltl not be economic to buy advisable to steer clear of the very cheap mechanic Is forced by circumstances to
many of these twls. Where this is the case, M s . Beware of 'bargains' offered on market remove an engine or simliar Item without the
you oould consider clubbing together with stalls or at car bout sales. There are plenty of benefit of a garage or workshop. Havlng dona
friends {or joinhg a motorists' club) to make a goad tools around at reasonabte prlces, but thls, any repairs should always be done under
hint purchase,or bwowlng the tools agalnst always d m to purchase i t m s which meet the the caver of a roof.
e depostt from a local garage or tool hire relevant natlonal safety standards. If In doubt. Wherever possible, any dlsmantllng should
smjall@. R k$ ~ $ 4 7noting that many of the j t c the proprietor or manages of the shop for be done on a dean, flat workbench or table at
larger UlY superHores now cany a large advice before making a purchase. a suitable worklng hefght.
mg,e of &p@plQtools for hlre at rnod~st Any workbench needs a vice; one with a
rates:
learn and maintenance of tools jaw opening of f 00 mrn is suitable for most
The follgwlng list contalns only those tools Having purchased a reasonable tool kt, it is jobs. As mentioned previously, some clean
and Indhments freely available to the public, neGessary to keep the tools in a clean and dry storage space Is also requlrd for toots, as
md not those special tools produced by the serviceable condition, Aiter use, always wlpe well as for any lubricants, cleaning flulds,
vehble manufacturer specffcallyfor its dealer off any dirt, grease and metal partictes using a touch-up palnts stc, whlch become
network.You wlll find occasional references clean, dry cloth, beforeputting the tools away. necessary.
to thew manufacturers' speclal tools In the Never leave them lying around after they have Another itern whleh may be required, and
text of thts manual. General1y, an alhrnirtive hmn used. A simpte tool rack on the parage whieh has a much more general usage, is an
method of dolng #e jab without the vehicle or workshop wall for Items such as electric dtill wlth a chuck capacity of af Ieaet
manufactured sp& toot is given. However, smdrlvers and pliers Is a good idea. Store 8 mm. This, fogether with a good range of
st~mefime'sthere 1s no alternative to using all normal spanners and soek~tsin a metal twist drills, is viWally eessentlal for flttlng
them. Where thls is the case and the relevant box. Any measuring instruments, gauges, a~~~~sorles.
tad aannot be bought or borrowed, you will meters, B~c,must be caremlly stored where Last, but not least, always keep a suppty of
have to ahust the work to a dealer. they cannot be damaged or become rusty. old newspapers and clean, Ilnt-free rags
Angu\er-tightanlng gauge Take a littfe care when tools are used. available, and try to keep any working area as
VdJue spring compressor Hammer heads inevitably becorns marked, clean as possibla
Valve grfndlngtool and screwdrivers lose the keen edge on their
[7#ston rlng compressor blades from t'ime to time. A little timely
0 Piston r(ng mmOval/Imtallation fool attention with emery cloth or a file wlll soon
Cylndw bore hone restore kerns Ilk8 thla to a good finish.
BaI~uIntseparator
con ww 7 Iwh- WPI-1
I7 Tyo/three-kg& hub and W n g puller
Impad screwdiWer
Micrometer and/or~erni&caIipem
Dia/puge
Stmbasmpic timing light
Dwell angle mefef/tachometer
Fautl code reader
Ci Cylinder commssim wge
U Hand-operated vacuum pump and gauge
tl Clutch plate alignmentset
Bmke shoe st=& spring cup removal r o d
17 Bush and bearlng mmvaI/insfailation set
n studmcf~~
Dial test indicator ("dial gauge'q
Tap and die p3f Micrometers
W n g tackle
Tm!byjack

Compression tester Fay# code m d w

REFOIO MOT test ch,ecks
This is a guide to getting your vehlcle through the MOT test.
Obviously R will not be possible to &mine the vehlcle to hsmr
shndard as the professional MOT tester. However, working thmal I
the faltawiilg checks will enable you to Identify any problem areas
betore submitting the vehicle forthe test.
Whsre a testable campanent Is In trarrlwkm crxldMon, the tester
has discretion In decldmg whdher to pass or fall It. The bask of such
dlscretbn I$ w h ~ t h testw e W d be happy for a close r & t b or
friend to use the vehfcie with the component In that condition. If We
W i d e pFWWM Is clean and evidently well cared for, ~e tester may
be mope IndinedTO pass a borderline cornpartent tlm~if the vehicle is
scruffy md'apapparently neglected.
R h a odhl$ been pmslbL to surnrrraim the test requlmments her&,
ba& cn the regulations h fwce at the t h e of pri~ting.TW standads
are becoming Inweasingly stringent, dhough fh&e are m e wm~ons
for oWvehtcies. For full details obtain a copy of the Haynes p u b l i i n
!%ss the MOT! (airailablbls from stockists of Haynes manuals).
An &nt will be needed to b l p carry out mme of these checks.

7lte he& have been sub-dlvlded Into h u r ca-des, asfolIows:

Handbrake
Test the operatian of $ha h a n d h k .
Excessive travel (totoo maRy ~ i c k IndCatt~s
)
Incorrect brakeoreable adjustment.
Check that the handbrake be
by tapping the lsvw d d w y ~Cheak
.
the security of thelever mountings.

Q Check that the brake pedal Is w t e and h
g o d eondiflon. Check far suns of Wid
leaks on the psd81, f l w or carpets, which
would Indicate falled seals In the brake m e e r
cylinder.
0Check the servo unlt (when appllc&le) by
p i i n g the brake pedal several timm, men
keeping the pedal depressed and startfng the
englne. As the enpine starts, the pedal will
m a y down ellghtly. I not, the v w u m hoae
or the servo ItsW may be faulty.
movement of the steering wheel, hdlcatlng
wear In the column support bearings or
couplmgs.
Wfndscmen and mimm
The windscreen must ba free of cracks or
other slgniTiwnt damage wlthin the driver's
field of view. (Small stone chips are
accsptabls.3 Rear view mirrors must be
secure, intact, and a@h of Mng&adjusted.

Steering M - 1 and d u r n
FmWmk9 IJ Examhe the stew'ng y y h d hr WUTW or
n 13- m4 bmipfldal and c h e ~ km a R loasen- bT the hub,s p o h or dm.
does noi cmp dam to the fbor, lndlcatlng a O Move ~ R Bstewing wheel from side to side
m m r cylln#q fault., Wegs@the -1, wait and then up and down, Check that the
a few .seconds, then ,&ptess it again. If the steerlng wKmt is riot loose on the cofumn,
pedal tramis nedy the flwr bejore firm Indlsatinq wear or a loose rehlnlng- nut.
mshtancg is felt, bmb adljustmerrt w repair Is Continue mavlng the .&@ring whml as W e ,
nmesswy. If the pedd W s spongy, them is Malsohlm~dlghtiyfmrnkfttorisht
air In the hydraulic system whkh must be Ghmk that the steeiing wheel ls not loose
removed by&feeding. on hcolumn, and that there Is na abnormal
\ E l e @ d ~~l , U ~ M R #
Ei Switch gn W.8 jgnltltm and check -the
test checks REF.11
MmOT
In- both frpnt b&e A&$le hoses for
wack or deterioration d the rubbeg.Turn the
opwatlon of the horn. W ~hioh Qluck to'lmk,andokwetlxatthe
mgqk 9.em s w washers ~ a@ wiprs,
hmes do not mnW the wheed, tyre, ot any
mmhing the w l v . b l a d w renew damaged par! of thB &rlg or smp&dan-rnechanri
Wdh.the brake p& firmly depm~ed,check
or pvsha el*. Also .FhW tile 0-n i h e h W S f o T b U I ~ ~ l e a b ~ d e r ~
of the stap4lgm

N o k 731: fdlo'wr"ng ch&ks we app!l&k ta

&!I mfb$&, b m t &.mar-
O'lWWtle wbbhg of all the belts
(fndWalrig:fw blts if fitted) for cuts, se~iow
fr&$hgdf d ~ o r a f l m mFWeh Bnd LmfaShn
each belt trr cheek t k t ~buEklm. If appIIwble,
chwk the mactbg tnachanlsm. Check the
-r@y o f d a4 hit mounilngs messlble O.Check the oPmlon of the sidelfghts and
w( ha@ %@ numb& date Iiatits, The lenses and reflectors
UThp 'fr-ant seats -1hernsdw must be must im'*t'K 4ban and undm+.
mering and smpension
em@yaWhM and the bncbests mhst D dhkk the o$~caftonand allgnmairt nf the a H B V ~YO^ d ~ t q $f~ tp~w,w,+I
from side to slklitly, up to flie,p&nt
lodc hthe u p r p p d i o n . hwdl@m. The headligftt reflectom mud not mi
w h w , t h ~~, e & n g . w j & itie$hs%
t
be fmid'h'ed a& the lbnses mu8t be this m W - ~ ~ e f S We
t : b rd@&h&ls. ,W@kfor
undartmgrsci. excesslue ,free play between the i1wmg
a m.mnth ~ 9 ' m w xrbl~q't~.be
~pmd swftdh on the lgnttion and check the whdel and W.stqering w#, Indloafhg x vw
and.ln$% md mugt
anal dosed fm wid@
WhawreIy when dmd. or lnmuritj d thp steering mmfumnioirh, the
ccrtumn-td-aeerlng mar ctaupihg, or the
mlq IQhts. Opedim of the sjddlghk and
&oP;tiQhGrriust n d -the -
Indl~Btbrs T
does, the cause IB usually.a bad mtth at ttm
I It
w n q gear I-,
D Have, your asWariY turn' the steering w h 4
mom vIgwousty In saeh dtrection, so that the
resir light clu&r. roadwheelsjust bqin to hrm. A6 tMs is doion%
nCheck the operation & the rgar fogllgM(s), examine all the steering Jolnts, Ilnkages,.
Incl(rdirrgtlie warning Itght on the krstrument flt2lngs and attachments. Renew any
pard w In the awltoh. mrnponent that shows signs -dw a r or
Feo$bmke damage. 'QRWl$ea w1R power ?teering,
check the murib and condition of *d
lsmiir&.wq-m&&r wlhdw, b r a e pip*& Hewing p m , drbbett and h o w .
and servo unit 'fgr le&, Imse mountings, l l Check.thak the vehicle b standing Isvel,
& W d n ar p#herdab* ahd atapproximatelythe correct ride hdght.
sha& abgmdh
D 9@W8e& w , W of the vsMcL h turn,
then release it. 31svtrhjcb should rlse and
#I@mls In lpnpmlal p6sltbn H th'~veh1cls
contInlrea fP r b and'W1, the & w k M
ts,gafectke. A shock. a b ~ r b e rwhtch has
seize'd wN1 Ssb-mwMe W d b tu fall.

f h a fluid resewoh.:must be w w e ! and the

nThe VIN plate and/w h m o ~ t l o npiate fluid lsrrel must be b&- tb upper N a n d
must bIdib. law& Is)mm,
REFW MOT test checks
Exhaust system Front and mar suspension and
Start the engine. With your assistant wheel bearings
holding a rag over the tailplpa, check the
entire system for leaks. Repair or renew
teaklng sections.
k p k up the fmnt and mar of tbe vehiclq
add S&IH@ support It on &e stands,
e n h m n & &r ofthe s u s p h n
a ~ b J i e 8Ensure--that
, the whleels am
cksac of the gmund and that $he stawing
canIbetumed~kZck~locIt
CI Have p t r assistant twn the &wing from
lo& t~ tack, Grre~k€atWle, m@rhg turns
;gmsihly, wst -that no part of fW. s h d n g
rnehaniam, Indudlng a wheel. w w,+?fpwls
my ~ ~ o r ~ p e o r a r i y ~ d o f t h a b d y
shere.
D Wmhrf the Wring.rack rubber gait&
for & m e w i n w & of oftha Wining ct@&
If &W is 5t?ed chkk. fof Cm i s of
W e o r t . 0 of the W d R-, pipes w
Gin&ons. Alsa chIgaK for BXCwis\ue
dw or hlndlng of the steering, ;a.misshg
split pln & Wdng d*w, of &a@ma!atl
of fhe body structure wlfhin 30 em of any
w r i n g aapponant attachment point.
Starting at the front right-hand side, grasp
the roadwheel at the 3 o'clock and 9 o'clock
positions and shake it vigorously. Check for
free play or Insecurity at the wheel bearings,
suspenslon balljoints, or su$pension mount-
ings,pivots and attachments.
Now grasp the wheel at the 12 o'clock and
6 o'clock pmtlons and repeat the previous
Inspection. Spln the wheel, and check for
roughness or tightness of the front wheel
bearlng.
El ff excess frw p t q is suspsaed at a
@rnpiLhtpldt pah7t, mls can h~~~
by uBIWq 4 largs Prewdrivw or ' s h l tar YQpl
and levding between tha mwntlrli arfd>ths
mnpan~ntatr~chmsnt.This wUl confirm
whether &e wear is in the p h ~ bl ~ i h tt3 ,
retaining bolt, or In the mourfblng Itself (the O If ~QBSIMB Wbut dismantling, check
w hilEe can 0m-lb h n i d t9tiinga.w). bmka pqd We& >enddl% ccnditlpn. Engum
that the Metion l l n h ~material hae not worn
sx~wl&y,
fwd,
I7 Cany out all ttm cheoh d 'W.&er
frmt whm!, md M n at Wh Mr wM&
Springs and shock absorbers
Examine the suspension struts (when
applicable) for serious Ruld leakage, corrosion,
or damage to #e casing. Also GW the
m d t y af th mounflng~pOinW
t
i If dl sptlnp ara fittad, chsk that the
sprlng ends Im&eIn mlr W,and that the
spring Is not corraded, c m e M w b r o w .
If I& '~prlflg~ fitted, Check that dl1
leaves are Intact, that the axla IS securely
Q&dto m ~ h and that th8f-a Is no
deted~htlonof .the sprlng aye mountlnw
bushw, and *zwe
The same general checks appiy to vehlcIes
fitted with other su~penslontypes, such as
torsion bars, hydraulic displacer units, etc.
Ensure that all mountings and attachments are
secure, that there are no slgns of excessive
wear, cormion or damage, and (on hydraulic
types) that there am no RuBkk~midamaged
Pie,
El lnspeot the shock absorberlk~W$&hBd
serious fluld leakage. Check for h8
mounting bmhs or attachments, or damage
to the body of the unit.
ther constant whityjotnt gdtm fw qt& w
damaw. Also &8ck that each driveshaft is
(A) and that the dism are not
piw ,wd ur badly worn Bh
t
i SxaWne all the rigid brake p d w
underneath the vahitls, and ihe flexible
m&) w thaw, L ~ k 4 Q T . w r n I 0 ~
or insmrrlty of the pip, a d ' * &ins d
bulglng Under pwssyt, ghMrr& ,sgIita cn
&Mwatron d the fikklble hias.
I7 Lr@kfor signs of4vld -1 at the b n b
calipm w o n tte hake bmkphbs. R@r w
renew I W n g a w r m t a
f7 Slowly spln each wheel, whlle yqur
&atarrt depress* and releasea the
f o & r ~ . W e that &ch:bmke I s . o M n g
and d w not bind w l m 4hs mdal
IG rdwsd,
 MOT test G he^ k~ R E F O I ~
4kwu the engine speed b return to Idle, and
watch fafmW krnlssiow Mrn bhe QXbaW
fallptpe. If the idta speed 18 obvIou8Iy much
~ tidy pqrly-visible
too klghI or If ' d w s Mu?
blackm o @ ~~omes f mm the'blkplpefnr more
than 5 & n d ~ ma ubbi~le* wNl ell. ,& a rub
&thumb, Qlluem&esfgnibs dl betng burnt
fehgrne weat3 ' !File blqlr chow siglfi@
+

unburnt fuel ,jydlrty 8s ole~nwelement, or

athd karbur&w #.fuel systemTam.
An &aud gas analyser capable ol
rnor?surtng W& mwPJe (W v d
hplromrbons $ how w. 'Ifla~chan
he han Ensvurn?nt gannqt W g b~rrawed,rr
checking for frayed or ,broken cables, d ~ a k ~ . I C d gmp may ag&h p m ' t h e ' w w k
mewive cormslon, or wear orlnsecurlty d a chathat ~ p ~ ~ ' o f w m fdr
. s p W.
d Bmd
&a liwe.C W that the rnecl-wismworks 'fw,#heve@clej%at they a r of ~ the same ake CO emissions (rnlxxum]
on i i h , &e&nf wbel, and rele&m'f~lW, aird &"'s"ach aid&, thEit the ~ x B W ~ B S
fiat blndjng, are c p h t . a At the trme of writin& the pMmu>mGO
It is net pomtble.^totest brake Wcleney n ~ , h m kthe :+yrfltt ; r d depttl. me 18gd led d idlet $.5% forvcehlcles .pw . & e r
August 1986 and 4-5% fo~pbjy vcifiidw.
Yvlttimitepec26li equlprnmt.'buta road test rn mlnhwn @qtimafwrltlngIs 1B mm wer
we,G#W l&&tb f p s k that UIC vi3htck -a*de&t thi&qltotdbrs of th9 Wad width. F M Jmuary ~ ?%6<a much rrl'&
pullsuph a-gM line. AbmM tread wear may Indimto I n m r d [around a$%) &ppliBst~Wdgst-equjpped
iTo~wh&Eallgpmant, v&tctes f'mt us& *dm August'TWk If the
Fuel and exhaust systems GO IQUQIqamox Bp re@uMfar mygb ta
U l ~ ~ c t - $ p - ~ ~ (~i p+c l)ucd i ~the %filler Bo~cBmsbm pass the teat [and the fud and I~nltIh
'mp), +uds h h s &sl- u n a r Ail tj Check he ~ndlitianrrf tha entire vehicle *m'8 qre@lerwIEm h g m cbfl,dmI)h l l
aar?lgment$
.- m u s t ' b ~
secure and free from ~&uWMor signs ~fM,n+pgIQn h load;Wrfw t b W u r B o r ~s M& warn, pr- =he
w.(These tncluda ah&& box 8ectlms, probhm Ih the -fuel h@tYan s@dem sr
ald& siffFs3m m d m b e r $ plllars, and all &a!@c Gdnvew (Ba E@lwiF)b
su~pwslon,dwrin&braking sy&em and HC emissions
Eisaf bdlt niolintbtp ahd a ; n c h ' ~ ~Any .)
~rm9fdn.yHlchha? serlpu@y reduced the 0 With ff78 (30 ern1~38j0~~
withln IImlts, HC
thfcknksa 6f-a Iaad-baafin&aka Is likely to midons must be no move than 7qu ppm
w w ,the vshicb 'lo MI. In Yhls case ,at '(park per millim). if the .vehicls falls khk test
h f b l o n a i r e d s ave IIDiilv td be -4. idle, h a k %tested a! w m S 2QOQ wm;
if thbHC I&bwgn 7200 p p m o r k , thls
b Dqnage or corrosion which causea sharp :~ountaas B pass.
or otherwise dsnC~musedses to b W O S ~ Excesd~eHC missions can be M &
011 bum, 13yt.Wy a n m m Ukeb it, be
due to unhumt fud.
Diesel models
The only emission test applicable to Diesel -
engiqes t$Wi rnedwhg of exhaw srnok
~ . test Involves -rating
d ~ r i s 5 tThe the
engine several tlmes to Its m d m u m
Petrol modek unloaded sped
W W h and tyms 13 Ham the q$tw ai normal aperaklnq N o t e It & d fh8 Utmost I r n ~ n W mthat the
W$mirte JdeWalts and area of m@&ub, and ma!4esurrrthatft is hIpod
wrgfne timing bidt is in g d cadi- befo&
@m.liCl~m. &aek b r Ws, M r Imw, tune spsrem In goad oordr, #r-filter
rheWTsm~arlt
b-, sepamtka of the*, and exwsure element elem, &).
rrf thb. ptl"&'md rfue tb w&r or damage. D Be- any msasurements are carrld 04 dExcwhrbmke.canb#dkwadlW
G h d that the tyre bead $ correctly 8 w d mi% the m g h spmd ta around 2500 tpfi,, air cleaner etement, OtrPemise, pmf@Stonal
on M@@ m,Xl?@%t~le vaIwAb~ t afldd md hold It at thk $peed far 20 seconds. advkamaybenew@btincl&e-a
 REF44 Fault finding
Introduction
The vehicis owner who does hls or her own
malntonance according to the recommended
sewice schedules should not have to use thls
section af the manual very often. Modern
component reliability is such that, provided
those Items subject to wear or deterloration
are Inspected or renewed at the specified
Intervals, sudden tallure b comparatively rare.
faults do not usually just happen as a result of
sudden failure, but develop over a period of
time. Major mechanlcat fallures In particular
are usually preceded by characteristic
symptoms over hundreds or even thousands
of miles. Those components whbh do
occaslonally fail without warning are often
small and easily carried in the vehicle.
With any fault-finding, the flrst step Is to
declde where to begin Investigatlans.
Sometlrnes this is obvious, but on other
occasions, a little detscttve work will be
necessary. The owner who makes half a
dozen haphazard adjustments or
replacements may be successful in curing a
fault (or its symptoms), but will be none the
wiser if the fault recurs, and ultimately may.
have spent More time and money than was
necessary. A calm and logical approach wlll
be found to be more satisfactory in the long
run. Always take Into account any Warning
signs or abnormalities that may have bean
noticed in the perlod preceding the fault -
power loss, high or tow gauge readings,
unusual smells, etc - and remember that
failure of components such as fuses or spark
plugs may only be polnters to some
underlying fault.

The pages whlch f~llw pxavlds an e%y-
reference gulde to the more Gommn
,probleme wtiich may occur during the
opeczrtton of the vehtcler, These problems and
thah poSsbte causas are group& Under
headings dmflng various.m p o n e n h or
syMnms, h e h as Englns, Gooh-@aystm,
etc. The Chapter mdor M i m which deals
with the problem Is atso shown In brackats.
Whatever the fault, wdaln basic principles
apply. Tbse are as follows:
Verify the hu/t. This Is simply a matter d
M g sure that you know what the symptoms
are before starting work. This Is paCtlcul&y
important if y ~ .am
u Investigating a- Tauft for
someone elm, who may nd have dwcrlbad It
wry amately.
Doh? oWo& the obviws. For example, if
the rrehble won't start, Is there fuel In the
tank? pony t4ke myom el&s word on tMs
parli~ularpoint, and don't t dthe fuel gauge
elthem ff an slectrteal fault Is Indicated, krok
for loose or br&n wires -8 digglng out
the test s a t .
Cur4 the disease, no6 the symptom.
S u b s t l f c r ~a flat battery wlth a hlly4arged
one will gat yau off the h a d shoulder, but If
the underlying cause Is not attended to, me
new battery wUl go the same way. Simtr8rlyi
changing ail-fouled spark ptugs fw a new set
Fault finding REF815
will get YOU mbvM m&, but m e m b e r that
&e w n forthe fouh'rq [if it w m ' t simply an
I n c a m grade af plug) will have tb be
established and wrrected.
Don? W e anythng forgmbd. Wcularly,
don't forget that a "newu wmponent may
i t s ~ l fbe etsfective le;spsclally if it's been
rattling around in the boot far months), and
&nY leave comgrorrents wt of a fault
di~nesiswquence Just b w u s e they we
new Or rwntly-fittad. When you do Rhally
d l a g n m a dfflkult fault, you'll pmbably
reallse that all the.evldencewas there from
theshrr,

Enaine
Engine bflf stops immediately
t
l W h y terhdnal mnn&ionS loose or c m d d (wUWee& tl hose or faulty elwtdml mrmctlms In the tgtlition ekuit
M-7 (ChapXera I,%Band SCJ
U Bamty dlmhargad ar fauW (Chwerm5A) VmUm I& at the c&ur&tbr, thmW body or inlet mnnIlbtd
1 1 t
l Bmken, loose or disconnected winng in t h e , m h g cimdt
(ChrnWW
(ewer 41
Blockd c e r b u W pawage, or InjwW#uel iflemon qslm fawh
M&i~&arta~ solanoid orswlt* (ChaW5A) - a w11m10.
~ { I C 4) ~
a wectlvmw motor p h a p t 5~ ~ ) Engine idrrss e-I&
'1 I7 slerter piaon w WW r i n g g w teeth loose a w~en
I (Ghapms 2 and 5 4 17 Alf fllter element '(Chapter I)
Q Engine &h strap broken or discommted (Chapter 12) Vacuum tmk at 'the~ ~ w t t h r o t tMl ey , lnk e t t d or
associated hoses (Chapter 4)
Englum rotatest but will not s&ut IJ Wom faul€y or lnmrredy-gappd sgark plugs (Chapter I)
U Fwl c u t d l swltch mergised (Chapter 4) n Unevenpr low q l l W comprmsians (Cfiapt~ 2)
F A tankempty U C m s h a f f l ~ w o r n ~ 2 ~
'0 Bmq dwha- (engine ~ S (Cham 5 4
B slowly) Q Tmln@bawchaln fncorrectty Wed (Chapter 2)
Q a H q terminal c o n n & s h s e or c e d e d (see "Weekry Blacked & u r W passage, or Injmtofffuel injection@ m h l t
cbmw)' --asa~pIi- IGhavW 4)-
-
Ignltton mponents dmp or damaged peCrd mcdds (Chapters
1, SBarld5C)
/ W e n , I- or dmconneetedwiring in the ignition circuit
(Chaptars1,58andW
[7 Worn, faulty or inmwwy-gwpdspark plugs (Ghwer 1)
Faulty spark plug HT leads @hWer I)
a Vwurn laak at the c a r h u r e t t o r ~ Wbody, Inlet manlfstd or
fl Wwn, faulty or incorrectly-gappedspark plugs @hapier 1) erssociakd hmes (Chapter 4)
Carbumitor w IWh system fautt - asapplfcabb LJ Black& carburettor pftgsage or inioctwfiuel Injection system fault
I vhapter 4) - as appllmbte (Chaptw41
Major mechanical Whre'teg camshaft driwj (Chamr'2) Uneven or low cylt'nder compr&opts [Chapter 2)
E h g h dliWwlt to start when cald U Disconnwled, W n g , or p m e d c m k a s e vmtllatlo~hoses
(Chapter 4D)
m w -w FhwtmSA)
W t t q tminal conn8cti0ns-1 m mmded (see "Weeldy
hk'7
I Wan, faulty or i n c o r m f l y - w spa& p l w @we r
1) fuel ff ltw choked (Ghapter 7)
a -
Oarbumitor or fuel injection system fault as applicable E! Fml pumpfaulty, or dellvery p m u m bw (Chapter4)
Fhww41 F:u~l~tankvsnt~Mtorfu8tplp~trlcf~(C~~4~
ather ignkim system 4auit (Chap- I,% and 5C4 V a m leak at the W u r & o r M t t l e body, b i manifdid
~ or
ow cylinder Csrnprwlons ~ ~ a p t e t ~ ! ~ assad&d hoses (Chapfer 4)
eZrgIne diiWmlt to mwf when hot Worn, faulty or Incmtiygapped a* plum (Chapfar 1)
U Faulty spark plug HT tea& [Chapt~I)
Ajr<fnfwelem~ntdirty or clagw (Chapter 1) U FauJG/ignition miail (Chaptw5B or 5C)
U Dshumttor or fuel lnjeotion systemfault -as epptieabls d Uneven,or [owcyllrtder campmsions (Chapter2)
4 mocked carburattor peswgp, or jnjecW&d lnjedbn system fault
I [I Ci Low cylinder mmp-ions (Chapter ?j -as applkable (Chapter 4)
S b d r motor noisy or e x w d v ~ l y - m g hIn
17Worn, faulty w InmrWygapped spark plugs (Ghaptw 1)
I I SCatter plnton or.tlywb4 ring gear t&h loose ot broM U V a w m leak at the mrburdttor/thr&le bdy, In& manlfoldM
BhagtW 2 and 5A) associatad hoses {Chapter4)
U S W w motor mounting bolts-1 w mising {Chapter 5p3 U B l a W wburetiw pas@ge Pr ~njwtwtfuellnjedon system fault
SbWr mow IntehralWponents w m or m g e d (Chapter SA) -as app(iWe (Chapter 4)
 Fault finding
REF.18

Engine (continued)
EmIne runs-on after switching,off
n ExmssW h n b u I U 4 ~R:engirre m p f w 21
0 Yigh wtne oprath-19temperarum (Chaptw@
~~orfualtd@m~Wm~R-~aa9plI~Wapteft
EngIna nsims
(Chzrpter 4
Fuel tank vent W o c M , oriud p l p Meted (Chaptw4) M g n f f l o n winking] or knno~Wngdurlng a w e l e d o n or
t
i Blwkgdmhuwtkor@ssage or ItijW/fual Ihjeetbn eyetern fault Wer bad
-
-

w=lt.abk (ChWtW 4) IpdUmmlrig hc@gnition @&rn fault ( G h a ~ r 3,

sM
and SBI
0 of- plug ~CM@W31
lyfltbed WaptH 21 f3 InsofWt@W:or ru4f $hap&~4
11 Vapuwn 1W at the cwhurd#witWttkb,b$, Snhlet manlfdd or
t3f Fuel p m p fauby, or dellqmy ~ Q S S U W
low (Ghsptw 4) 'kssoclahd mI[Gbapter4)
a Uneven or law cylinder ~ p [GMp&r d a Mc- when bullchp iriengin&fGhapter2)
,Q Worn, faulty of hm~&lyge~pped sp& pi* (Ghaph 1) 13 Bt-d &@uMbr passage y I n J ~ ~in]- e l 9ysf$ni fM
fI1 Vacuum leak at t h e m ~ u ~ ~ ~ rNbyt ;kinW e manffeld W -as applbhle phapkr 4)
assodated hoses (Chapter 4)
n Blacked carburettor passage ar injectorffidlnjedon system faun WhMing rrr wheang n o b
-aS-qr$2&10(chapter 4)
Brakes binding (Ch- ? and 9)
a amhdipping ~ ~ h a p 0)t w
EngPm

17
-
TlmlHg W hcar~ecW

4)
W (Chapter2)
Vacuum I d c at athe c#burBttorIthrMle body, Met manifold or
&atwd l?wes(Chapters4) .
[I1 Blocked arbvrettor pasage or Injectorffuel Injection system fault

ORpkswm wmiw ltgM i I Z ~ m C a h drdlh engbm lUMcWngor thuwm

nrnniw
Low 011 I d , w 1nwr1-W
Wl&:dl~~@&u~m
& grade-i m u W w@m@@)
wsw @mptet5A),
a im~&m0~(-4fidg
head g e (Chapre't 2)
~toWIn~-cyltr;der
Tqplmg or ratniag n o h a
a Worn valva gear or camshaft (Chap& 2)
0 Ansiltay wmpmt fWlt WLarrt pump, dkmator, dc)'
phapfea3,5,

Worn +d
w
Mf@s( w l q ~ h knotinlm,
undw bad) (Chpter 2)
w p w h ~ -1S

W&n m$n'b@nga (rumbllrqmd krroddng, perhaps whenlw

n W m q ! n s w w a* oJ1 wpp<<m.* ?I under load) (Ehapter 21
nbh &ng!aeq-g iernp&Um'(~63j Pion slap #nost n o m . w h m cold) $haptar 2)
a bilp ml?k8'\;$lh,d$f@~~(q~-2) A n d a y cornpanadfault M W pump, "antWW,
D Oil pi&-up slralnerclagged (Chapter a

2 Cooling system
€&&edng
D LMdmwolint In Wem (see eWak@c h W )
m m a t fauw 3)
. M W o r core Mocked, or gdlle restrlebd (Chapter 3)
U WJiq fan fatlib (Chapter3)
I m 4 tern- unit Gh-3)
g8wIe.W~
U Airlock in d w @ern (T;hapter 31
dP ~ P 'faulty
B Ghwter
. ~ 3)

W n g qyljndat head gasket (Chapter 2)

U C m M qllhd~tbad or fltnder block (Chapter 2)
O o d n
h tnfrequmt drambg and Rushing (f;fi8@w 11
16webtc oaw w w a r happr#priateedant tup8(see
"Lubdantsand lYurclsaBna C W a r 1)
 Fault finding REF017
3 Fuel and exhaust systems
+ Excessive fuel consumption Fuel leakage andfor fuel oodour
7
i Air fllter element dlrty or clogged (Chapter 1) Damaged o r q o @ d fuel tank, pllregpr mncsdzims (Chp!w 4)
J Carburettor or fuel Injection system fault -ag'app11mble
ExcesMwe noid or Rnnedi frrorn d m u s t m r
n
~~4
Ignitiontiming hicomdgnlWn -em -
fault petrol mdbls
E
LwMnh) exhaust sysfemmor mmtfdHjoints (Ghaprers-1md 4)
l Wing, c o m d d or dam%& sllencm or plpe (Chapham1 and 4)
(ehaptiimi,6Aand56)
a TW u r i d ~ ~ "WWi ~check")'
~ . ~ B r m mountingscausing h d y or suspsnstm c o r n w pm 1)

I1 4 Clutch
-1 travels fo floor -
no pmssure or very IiWe resistance
Clutch slips (engine speed incmsss, wifh no
incease in veh~de speed,
Broken clutch cable (Chapter 6) [3 Fwlb ctLLtUP IYeKlalS~-ZK!I.I# mb$@m FhwWsl
Faulty dutch pedal self-adjust mechanism (Chapter 8) Gluhh disc Pnings excmeidy worn (Ghqtwg)
Broken clutch release bearing or fork (Chapter 6) Chrtch dlsc linlnw mumlw witti ahr g r w a (Cm@y%l
Broken diaphragm sprlng in clutch pressure plate (Chapter 6) Fwbp-ure ptatem dlaphresm spri?g ( C h W @,
Juddw as ~Iutch Is engaged
CI Glutoh disc I l n h p conhdnatad with oil ar gcaase (Ghapder 6)
a Wutch dim2 lrnlng excmshely worn {Chapter6)
1 LI Faully w &Wed presm plate or dl@h+spfing (Chaptar B).
Clutch feik k dimngage (umbie ta seleEt man?) Worn or loogs mans or gear&x mntlngs'ICM~ter2)
D,, F~ltydutchpdal self-adjust mmhanlam (Chapter 6) Clutch dkm hub or g h o x inp* shaft @In= worn (GhapW 6)
D Dtch &sc sticking on gwbw1nput shall splines (Chapfir 6j Make when depressing or relei3uIng d m pedal
CLuM disc stickirp~sto #wheel or pressure plate (Chapter Q
F?ulsy?- plate .assembly ( W p b r 6) U Wwn clutch re0easwbearlng [Chapter 6)
Clukh d e a s e m ~ a m warn or-wrrectly wembhd Cl W o m ~ U r y d ~ ~ b u ~ ~ ( C h a p W r 6 )
(chapterB) [3 Fautty pressure plate-mbIy [Chapterg
D Pressure platwdlapbragrnsprfng brbksn (Chapter 6)
U Sroken dutch dk.cushlonlng sprir?@(Chapier 6)
I
I
I
I

I 11 5 Manual gearbox,
N o i s y in neutrsl with engine mnning Jumps out of gear
Input shaft bearings worn (noise apparent with clutch pedal Worn or damaged gearchange linkagdcabte (Chapter 7A)
released, but not when depressed) (Chapter 7A)* Worn synchroniser unlts (Chapter 7A)'
El Clutch refease b h n g worn (nolse apparent with clutch pedal Wwn ~ ~ f o l . (Ghapk
k s 7A)*
depressed, possibly less when released) (Chapter 6)
Wb-n
U kkofojl(GhWer~1

I W9ay in one d M a r

~-rty-4lw%t9 47-m
gear
Worn, damaged or chipped gear teeth {Chapter 7W
fl
a
Worn bershgs (ChapWfW
Lubricant I-
LeaMngd l f f e d a l O U @ ~ €olt seal (Chapter 78)
L a n g bsing mt ( G h w W 7A)'
Leaking inputshaftdseal(ChapW?A)*
"Akhaugh the cprm@vea c h n n w s q m m m d y the symptoms
U Clutch fault (Chaptm 6) desctibed is beyond the scope of fhs mme mdsnic, the above
W m a elmaged ~earehtulfis
I l ~ d c a b(Chapter
l~ 74 i ~ s h l d b e ~ I I n ~ m M n g # e ~ o f t h e c m d i W L s b
U Worn ~~ units (Ghapt&7~)* that the ownercarr ownmunbcate d d y wIftrftra profesdond m-k.
 Fault finding
REF.18

6 Automatic transmission
Wote: Due to the wmpl~xifyof the automatic transmlss~~on, it is difficult
for the home mechanic to propefly diagnose and senrice this unit. For
problems other than the followii7g. the vehlcle should be taken to a
dealer seivice depament or automatic fmnsmission specidisf. Do rmt
be too has@ In ernoving the transmission if a fault Is suspected, as
m a t of the Wng is w i e d out wifh the unit st111 fitted-
Fluid leakage
!I
Automatic transmission fluld Is usually dark in calour. Fluid leaks
should not be confused with engine ail, whfch can easily be blown
o h the transrnlsston by alrflow.
C j To &&mine the source of a leak first remove all bulk-up dirt and
@-hefrom the transrnlssion houslng and sumundlng areas uslng
a degreasing agent, or by steam-clmnlng. Drive the vehlcle at low
speed. so airflow will not blow the teak far from its source. Raise
and support the v~hicle,and detmlne where the leak is oorning
from. The foliowing are common areas of leakage:
a) Oil pan (Chapter 1 fad 78)
bJ Dipsti& rzibe (Ct~pter1 and 7BJ
CJ Tmsmisslon-ta-fluid cooler unions (Chapter 78)
TmnsmissTon fluid bmwn, or has burnled smell
Transmission fluid level low (Chapter 1)
General gear selection problems
a Chapter TB deals with checklng the selwtor cable on automatic
tmsmlsslona, The following are common problems which may be
I
cawed by afaulty cable:
a) Englne starting in gears ofher than Park or Neutral.
b) Indicator panel indicating a gear other fhan the one actually being
used. I
c) Vehicle moves when In Park or Neutral.
d) Poor g w shift qualHy or erratic gear changas.
Transmission will not downshift [MckdownJ wifh
accelerator pedal fully depmsed I
Low transmission fluld level (Chapter I)
Incorrect seiector cable adjustment (Chapter 78)
Engine will not sfaxt In any gear, or starts in gears
ofherthan Park or Neufral
I n c o r r d starterfinhibitor (multi-function) switch adjustment
(Chapter 73)
r] Incorrect s e l e ~ ocable
r adjustment (Chapter 78)
Transmission slips, shim mughly, is ndsy, or has
no drive in forward or mvame gears
C] There are many probable causes for the above problems, but the
home rneGhanic should be concefned with only one possibility -
fluld level. Before taking the vehicle to a dealer or transmission
spacialist, check the RUM level and condition of the fluid as
descdbed In Chapter 1. Correct me fluid level as n m , or
change the fluid if ne%ded.If the problem persists, profersslonal
help will be necessaty.
I

7 Driveshafts
Wbmtion when accelerating or decelerating Clicking or knocking noise on turns (at slow speed
Wbm lrlner constant velochy joint (Chapter 8) on full-lock] r
Bent or distorted drivashaft [Chapter 8) Worn outer constant vetocity joint {Chapter 81 I
Wom Intermtadlate beating (Chapter8) 0 Lack of constant velaclty joint lubricant, possibly due to damaged I
gder (Chapter 8)
h Worn intermedl- bearing {ClpJter 8)

8 Braking system
Not= B e f m assuming that a brake pmbtem exlsts, make wte that the Exces$jve brake pedal Wave/
tym am in gmd condition and carrectlg.inflated, that the front wheel
alignment is c o r n , and h a t the vehicle ;s not loaded with welght in an
unequal manner. Apart from checking the condition of all plpe and
[7
Faulty master cytinder g)
,
in hydraulic system (Chapters and 91
Fauny vacuum servo unit (Chapter 9l
hose mnaefions, any faults occurring on ths anti-lock braking system
shot~idbe referred to a Ford dealer for diagnosis.
Vehick pulls to one side under braking
Worn, defective, damaged or contaminated brake pads/shm on
one side (Chapters 1 and 9)
Brake pedd feels spongy when depressed
Air In hydraulic system (Chapters 1 and 9)
Deterioratedfiexible rubber brake hoses (Chaprers 1 and 9)
s
[7 Sslzed or partially-seized brake caliper plstonMheel cyllnder
( C h a p t 3~ and 9)
a Master cylinder mounting nuts loma (Chapter 9) II

[3 A mixture of brake padlshoe llnlng materialsfitted between aides

17 Faulty master cyllnder (Chapter 9)
(Chapters 1 and 9)
Brake caliperhackplate mountlng bolts loose (Chaptw 9)
Excessive brake pedal sffortrequited to stop
Worn or damaged st@ng or suspension components (Chapters 1
and 1 9
Noise {grindin or high-pitched squeal)when
vehicle
d Faulty vacuum servo unit (Chapter 9)
I
brakes applie % C7 Disconnected, damaged or I m u r e brakesewo vacuum hose
I
n
Brake padshoe friction lining materlal worn down to m al
backing (Chapters 1 and 9)
Excessive wmslon of brake dlsc/drum (may ke apparent after
9d CI
(Chapter 9)
Primary or seconbw hydraulic circuit failure (Chapter 9)
Seized hake catiper/whwl cylinder piston (%apterg)
Brake paddshoes incorrectly fitted (Chapters 1and 9)
I

II
I
the vehicle has been standing for some time (Chapters 1 and 9) Incorrect grade of brake padshhoes fitted (Chapbrs 1 and 9)
Foreigm oblect (stone chipping, etc) trapped between brake disc Brake padshoe lldngs contaminated (Chapters 1 and 9)
and shleld (Chapters 7 and 9) I
 Fault finding AeF.79
Braking system (ccmtinued) - -

- , , ~ B I wad*
JddWm#$m~gh wh-1 13reW blndim
when bra- t
i SelM W e calfplsr/wheeb cylinder piston @hapiers3
CI =ive rum&wdbtortbn BY dw&dnfms ,(Ghe@m 1and $1 k c o r r d & a d ~hm*Ke rna.ahmlnlam( G b p e t 9)
D IChaptera 1 and 4)
Brakeaadfshoe Ifnlrrgs,w.~m Faulty masWfcylinder (Chapter9)
Rear wheals lacking under normal bmkfng
El Rear brake padkhw Iln-hp contamhated (ChaptmI arid 8)
Rear brake dlsddnmis Warp& @h&brs 1 @ @

9 Suspension and steering

~ h m ' W ~ Wbe sure.thei
h l d ~ ~ 8 d oditagnuaph~
m & t the & e s I y B play in m ~ q
t R l u M e L n o t d m t a l ~ ~ t ~ p ~ m m m r ~ $ &D3'woril&ngoolumnm~&e
~~&or ~ e r f t l w ~ c h a srlO)
M
MndIng bmkes. W m track cad M@ints 1 & 10)
VahPde gulls to one gtde 0 Wain
Warn.st&rinw ( C h ~ p t10)
~r
D & c h tyw [see "Weekly checks3
h gtsain9 wauspenslonjam, bushes or Wnpoflartb
(Ckapiats1 m d 10)
a in suspensian or steeringcomponents (Chap- 1
C] B i x s ~ Lwear

1ncorrAtfront whed ali'gnment (Ch- 30)

Accident damage, to steering or suspelaSFon components lerck of powmaW~Wnw
U Bmkrrn or inwr&ly-adiwM awilaly &I- (ChapterI)
M e e l wobble m d vlbWon I n m d power s t W l g flukl leva1{syae w yW W )
D Reatri&bn in pOweFstesrlng W h o w (Cfiapts1'1)
FraM rdwheols out of balance [ v b # ~ felt n inaillly'fhough'ther 0 faulty pwsreertng pump (Chapter 10)
steering wheal) (sea "W e W ch-0) d Faul'y ~ ' w . W , F h10)a ~
Rear W w h W out of balance ( v l b r a t i o s . f e ~ ~ g b wthe
rp
whlde) (see 'WeerWy Eheck")
Roadwhds d-ed or distorted (sw'bV&$y ChWa)
nF W or~&wedm (seau W ammk3 ~ ~
t7 Worn skerrnq .wsuspensI~1joints, bush= #m'mponents
[Chaptm 1 and 10)
wwetaolrs~l#w~rq
a t r e m l l .amund mwhem,
a D W v e shock absorhew (GhapWs1 md 10)
D Broken or wW sprlng andlor %uspgnsl~n
ccrmpanent F~&ws
1
a d 14,
, E
l Worn or darwgd anff-roll b8r or rnount~wGhapWlOJ
wandering or genemi in-w I I

Icou~ectrrantw h d alignment ( C h W l'o)

l
l Worn or suspmion jointsIbusnebr c9mpMlents
(Chapte-m Iand 10)
a R O M W ~outof ham= (8ae .WW Q M C ~ ~
U Faulty or dm& tyre (see " W W y check"?
Wheel butts hose (Ghapter 11
U DefeEtlve shock &sabers @hapiera 1. and +Q) T ~ N Sworn on in-e and outside edges
13 Tyrsa under-lnflmd (sm* W d y ah&&')
Examdwfy-sWf sfeerfng
Wad a r e h g Ilbktge baOld;Mdrsuspehsrsn batyPWt,(cbpiers.I Tyres worn unevenly
and 10)
BMkeh rn l n ~ l y i a d j j u s t e au~i1Iary
d d & W - m0dels wlth ~ ~ ~ M t t d ~ ~ W ~ b e h a C k 3
w W n g (a- 11 n EX&W wheel or tyre run-out [Wptet 19)
a
po
-
Fau& pawr steering pump whete applicable WapW 103 Worn &ock absorbers (Chapters1 and 10)
r ; ~ l tt
ym (e
*WWY -7
w n g '+
Incorm front wheel alignment (Ghapter 3 a)
dunsgd (maptet
 REF.20 Fault finding
IL
10 Electrical system
Not= For problems assocjated with the starting system, refer to the Windsemen wipers hopemfive, O r lJn~afisf8ct0ry

-
faults listed under "hgine" earlier in this Section. in operation
E a t f e y will not hold a charge for more than a few wipers fait to operate, or operate very slodly
dam n
7
Wlmr
- blades stuck to screen, or tlnkage se-d or binding
Battery befecGfh(eInternally (Chapter 5A) (chaptir 12)
O Battm tennlnal connections loasg or corroded (see " W e W n Blown fuse (Cha~ter12)
6 Cable or cable connections loose, broken or disconnected
A ~ l i a r ydtiWbek w m or kfmrrt)ttlY@Ustetl (Wpter I j (Chapter 12)
l Abmdor not &wlgat mrrect atrtput (Chpbr3A)
i 0 Faulty relay (Chapter 12)
h a t o r ar YO&& ragdawr faulty (Ctra@~r5 4 I7 Faulty wiper motor (Chapter 12)
13 @fj-t cau&ng ~ontlnuJ battery drain Ghsi3tes M and 12)
Wiper blades sweep over too large or too small an area of
the glass
'
, U W 1 p e r . m immectly pirsitkhe00 &ndb.(QhapW 12)
Amiiai~drivekit braken, wwni w in-ly adjusted ~ C W V B . ~ W D E M ~~m~t a gpaper
~) 14
(~liaptdf1) Wlparnwtbr or IlnlcagPi d d n g a h s r q or Itlsscum (Chapter12)
Internal faub h rrttbmator o r w k & € j ~ g u(Chapter
I~ $Od
Ej prom, S i W , or Iowawtrhg In charging d m
Wpr@r
&nitlan/no-&ag~ w d n g li@t,'faIIs come ma
0 Warping Rght bun3 bklwn (Cheptftr181
Braken, dWonWed, orloosw wirlng In d n g rtghtdlrutt
(Chaptep 12)
Akern#orfaulE)c (Ghaptw54
Windscreen washers inoperam#or
unsatisfactory in operatmn
Bl~f~~e(G~pt~r-12~ One or more washer jets inoperative
,~auw d a y QMf $8
Bfolswl. ?-I QY @$tmmW
wiring ,(GhapW,Ia
a FBU~ S(mapper
~ W i21
InsXnrmenf m8dlngs- j or emtic Washw pump fails to opelrate
imm r d s n g s i w e m wfth ~ g h sep a C7 Broken ar;dlWfinea!d-Wg or,mn&iow (Chapbr12)
d Faulty voltage mguhtor (GHaWrla E l Blown fuw Ghapter $21. a
t] F d y h e r $ w b h @hWr121
Fuel or ternwmture gat14- @weno m g D FauN wzgber pump @hpt* 121
D F a & t J ( e sender unit (Ch@wrs %rid 4) Washer pump runs fqr some Zime before fluid is e A i M
D &7rljirlng open-cmlt (Cbapter'l21 f ram ids
D FauW gauauge (Chapfw12) a ~auttyone-way valve inn& suppty hms (Cf~opwr
l?)
Fuel or temgerature gauges-givecon~nuousm i m u m
=dw
13 F%UWgauge serrder unit (Gtrapfek3mdrt) Electric windows inoperative, or unsatisfactory In
Wltii5~shMt~tiffiuW&h@~~
12)
Q FauM g a u p (chaptw 12) operation
H m fnopemb, or unsatisfacfOryin ,opempon Window glass will only move in one direction
Faulty switch {Chapter 12)
H i m ,aperatesall
Horn w h rpitksarthad or down [Gblapt&t$2) Window glass slow to move
d om &le-ta-hwtl wsh'$arthd(Ch~tw-t2) 0 Regulator seized or damaged, or in n e d of lubrlcatton
Horn fans t~ operate (chapter 11)
n f l ~ w n(EhapM
f ~ @
I Door internal cornponentS or trim foullng regulator (Chapfer I f )
'0 C;abk ~r.eatSh5mnediwta l o w broken or ds*anrtM Faulty motor (Chapter 1 1)

ama*
FaulWhmIChaptw33 Window glass fails to move
Horn emle l n t e m or unsatisfa~tosy
sound D BWn fuse (ChapterI@
r;abte:aonndonsldw ( G ~ 1Q21 121f
Faulty m l ~ ( ~ h & W
El Hpm mounangs lase (Chapk 1
4 Bmkh w dtsconn&ctddttrpg or mnMions (@hapter,121
fl Faulty horh (Chaptir 5 3 D Fmhy motor TGlmpW 11 .9
 Fault finding REP21
Electrical system (continued)
OenWsl loEWng sytsiem kmperaive, or O m mlendcVn#or fab-to operats
unsa~cfory in ape&br# Wkeil or dlaoonhected Wtg or mhn-s (Chapbr I?)
Cornplmsystem failure D
@ulty-arnt-a-w. Im.* f 1)
Emken, bhdlng w dWo~W&bdfafch apemng rMs oi tww
Blown fuse (Chapter 12) {Ctwter 1I)
Faulw.&y (Chapter 7Ql D Fa& In dmr I a M (Chapter l q )
U Brbkerl w dlmnn&ed wirlngor ornnwans [GhzrptP It)
n FWIQ -r; (CQW 113
Wch-1 b& &I ndml& ur unlocks but will not: lo&
n ~gluwW ~ I ~ W R G ~(CWW 121
D Brdben ,ordkmn- latch operating rads of L v m
(chgpk'gr 1'$ -
n WQ,day'@hqter 12)
fi FW8WW{ChapPterf1]

i
..
 REF022 Glossary of technical terms
would tend tq dog the mdiatnc and cookfit
passages and.redu# c&g effk@ngr.
ABS (Anti-lek brake system) ,Asystem, Aiitl4am compound A codtihg t h d
usually dWmnlWy .m$~oll%d,, that sans= &urns rlls 8dR of ~aflrrsoh f a ~ m w t h g t
Incipient wheet k k u p during bW)ng ah! ,are sub@* to high temperatures, s h as
reliev@ hyOraulic pp$sumat wheels that m exhaust manifold b o k ' W Rufs,
a b u t to &ld.
Air bsg An lnfktabk bag hiddm In the
er Wte8dwhor
Wring w h ' d (EkQver%>s.sldkj
glovsbx (pawenpr Jde). In a head-on
C&M, h , b a g &Imre, pre?rem&shedrivm
and %q$passenger fmm belng throw0
W H Othe M i n g wheal or windscreen.
Alr w n e r A meld or7piastie kwblng,
8 filter plerpeh& whi~hremoves
o.srbtrrlnk~~
&st ?nd art from alrh
.btgdrawn 1litP.W~
-e
n
Air Wkw dement The mud f i b in an air
cleaner system, usually manufactured from Admtm A natural RbrouS' minerd wfth$@
pleated papet and mqufrlng renewal at regular Keat f@istmce, cgmrnonly used in the
temporary electrical connections.
Alternator A cohponent k tti6 electrical
SS;sXem wfilch gonye~smhaniod energy
from a d r i v W lnttr eIflcfrittl Aensf$yto
c h w She battery snd to opwrate the starting
system, Ignition' n'ystem and elwrirgl
aGl%ssd&
Ampere bmp) A unit of JTIWW@B,~~
fw the
f r 4 'of BIWG ~urFBnf.One amp is the
mount of cunrii pmduh&tt .by one volt
imihgtm,ugba~~ of om ohm.
Anaerobic wler A pubstm'cfl wed to
ptewnt bolts ,and screws fmm Ioas~Crng,
Anmmble m n a that M does not req~lfre
oxygen for antivation. The lactile braind Is
Wely m d .
A n t H n w 8 A substame (usually ethylene
glysd) h l x , d with w,ater, ertd added to a
MkMs cooling systerh, ta p i d o t fnSdng
oT t h ~eMl@t In yinter. AiMft.@ezealso
mntains chmimls.20,fnIWt corro&ionand
theYoh~~tlw @ ru$hnd other depOsik thd
I ~mnbrn*
~omposltlon oi br&e frktbfi rnanerihls.
Apbegtq$ b a health hazard and the dud
created by brake sy&.rh% should never b~
ch alpel revokes, of
whtuh revolves with .a wheel. Also, a sutld
b e h Mat c o w tme two wheels at one
and of the vehicle. Ah axle whibn i E o
'tmsmitspnwsr to the Wfqls is h o w n ets s
Nv4 *.
Axleshafi A plngleur~rat~ng &aft, m efther
sjde d fhe d h n f r a l , which detlvg8 pow#
from tM final drl\re wbmbfy t o W ddve
wheels. Also catlad a d r i ~ a ~h R~ W
B BreWngshWms For more infbrmatii on
k t 1 1 bmtltrg An 8mTkic#bn b-yring
G W m g pf a h a d m d inner and outer rack Breaker barBrsha Maqd*
with h ~ Mwm
~ steel bajk d wmnm providing greater
k d h Me ~ o~:&@sucfp,on a shatt-wln a
bore, er the parl a m b W i m o - l i i r , that
~ R Srer1,qtiva
. rn~ttm
Wmrn them wlfh
mhirnum wewTandW&fi
Bk-end bearlnn The b q h p In the enrl of
the connectlflng md &&'s ~ & G W To the
Sf& nipple A v a b db a brw wheel
.cyilhdw,caliper orather hydfaUllc.mponerrt
that is opened io, p w p th@' -E, +YSMn
aftllr.*c$)tedBbw-.
BfAh w i n g
Brake bleedha WOwdure for m 0 4 n g air
frdm llhes of e hydmulic brake sysfem.
Brake dlsc The ,z+rnppgent of a di* brah
&at rQW6-swrth the whaela.
Brake drbh The compopn2 o#a dwm brake
that rotates Mth the bvtwk.
W k e linings The frlcllan material whlch
mnt- t.lw brab dl% ardnih-rto reWd the
hiehfcle:s spa@* The linlrt&ls-arebond& ar
r l m d to ths brake pads or stwe&
Brake pads The mpiamaMe frictton p d s
jhak pplnch the tirakeudIscr the kt-akes v,
aaRRJlsd.Brake pqds m& of >aMCfian
mahat hnd;rd b r riv- b a rigid backing
plate.
Brake shoo Me m"mnt+apd ~ w r i tn
y
w which Wa brake linlngs are mwnW and
whi& ~QW
the Iinlng Bga!ast the rot~ting
:dPrtm dymgbraking.
braking systems, mhsult thg Names
AbinbtWir
A: tons socket wmrleh W s
levitage.
Bulkhead Tha Insulated partition b e t w m
C
Caliper The non-rotating pattofa W M k e
assembly that stmidlm the dlsa ah,d wries
the brqk4 pads. The wllpr aka conblns Phr
hydraulic cornp&ents Wi& gw the @& b
pinch the.disc Menthe b & & ~ apptled. ;4
calw is &sb a mwun'ng Qol that can bw
& w, measure Ins& or autsW dimeh&ns
d an object.

C m M a R A rotafing shaft on whiih a &9s
of e m -1 operate the valve rnechmlm.
Tbe wnwhaft ,may be driven by gears,.by
sproWs.-and ealrl or by spmkts and a
belt.
Cmlstiar A container in an evaporative
edssiw control system; conWs aetlvated
charcoal granutes ia trap:v-urs from the
fuel ayslem.
G & ~ TA &vim whkh M a s ke! with' Oiearanee ?$ y p ~ n of
air Iii the ~ " b p eprQpsr2ions
i tb pruvide a two park Forem@!+,
d891red pwer output from Ig3ition 4 wllndw, beWfi.abearjng and a J o u d ,
lrct&&~mbu@an e r q 1 ,
m w o r
~ d e l l a f e dRemmbUng be W t s aJohg Brqugh an andle.
th6 top of a castle, wall. Far example, w Cam plug A dlsc ar .wpsh@peglm+id
WekW balljoint stud xiut.
Glossary of technical terms REF.23
c&&b m m r A sitmh~-tike,dW.lh c d H e clip See Aliior clip
the exhaust ay6t8m which converts cert~in
p~UlYtailtstn the exhaust gas& into
harqul substances. h
U
Dbgnoattc Cede n v m b ~ W n e r d
by
wmsh&1the d@ngqc mFlcis d an engin9
m m ~ m e n t . ~ ~ m g u tTfib
e r . M e ci# be
uired'to d4feflIne thhp F a h the sysbm
w h n a maffun4pron m q be locatd.
Wise brake A b p b WIgn incorpomti~ a
r~tatfngdbe dnW WTch Wlte Pads a n
qWgd The Whl the
energy of a mwlng vehkls Into heat
Pwble-e-crverhaadmamWHC) An engI~4
thar uses ~ W Q~Varhead&~rnshafis,muk@
on& for the intake valve8 and one for the
%Mukt mid.
cmi#c cmverfw t)rivebelt{s) ne IMtle usad to did*
CifcIIp A rlr@-shapadclip used fo pr?veF ack@wor[e$sucb as m e pRIrnarw, wm@
e~dwieemom8m.M wlinddcd parts angl pump power st#rIng pump, al'i,'@hdlfl&ft~$
,$@a.rts.An intsmd ~IrcJip,is !nWied In a crirpr&@tr HE.pff cranksha pulr@yf
groove In,a h&&j.ari extmJ.dircHp.firs
Into a gwvs-on th$.~utsldeof a e y l i M W
piecesuch aaa sh&,
t space betwwn
W w & e PlWn ilnd
eta
Coil sprhrg A. q p l d at elaatle sttee3 found in
varioue S- through~ut a yehip@, ibr
exqmde as a springing me&wn in t&
skqmabn md In-fia.%t!vgtValn.
G o l r l p m s i ~ RBChadtioh h m(urne, and
ineba& in mx:e%yreg d Wmp.$mtU~J af^a Dr9eshmft &iy st& us&$ @ t m ~ m l t
gas, o@u-d by quaezlng it Imtw a smaikf mo#an. Cmrnonly used when ta W
&asha% on a front *eel drke whicle,
Qomprwsion W o , Thi ~eMjar$hipbetw88n
c y I i M r volume when the piston 19, at top
dead centre anrl qlfnder velum Whw the
plstorr L q Wom-dW,mtre:
c o m a @ ,kdoclty (CVJ Jotm A type of
w n i \ r w MnP Ittat ~anwlsout vlbratiens
mused by drtdhg pawer bdw wnsmmed
& b f i b A tirpidsWb,us\ng 8 a m -
W e Imetted'ina hole In ,a casthg thmmh Wd metal cylinder attwhed to the ~ifnbr
which flre NaC nmovep whgn the casting st&& of ttG whwl. menme tx$w pedal is
was forme& Also known m a f r m e pltcg or pressed, curved br* shoes d t R fric~tun
~ 1@lug: ~ ~ 1 tl?lh& p&$against We Inside,af the drum tq.
Crank~aswThe lower part ~f the' englna slow or* ttm Vehhls.
block in whloh the crankshaft @at-.
Crankshaft The main rotatlng member, or
shaft, running the Cngth of the creytkwe,
with otlset "~rowsd~b wh~chme connltCtlne
rbas are &wed.

Eastor In wheel allgnmt, the backward or

1 0 t W ~ dY)lt 6f th8 & Q & ~ Q Mi8. C@0r is
positive when the Bkeerrlng axis 1s IIndhed
? W a r d gt lttop.
REF.24

E
Glossary of technical terms
Feeler blade A thln sMtrip,or blade ofhar&Wed elW b d e In @ sp&% plpg. p l l p l l ~ T 'to
steel, ground to an EX- thi-, US& to smClng bdwaetl tthg points In a' con@&
& ~t
b
i
EQR vzmw A vaive W to h i W m ax!!&& ,mar ~ U ~~w E r u a nm w pdk. breaker m m bIy a ~ ~ n v ~ 1-pal* on~l
g#wJntoWlnkke&Or. type igrtkim, ~ r t the
o di&mbetwaen fhe
reluctor & rottor and $he pickup coil' in an
electronic ignition.
-
Qmkt my mn, s80RmaWat usually wrk,
cardboard, asbestos Gr SO% M I-Wled
Is.etw$mtwq mtd eurkes fa ysu.m a good
seal. hr Instance, '€he'cyllndief,,b@dgaSlW
gears tha ~ ~ktw nm t ttre 6'biaFaFyhd
< >the
GVH* hedd.

EGR VaM
.r'
m u l e ~ n - 1 mlf (EcQ A computer
wMch GO- (for iW&) twtb bd fuel Fdw W e
IWQ~ %@tWS, Qr 8il ~ * h k b q n 9 Firing oyler The Md6r h Which the mgil
m m .For'mcp information r@fwto the q ] l d e r sflm or d d w r **ir me+ S~FOR~
AWomatic?zr#emHu.al and Ef$Cfmnl~ tieghnlng with h n u mM18 eyllnder.
Systems4&nff al. Ftywhael A heavy !$pinnlnQwheel in wh&h
EhWonic FueI I d d o n (Em)A ampufgf energy 1g abqrk$ gnd storad by mems'd I
conM1wl fuJ ajlgem hsftdMtribMes fud m m m , Qn m,Q I ~ i . R ~ l s & lel F g h d
throughm-r b t e d in -h lrrtake part. to t h ~;tmbhaftto smooth out firfng
of W m 6 ~ ~ . Irnpub&. Qeyge @I instrument panel display used to
Emergency b W A bmkh SYsbm, Free play l-tm ammt of travel before any tnanltor mglni dnditlons, A gauw M h x
IndB D BWit
Wt can be uwomslaw br W
P
~ @ !the g $ ~hydmd c W3t8m3 ~mn tdi~ pl-. me al&qnesam in a movable pIWm &dial or a flxd %aleIs an
h
V & $ h If ]ma?, an m-bly of p a , kenteen h e
Wm TbII,. dr to-md ~ e h l d g jnftiJ &ppticaHonn OY ~QY&,, :wd -WU@I
anat@& gauw. h gauge wlrh a numerical
d o & is agM, w g e .
@ M C ~

atationw wen though the-bee Pedal Isn't movepwjt. FW example, the dlstanoe the
& m m . It *uaily oan- of a hand lever. petid movb $dfm the @stomIn-the
that actuafm eithw fibnt or r4ar 6i&e'8 g~~
m@prIlrslly hmmh a *I=
Il-
'of cables Fuse An &lectr@l d ew which prdy2b 8
known as handbrake 07 dmust a g a i d . scidentksd. mrlozd. The
H A. rahtihg shft that transmits
@ m W ~ ~ - typl-mlW q a i n g s -803 PI- of metat pa w vom,trip dnq!'dri\ce unit to a drive
I

~ n d t f d f"h& mldrlt of l~!$hMke which d b d d t~ mett at rr pi&etemiihed !hen referring to a Iiva r k

w h d , ~u;iil$
m 0 V - m m b WPlM to a wrrerit flow -wed @Samp$ arrd break axle.
*ramhati, I h dlWanc$ that the emnLt8haft t h ~~W , U K H m u ~ i l 'baliih~er
e A U I c e W g n e d to
?an, w e Torward end back i n - t h e ~ l l n d ~FUSIMVJ,tjnk A circqlt propoiiqn dedce MU^ fbmih or misting yibratjon In the
blot&. oonshling of a ~onducrors u ~ b u ? Mby wanj&ftiM a y & i n o a p r a t ~ i jIn the
Ennine management ,batem (EMS) A het-mshtant tnsulatton. The ~onduatorIs -maft pulley. AIW known a~ a vibration
w m w r mntrolled System which pmag,e mallsr #an the w1ra.R prohc&, % R aFfs as dmper.
thefuel tnjdton and *he gnnlon sflem>Tn the w e {Ink h the d r w k UnlIkea b l m &I s&&e b o t for camcting small
a n C ~ ~ ~ afatld
fuse, ~ fuslMe IlMmwf fraudntly be Imulirjties 6r d#qrencrhe ln'&?iiZar h hn
Exhaust manlfold A part wM1 seveial c @ f m t h e w i r e f a r r e p t a d wglh&gylind$r, h k 0 CYI- etc.
pwage$- W L u w ! hm We@, twve Nydradlc tappet A t a # M that utnlhw
the engln~ewnbustbn chambps and enMr .hydraulic prpsure ,fi.arn the ~ g i n e ' s
theextwstprpe. bW&n s@erdto mal+ mc Makhce
G
Gap The dlsimw.the spark mtisrt travel In
toonstant CQ#&&, w h @bath oamshaft and
wm
'due-stern). A W ~ ~ . & l ~ KQ WW
jumping Worn the e m e l m d g to,o.the sZde In wive atern IenQIh. Hydtaullc -pet$ a h
reduM ir rid@.
I

1
IgnMon #mhg The m m t & Wch WUel
spark pltig<%hs, us@lQ wr-, In 2M
number .of crankhstt degr- b&re the
l3hau-!@d ptstifft mlmmetop &&,stme.
Inlet rnanifald A tube Or houslng with
pa&ages tkirouQh which f l ~ w thgrklr-fuel
F
Fan cluteir A Vhcaj~s(fldd)drhe c o ~ l t q
miflure jcarburettar u$hlola and uehigles
Wrth thFdttle W y Ihjs%Han) orair mly b r t
device whkh peftnks varlabb engine 'fan fuetiflmted vehldes) t~ the part bpenh7N h
In MatIon-toen* speeds. Aalusting spark plug gap Ws'cglnderWad.
 Glossary of technical.terms REF*%

Overheaa cam fohal engine An, eryline'iulth Rwker a m ,A l e y inn that i-ocbon'sshaft
rh;e camshftjs) I
- cm tap,?ftho qllnder or pivots on a stud. In an overhead waive
Jump st& Starting the 8ngine.d.a vehiok hha6(~). 'therndW % COW& the 4 p w d
wth. a- discharged or weak baXtev' try Overheadvahre,[m +me An-enginewith movmsnt of the pushrod Inb-a dawnward
attaching jmp beads from the weak M e r y to the valves kue@cY in Me:dyllfider h k d , but rnwemgnt to o#eh a valve.
n cYlarg&.or helper M e w , . wite, the me lacat+ in the engine bl&. Rotor In a dfstrlbutw, +hewtattng device
Oxygen sensor A devtce' Inapalld i h the lneld? ih& cap that 'cpnnem' the cbnwe
engine exhaust mynibald, which senses thm d&x)de and the outm bmt& as it t ~ ,
axy&e'n opmbnt Inthe e'~xhaxhauSt
mcb mSIP,&s distributing $13 hfgh
WFWBfrom thq.'W11
tR& hbrmdlon thtO w e&th m. Also ~ d i d n q f ~ t h p m p s r ~ p n g .
sehsrng Prppo$mW valve ILSW c%lM4 WW ghsbr. Alsoj thai paft Of a! a l t w w whim row '
A brake.hydryl@ sys&r~ qontrol vdva that Insids the slam. A h , rotsfmg aasem$
worb liks ,a~rmq>@pning 3alv$ but also af a>ium~h~rgq, ln+udt$g Itlie,,ciom~w~r
takes Into c o o s l ~ l the ~ namount of wdght ad, shaft and tljrblb whed
o w e d by Me I.eeu'wle.
LOG^@ A nut used td lock an andfustmed P sw he@dhavfnga
Runart The am.ount,pfw o l e fln-~d-gqt'
m o v s m t ) of a &wWwh& as Ws rot&&
nvt,~~mer thwauc@wrnpmeht, tn ~ I ~ C QPhllUps
c
:
m s
w e w A8typetYPeof
tnstead'hf. a slot for a *omspanding The,mopt *shaft ~e5Raut-of4rue.* The
For + x q h , a locknut Is m p @ d ta keep df'a roMthg -Fjart
outd-r(3u'nd~mndiim
!he.,a#y&g nut on tho roOcW fn a r P . p f ~ W .
P M g a g a A min sf@ of piastki thrwd,
posttian,
Lodnvasher: A Tom of washer d v i n e d 'to wdtwble in different slzes, used k r maswhy
prb$ird $I attach'rrignut from working l o w * c l & t k c b Farb&$a, adstlip-or H#M@aGe
Is l&d a-a b w n g jwmal. Tim prts,gre
&&bled md * d h , H b d ; 3 h 8 width d We %slant A Ilquld or p&te used to prevent
m s h e d s b i ~IndIcW the cleganm b-f? leakage at a 10Ini~ Smetlmes used in
M
Akao~h-n strut A type of front
iou~#andW n g . cdnlUnCfi6if With %@W,
w e c l b w m lamp An older headlight
$uq@$l$it *fern -de$*d by Eaflb d@I@ whfch integrates t y Peflwto~. mq
h ~ h e m o atn FM.dEnghd.In &adgin& fihrn- into a Rmeticallv-sealedone&
@m ~MIPIP~B iaperal I k w i f htheantI4l W unR, when a,fiIament hu&s put ar &Jnn3
i:&h-the m wr cdriw mi.A lonP strut - cmb,the antlre wiit Issimply rapliied
+EpWttns drivebei? A singleJ long.. wide
an integral coil spring and shock abso4wr - la
m o m d between the body and We S~W~IIQ accessow drivebelt-that'e umd on somi
newer v&lcles to drive all the acwsoricss,
bt& o f a serfes of small@, sh~rterbelts.
4 &nut rely om the anti;mll bar for Iomtlon. Sspe&m drivebelts are usually fenslond by
Y riRZm9 An aktrlFat tesI InGtrumeht,w$h ill asltomdc bensronet.
the cap&ility 10 mweure voltwe, cumnt and
Teslstanoe, Propeller shaft' Tha tong hollow tube wW
udversal lolnte ,at both ends that mrrles
WBI' ffwri zr'anemiwlonto t$~edIffwTdkl
on fmnt-dgined rear wttddrjve vehiClw.
PropMtlohing vahie A hydraulk c,ontrpl
NOx Oxid- ot Nltr~gen.A mmrnoir'loxj~ valve whlch Ilmiis tb8rnount of prmum to
porUtgVlt emM& hy p&ml and d I M engines the *brake during p a n l o ~ wto. w e n t
@ Mgh& &mprpltures. wheel lmbup.

R steerlng A &iring
Ohm The unlt uf ifelektdcd rdstance, One Rack-and-p1-n
volt applid'to a resistance of one ohm will system with -a pi
p i
n i
o n g s y on the q d af tha
pmduce e m n t of one mp, steerinb shaltthit mates with a r a ~ &ink k bf &qOMfim drivebelt
Munmetw An lnstrtment #or rneasuPIng a geared wheal .opera& yp wd laid flat).
84arieal reSIWC8. When zhe WM shim ftrh & w r , dbmwtohly used ta adjust
i~'turridd,tfiBBpinidn
O-ring A.wga of se31n~ring made of a turns, mwhg the rack t w t b M o r right+This the daarance or rdative pitions between
specla I.lrbber-1ffEemaXeriak in W7$6 O-rlng itibkerilent' Is fmsinltfed tfimGgfi the trakk two parts. Fot w@rrplq,Nms inW@dIm:op.
la ~ornprewnsdInto e g m v a to prwlde the rods to the steeri* arms at <thewheels undw bucket tqppets control valve
sealing &ion. Raqiabt A Itquid-io-atr heat tyaJlsfrjr devib, cleamnces. G @ B ~ G @Is adjusted by
designed to Pedu~ethe tem@sntured t h e chmghg the khickn~asof thd shim.
wolant In 'an jnternal wmbustIon en@m Wide hammw A spehl p$i,e fhai hqews,
Cmims&m. Into ar hodka onto a com~onsnfsuoh as a
~ & n t Any substance used as a heat shaft or bearing; a hesvy diking handle on the
transfer agent in an alr-conditionina swtem. shaft bottm walnst the end of the shaft to
R-72 haa"baen the principle refrliGnt far knack the eomp&rrt m.
many years: ~ M l yh,d w w , rhufadwmrs Spmket A foth. or pmiedtlatr on the
have begun uskg R-l34a, a non-CFC p&phwy at a wheel, shaped ?o engage wlth B
sobtank 4hak is -mnsidW lw hamtlll id &kinn~r'driv'e23alt.C~mmonll,&d to mfwb
the ozone in the uppr atmosphetra she wpckd wheel Ibelf,
REF.26 Glossary of technical terms
8tarter inhlbltor switch On vehicles with an
autornatlc transmission, a switch that
prevents starting if the vehicle Is not In Neutral
or P a k
Strut See MacPherson stnrt.
"r
1 a wire insulator to dlstlnguleh H a t wire from measurd when t h e d w is410~&
tqpget A q4i88ricai component which
m s m r t s rnotion+fromthe cam to the valve
stem, either directly or vle a pushrod and
rocker arm. Also called a cam foltowar.
Thermostat A heat-controtied valve that
regulates the flow of aootwi between the
cyilnder bl6MaMf Vte radiator, sq h t o r ~ l
optimum engine sp?f@t,leq fempmfure. A
therm-t qlm u@dTn.mhairelemem in
which trw temtpwmm 1s dulated.
.-st byr[h$ Thft .t$@rlng En me clutch
w6mbly that i s mavgd in to the release
IWmby,dutch wdd 'action to dIsmgqp the
clutch. Also mfmd taas a d m s e b d m .
amlng belt +At&@ be& whlch dr~ues-h
damshaff. Serious&@ne damage may result
c b e r tw&w et the h n 4 than at the rear.
On rear WM drive vehlW,a sdl&t amount
Toe-out The amount the front wheels are may be started, stopped, or regulated by a
t b . rnbvhki mftthat @peps,shut$,, or *[ally
closer together at the m r ~ . q i ~ frbnt.
On front wheel drive v&Wpia slight amolrrlt sMm& one .or ~ mmp q b or pw%Mp,
of ttoe-out is usually spWM. A valve Is a t s b ~ mqWJe
~e part .ofsuph-a
Tools For full tnformtjpn qn chowing;wd dwice:
l ~ e dmancs F'b'dmMNe m e e n Vw
using tools, refer t~ t h d , H @ ~ % W ~ ~ ? o f Value
Tools Iwanual. . vatwe ~IP(the end Pi ttle v&e,lem) and the
Traoer A strl* of a s&md &lour a'pplbd @ m k k i or Mmt. T h e ' ~ l y e ~ . G l W W
IS I ~
another one with the same colour insulator. Vernier ~ f p e r A pm&@lon m@surIt)g
Tune-up A process of accurate an4 careful iinatrumed Far rn-ud lnsi&).dit 0bfiMe
adjustments and parts repla&mf # bl%n dihiehsrdris. Mdf q u b w asburem as a
the hest m W eenglm petformanm. micromety, but more convenient.
Twbadg.er A centrifugal devlce, drivm by W h s l t y The thickness of a llquM or It$
exhaust w , that prassurises the intake &. ~ ~ t o f 3 w ~ ~
nNormatly
l~ u W to increase the power autm *oft 'A'+ :'Dm
f~ ~ Q r e s l n ge~e#rtc~tl
from a given engine dispfacement, but can s p r e e W b a a%ik Ditk volt that wilt
also be used primarily to reduce exhavj pw+bi q q t ~ 'ho oilaqpcwe ~ through h
missions (qg on VW's "Urnwelt" Djesql - d p n e h
engine).
. >
. '
w
Welding darious procwe& used to 301"
metal 1terh8by w' fhe am to b low
to a mdtm @ateand f~aim m w .
For Imare fnfbth~tianrakjr to W B ~~
dubnWw .IrVeldm~Mmd.
Wir&tg diagmrgr R dfwing m g n g the
cmpmmt&.andwireseh a mid&&9 I M W l
system, u&ng d m W I W WIrqIs. For
more, 4&maaUom refer $a . .&e
~ u m a~~~~~~
m
Mamat.
 1
I ' . .
Index REF=

Nde: R&mc@sthporrgbout this iq#&,&re h tW fsmi - Fhapt&nurnW "Page n w

A Mjary
--
drivebh IA*8,1@*0
fuel pump 4 C d
t ASS-949, g a l
Ascelefator
fue1tank -436
$&ud& - 12-14
d&~ -
4As2, 4BB*4,>K*4 -
shaff 2E.12
p W -'dip& &Mi4 0 4 w a r pump,-,3&
I Aer$at -12*j8,
Alr.cleaner
air tqpe* Cqntrol system - I A ? a
- B
1. s m 3*f ,ef saq
W,-IA*lR1B*17
-
h?tJ@&q b i j t * 2 , dk2,4C*2>

h ! l d and mfitdrrg - 3*92; 1

.
3 3 hfmy 01 -
. 8 5A*2
4&fibt$r~lement-lAfl,jB*l'7 dlsronnection - REF*7
" - -
12*18,i2-119
-
1
A~@WW t i ~ = 2 + 5 ~ 4
bnrsh h g b i r q u h f o r ~ d u l -$Wa6
A~U-IO* G ~ k i n @
g PgIQ,g e l -
-
bracket b w h ~Iam12
enan&2E*18
hub - 104,10.9
1 Anfl-mM081 4C*-I4 - W f i g arm - 10-11
Big-end b 8 & -~2%18
1 @r-I.OIT,71D.g'
1 And-thM8Wm--l12*18 WW
W w -0*33,OiI#, 1&*2,1A*25, 18.2; 7Be22 brakes - g-4
- wst&,g - 1P d S

--
Awb@?i?W:h m m m a3*l.@.twq po
.and enghetemqval 2E*7 B e 12.1 eP&q
-7h4
q@r~pUte;
d ~ l a l , ~ t pS~ ~~~tB*$
-
#I&1b.23, IB.20
S~ 1 1 - B W e x b r l w ~?1*17
BadyvPrwk- l f r l ~ t s ~ q
mUMon chpd - 1A*ld, lBe15
fluid.- Me, lA d , IA?& ?A=@, 1ar2, I
B*$' led20 Bonnet- 11 *7
d l s r -,T0*4 ~ m k l ~ s g g f -a *~ rna w
ici- - 7B*3 biding 9 .
4 -
lib# pwmimm 8 0 r - 7B.4 M@@ -9~9,948
multi-function awlkh '7B.r d i - IylFI,18*15,9.10,917
~ v e r h s-~7B.4
l -
dm& 1A*24,1 &*a, 9*11
rsMod ~d ~ ~ f l t € hWe4
g - fluid- 4 ' $ $ 0 * 7 ~ . 7 ~ ~ 2 4 , 1 B ~ 2 7
gWt& Wlb- 7 8 ~ 8 -
W s l44Et;1 B a l & -6, Qa1.4
5ehAQr~ - f ~ ~ h w7B$ i~m- pedal- 9 2
I
S mS a w -7343
spadometer drive - 7B*S
-
AWS 1A~$4,18.20,O+iP
I
I WSU poted,~~%7W4 & - htb-1.e7, I P f 0,
Bumpe~s-1 1 4
 REF^ Index

-
-
l3ismmeflng the b&ty
D k s IA*l8,1B*15, SnfQ, WIT
DMdbWw fit3*4,5C*2-
REFm7

eastrpemr 84, - -
!Xp n t l ~ k1fi*21,18*18
m B W R ?3+7> -
m*?Q,20.1 1 DO=
c h & k ~ v1l*7 -
fd1merg.- Silt$
e l y e - ap7. zc-7, ~ ~ 4 0 hgndte and lo& componenb - 73 6
-
o+3R#&k-
*.
GBmVmmr
la*&lS.2,
M44 -
'
'-&??*a
b m d m 3.7 et*
- l &*I&?,P
-
window g&a and mgulataris 11-9
7
'1,8*5,8*7
)-ma,- owhaul 8.7 -
-.-te - q I1.*H
13
removiil A d rewng 8-2
-
rums I A ~ t B-w~,
, 8-1I
-
,a-m-a*fef~
WhKe aabk w e -
G@WbngMeP- 12.15
,,&~k- 32-44

P * ? ' '@@+?-8*$
assrjrrlibb 6.4
w e -e*g
-
-
0pV&tQn 1'A*18,1Be15
pedal * w 3
m r h m g 6.6 -
Be*
mdiigfm and #lehnostatic $w&h - 3 6 3 e
pmer *ng
MdbWli - 11.14
pump - TO921
I
. mpsnent l 4 0 r l - 1A*5,1B?5
wgt a.5 X*, m.4 - w4,
Eleeftir;d
butt ftmlng 12*2
q i t e m -~Do17
-
@ ~ l i r m r sR E b 2 - mctmrlicknitm qsmn 5 C d &q -
-a*i3,'b-1B, 1A42, I A ~ Z 1~B, * P ~ , I B . ~ Dnf-s&w- -*I efhq
~ i n e ~ r n p a I r ~ u m - 2 A#*Z,. I ,X d $ , l t + f t t t *
P*P -
Godtllg fm -:a*5
t h q m ? & Mach 3
.6 -
~ ~ 1 r r m e v 6 f a n d ~ u l p ~ ~ - ~ l d s e ~
' a n d m t m a f b t . r p ~ wm
and manual g-ox
1 w d 2E.7
m b u d PB5 -
-
c m m m -3-f et5w

-
haas s.
2 - bq~rhg$--.ZE-18
fdentiflC&fdn - R E P 4
Crank&& -2Em14,-"LE*I8
- -
oil 0 4 2 , ?78,1A*2? IA-7, I B q
mrdn We5-h~
~llseetl~
running daarancs 21318
- 2 b l O & ! B l l , 2Ci'11,2Q417 -
wehaul 2E.9, &'&IS
-
pulby 22.s s#4lt-upBftW *@-Ialil- 2E.B
cvpoint gaiter - @-4, &7 won't statt- 01s L

E n @ W ~ e a ? h x-rigs - ~ A - I ~ , P B *X12,4D.*18
blWdrank"ka~~ and me@!?Eel5 - Exhaust gas ernisslawo m 1B.15
-
-
?~,

compression test W.3, -

2C-E2D.4 l%at&.maniTold
k h d m t ~
&*B1 ,4S*l2,a%-1 7'
-
c a r b u - 1 I~ A m f ,~
etseq
head -2A*Bt PW8,2C*8,2D*12,2P*13,2€*~~,
-1 0,2E.11
,@qtZlm
- ~~ ~ ~ t m 3 l ~ ~ ~
EirhaWqmbf?l- singiepu4?tfuad l d e c i h md& -43-f ofseq
c@k- 7A.i 8,1645
cnrnporrht 4A#5,48-13,4C*'ff-
Expamion tank - 3.
4
ww II&S - 12.1~
bulb 12.7 -
REF.30 Index

Radiator - 3*3 t
grille panel - 114
Radidcassette piam-12*?7
mi- 1$*18
Rear
axle- 1 ~ 1 3
quarter window 11116 -
-
Refemnee REFV &,-
Relays - 1213
Repair pracedures REF4 -
Road test - IA*22,18*19
-
Roadside Repaim 0.6 et seq
Rotoramcheck- tA*21,1B*18
-
Routine malntmance and smvkhg 1&1 et wq ISii et l ~ e q
RW-1'1.3

mfetyfirstl-0.5
011 &reenWfl1M-b*17
mgb - oela, o-18, w.2, I A * ~ , I B *I~s.7
Tafer-IM,fB.7
- 1 A e , TBQ4,11,18
p m - m D m r s ~ e m -t l i l l
and g w b x - W18, AQ, jA*25,1 B e , 1B*21 mh-?l*l8
-
piEtcup pipe 28*EO Senrlcb see #Odriirnaaimm
p i m w w i n g IQhta W h Wm.8- Shock absorber 10.9 -
pump - 2A4,2B*11! 2C*10,2D-l.& Sttm- 1A*24,1 Br20, Qi12
a d mais Short-circust - 12.3
camshaft -,%&ri,tC*7,2D*10 @are parts REFr4-
.-aft - 2A-1 d, 2f3.lt,,2Crl I,2D.17 spark plugs
-
0-
d'rplerentlal output 7A*4,78*4
-
constant velocity lolnf gaiter 8*4;g*7
O u b b air temperature display components - 12315
check - l k 1 4 , IB*13
renewal - 14*21,10*18
Speedometer cable 12.1 5 -
 Models covered by this Manual
..

-
unUr #WClMbW l@&!m:m 1
w

'm' -
~ ~ E - k & imw#+
@
&pflw?~~d@~ ISBN 1 85960 459 !