Scribd Logo
Upload

Welcome to Scribd!

  • FiatTipoManual Split

    Uploaded by

    Веселин Димитров
    12 views57 pages

    Original Title

    FiatTipoManual_split

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    12 views57 pages

    FiatTipoManual Split

    Uploaded by

    Веселин Димитров

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 57
    Chapter 10 Bodywork and fittings 5. Refitng isa reversal of removal, but examine the condition ofthe ‘gasket and renew if necessary, and ensure thatthe coolant howe is Securely reconnected. 6 Oncomplation tfil|the cooling system as described in Chapter 2. 41 Heater blower motor - removal and refitting 1 Disoonnectahe battery negative led. 2 Working in the passenger footwel, whore applicable, remove the Single screw securing the motor housing to tho air Gucting iphoto). ‘Altematively, the motor housing may be secured tothe ar ducting by & plastic elip which must be released by puling downwards (Fi 108) 3. Tuynthe motor housing anti-clockwise, and withdraw i fom thar ducting 4 “Disconnect the witing plug and withdraw the motor assembly (photo) 3 _ Nospare parts areavallablefor the motor, andi feulty the complete assembly, including hausing, must be renewed 8 Reliting isa reversal of romovel 185 Fig. 108 Heater blower motor housin ‘shown inverted securing eip()- sem Neecay me Chapter 11 Electrical system Contents Akemator dessttptOn © Instrument panel - removal and refitting. 0 ‘Ahemator~ fouft finding and testing 9 Instrument panel components - removal andiefitiog.. 3 ‘Altemator~ remaval and refitting.. 8 _Interoeiamp bulbs - renewal. a Altemator brushes.» removal, Inspection and refitting... 10 Loudspeakers - removal and reiting. & Altomator drivebelt— checking, renewal and tensioning, 7 Luggage compartment lamp rernaval and refitting % Battery - removal and refiteg. 5 Map ceading lamp ~ rernoval and efiting, % Battery - testing and chacging. ea 4 Map steading lamp switch(es) - removal and refitting, a Brake lamp switch ~ removal and vfiting. 25 Multi-function stalk switches - removal and refitting a Central door lacking components - removal and refiting 34 Ollresaure wang iam switch - removal andrei. a Check control system components ~ removal and reiting ‘3 Radioaarial- removal and refitting s Cigarette lighter vemoval and reiting... 29 Radiolcasseste player - removal and refiting«. 3 Courtesy lamp removal end refitting 34 Rearlamp unit removal end reiting a Courtesy amp switch ~ removal and refitting... 22 Rearnumber plate lamp assembly ~ removal and reiting ~ 4a Economy gauge sender unit - removal and refitting 61 Reversing lamp switch - removal and refitting. n Electric door mircor switch - removal and refitting, 20 Routine maintenance = Erectric door miror matae~ removal and refitting 21 Speedometer cable analogue instrumentation ~ removal and Elects window components femovalandefiting. 53 ref AQ enn 59 Electrica gystem ~ precautions nn 2 Speedometer sender digital nsirumentation -rereval ond Exterior amp bulbs renewal. Z 44 refitting... Cy Facia panel switches - removai and refitting. 18 Sunroof motor - removal and refitting 58 Fault diagnosis - electrical system. $3 Sunroof operating switch removal and tina, 2 Front direction Indicator lamp - removal end reiting... 40 Starter motor - general description. z i Front direction incicato side repester lamp - removal and Starter motor— avethaul Z oie 41 Starter motor - removal and refitting ieee 3 18 Starter motor- testingin the vehicle. 2 ipton. 1 Tailgate wiper motor removal and refiting a Handbrake “on waminglamp switch - removal and Washer fluid pumps ~ removal and refitting 52 tefiting. 26 Washer fuid reservoir - removal and refitting 8 Hazard warning flasher switch — removal and refiting, 48 Washer nozzles ~ removal and refitting... a Headlamp removal and reiting. “cee 38 Windscreen wiper motor and linkage tereaveand Headlamps alignment : 38 refitting 4a Headlamp wiper motor - removal and vetting. 50 Wiperairra~ removal and rafting... “6 Horrys!~ removal and refitting z 33 Wiper blades - renewal nnn PH Ignition switch andlock cylinder ~ remaval and reiting 16 Wiring diagrams - explanatory notes = a ‘Specifications General System type.. 12 volt, negative earth Battery Type (roduton frend » Low maintenance Capectty. a *a0An Alternator Typ0.. ee «Bosch, Lucas, Magnetti Maret or Mitsubishi Output SSamps Regulated voltage at 7000 alternator spe with 5 t0 80 amp load: ‘All except Magnetti Marelll alternators. Magnet Mare alternators... Minurmurn beush feng. Rotor winding resistance: Bosch alternators. Lucas alternators. Magnett Maral alternators... Mitsubishi slteroators. 14010 14 volts 14310 148 volts 5.0mm 2 ial 3.06 103.74 ohms 2.80 t0.3.00 ohms 3.00t03.20 ohms 3.70t0 4.10. ohms Chapter 11 Electrical system 187 Starter motor Type. Rating 1alitre models 16 litre models... Minimum brush length. Fuses See Section 15 and Figs. 11.3 ond 11.4 Relays ‘Soe Section 18 and Figs. 11.3 0nd 11.4 Bulbs Courtesy lamp... nanteh oid 8— c Luggage compartment lamp son ia Glovebox fam. = ee ee ee ay Hesdlamps. es : i Sidelamps. Directio DBiection ndcator sce repeater am. Taillarps. Brake lamps Reversing lamps. Rear fogiamps. Enieae ec Number plate lamps. ecu s Torque wrench settings Alternator adjuster ut... alia Alternator mounting nut and batt = 1. General description Warning: Before carrying out any work on the vehicle electrical system, 100d through the preceutions given in the "Safety Tist!” Section at the ‘beginning ofthis manuel, and in Section 2 ofthis Chapter ‘The electrical system is of the YDvelt negative earth type, and consists of a #2-volt battery, shemstor with integral votage regulator, starter motor ond related electnical abcessories, components end wit. ing. “The battery is ofthe low msintensnce type,.and is charged by an altemator which is belt-criven fromthe crankshattpulley. ‘The starter motor is of the pre-engaged type. Incorporating an integral solenaid. On startin, the solenard moves the drive pinion into engagement with the flywheel ring gear before the sterter motor is energised. Once the engine has started, one seay itch prevents the ‘motor streature being driven by the engine untl the pinion disengoges from the Hywel, Further detas of the slectieal systems Sections ofthis Chapter. @ given in the relevant 2 Electrical system - precautions it is necessary to take extra care when working on the electrical system to avoid 10 semiconductor devices idiodes and transis- tors), and to avoid the risk of personal injury. nation to the precautions ven nto "Softy st” Secon at the Bevnning of his manuel tao rte ofthe following points when 1 ivays remove ge watches ate Boers wort on the alocticl _systom. Even with the battery disconnected, cpacitive discharge coukl ‘o0aw ifa component live terminalis earthed through @ metal object. ‘This could couse a shock or anasty burn. 2 Do not reverse the battery connections. Components such 8 the Sonor oF tbe basing Ainconiaor roo Sid We reporat I the engine is being started using jump leads and a slave battery, ‘Connect the batteries positive to positive and negative to negative, This ‘also applies when connecting abattery charger. Magnetti Marelli oskw 1.0 kW 10.0mm(0.4in) Wattage 5 5 5 40706, 5 21 5 5 2 a 21 5 Nm Inte 49 36 3 36 4 Never disconnect the battery ‘eads or the alternator wiring when the engine is running, 5 The battery loads and the aftornator wiring must be disconnected ‘before carrying out ony electric welding on the vehicle, 6 Never use én chmmeter of the type Inconporating @ hand-crenkod generator for circuit oF continuity testing, 2. Routine maintenance Note: Refer to Section 2 before proceeding 1. Atthe intervals specified in the foutine maintenance Section at the beginning of this manual, carry out the following maintenance oper- ations and checks. 2. Check the operation of sll the elective! equipment, le wipart, ‘washers, lamps, direction indicators, horn ete. Refer to the appropriate ‘Section\s) of this Chapter if any gorponents are found to be inaper- ative 3 Visually check alt accessible wiring connectors, hamesses ond retaining cli for security, or any signs of chafing or damage. Rectify any problems encountered. 4 "Check the coolant pumpisiternator drivebelt for cracks, fraying oF ‘damage, Renew the belt if worn or, if satisfactory, check and adjust the belt tension. These procedures are covered in Chapter, Section 12. {5 Check the coneition of the wiper blades and if they ere cracked or show any signs of deterioration, renew them astlescribedin Section 45. ‘Check the operation of the windscreen and teligate washers, Adjust the norzies using a pinif necessary. Check the battery terminals, and if there is any sign of oorrotion. disconnect and cissn them thoroughly. Smear the terminals and battery posts with petroleum jelly before reconnection. If there is any corrosion ‘on the metal battery tray, remove the battery and unciip the plastic tay ‘complete with ite drain hose, thenclean the deposits away and treat the affected metal with aninti-ust preparation After treatment, repaintthe tray inthe original colour. 7. AI Tipo models are fitted with a low maintenance type battery ‘during production, There ig na tequitement for routine topping-up with distled water, Periodically inspect the electrolyte level, which should ‘bobetween thetwo reference masks on thebattery casing. ITnecessary, 188 Chapter 11 Electrical system top up the level with distilled water after removing the plugts} from the top of the casing, although it should be emphasised that this should net be necessary under norival operating conditions B Check and itnecessary top ui the washer fiuid level in the reservoir and check the security of the pump wires and water pipes. 8., It's advisable to have the headlamp aim checked and if necessary. adjusted using optical bear setting equipment. 10 While carrying out @ road test, check the operation of all the Instruments end waming lamps, and the operation of the direction Indicator selt-cancetiing mnechanisin, 4. Battery ~ testing and charging Note: The procedure given in this Section applies to the original- ‘equipment battery fitted during manufacture. Follow the battery imanufacturer’s recommendations when working with reptacernent bat {ries af en attertive type. Refer to Section 2 before proceeding 1. Ia discharged battery is suspected, leave it disconnected for at least two-haurs, then measure the voltage using a sensitive voltmeter ‘connected across the battery terminals. Compare the reading obtained with the fatiowing Voltmeter reading Gharge con: 1239 volt. 50% charged 1248 volts. 75% charged 1266 volts. 100% charged 2. tthe battery is to be charged, remove it from the vehicle, end charge itas follows. 3 Themanufacturers recommend the use ofa trickle cherger, which ‘charges ata law cursent (around 1.5 ampsl, and ean be used safely overah 4 Specialy ropid “boost” charges which ae elsimed to restore tho wer ofthe battary in | to 2 hours are not recommended, as they ean cause serious damage tothe battery plates through overheating, Never subject the battery to repid boost charging at voltages higher than 156 volts octahigh charging.currents, 5 Before commencing charging, remove the plug(s} from the ton of the battery calls to allow the gases which will be produced during charging toescape free the battery casing. This will prevent a possible build-up of gas pressure inside the battery which may occur ifthe cell vent holes are blocked. Charging should be carted out ih a well ventilated area. 6 Connect the battery charger leads 10 the battery, ensuring thatthe leads are connected postive ta posite and negative to negative, then ssiteh on the charger 7. When charging is complete, turn the charger off before disconnect- ing tha leads fom tho Bator. 6 Battory — romovat and-efitting 1. The battery is located at the front left-hand side of the engine £82 Disconnecting the alternator wiring plug 8.7A Altemator mounting bolt (arrowed) viewed from underneath... 2 _Laosan the clamp screw and disconnect the negative (earth) leads ‘rom the battery. Lift the plastic cover and repeat tha procedure for the positive leads. 3 Unscrew the clamp bolt sufficiently to enable the battery tobe lifted {fromits ocetion. Keep the battery in an upright position to avoid spiling ‘electrotyte on the bodywork. 4 Refitting is reversal of removal, but smear petroleum jelly on the ‘terminals when reconnecting the leads, and always connect the positive leads first andthe negative leads last 6 Alternator- description 1. One of a number of aifferent makes of slternator may be fitted, depending on model 2.” The aktetnator is belt-drven from the ererkshatt pulley. Coting is Provided by afan mounted outside the easing on the end ofthe rotor Shaft Anintegra valtege regulators incorporated to control the output voltage. 3 The alternator provides @ charge to the battery even at very low ‘engine speeds and besically consists of col- wound stato in which 9 {tor rotates, The rotor shales supported in bearings and slip ings are sed to conduct cureent to and from the field cols through the carbon brushes. 4 The sternator generates AC alternating current) which is rectified by an intomal diode cireut to DE (direct current) for supply to the battery. 7. Alternator drivebelt checking, renewal and tensioning Refer to Chapter 2, Section 12. Alternator removal and refitting 1. Disconnect the battery negative lead. 2. Disconnect the wiring from the rear of the altemator. It will be hecessary to unscrew the securing nut in order to disconnect the main ‘output wire (photo} 3. Remove the coolant pumplaltemator drivebelt as described in Chapter 2, Section 12, 4 Unscrew and remove the alternator adjuster nut, then extract the: adjuster bolt from its location in the alternator casing. Note the pos- ition(s) of any washer(s) on the adjuster bolt 5 On models with manual steering, unbolt and rermave the alternator adjuster bracket fromthe cylinder block. 6 On modeis with power steering if desired, the engine splash shiold ccan be removed for improved access as described in Chapter 10, Section27. 7) Support the altemator, then unscrew and remove the alternator ‘mounting through-boht and nut, noting the positions of the washers, and ‘on models with power steering the ier pulley and spacer on the bolt improved access Is available working underneath the vehicle). The alternator can now be withdrawn (photos) nd idler pulley (arrowed) ~ mode! er steering Chapter 11 Electrical system 189 8 _Refiting isa reversal of removal ensuring that any washers are fitted to their conoct locations on the alternator mounting end pivot bolts. On models with power steering, ensure that the drivebett idler pulley and spacer are correctly positioned as noted during removal 9. On completion, tension the drivebelt as described in Chapter 2, Section 12. 8 Akernator - fault finding and testing "Note: Reforte Section 2 hefare proceeding 1. Check that the battery Is ot least 75% charged os described in Section 4 2 Check the drivebelt tension as described in Chapter 2, Section 12. 8. Greck the security of the battery leads, alternator wiring, and associated wiring. 2 Tocheck the alternator output proceed as follows. 5 Disconnect the output wire from the sltemator {the output wire is thethickost of the thres wires connected to he alternator). {8 Connect an ammeter between the alternator output wire and the battery positive terminal, and connect 8 voltmeter between the slter- nator output wire end the battery negative terminal 7 Stert the engine and run tat a speed of 3000 to 4000 rpm, 8 Progressively switch on all available electra! loads (headlamps, beater blower, heated rear window ete). 8 Note the ammeter reading when the voltmeter teading fas below 135 volts. If the arnmeter reading is less than 60 amps, then the alvemator should be overhauled. 10. Disconnact the test instruments, end reconnect the alternator output wire on completion, 10 Alternator brushes removal, inspection and refitting 1. Remove the alternator as described in Section 8 Bosoh type alternators 2 Remove the two seowring screws and withdraw the regulatoribrush ‘box assembly from the rear of the alternator. 2. the length of either brush is less than the minimum given in the Specitications, unsolder the wiring and remove the brushes and the springs. 4 Wipe the sliprings clean witha fuel-moistened cloth. Ifthe rings are ‘ery dirty, use fine glass paper to clean them, then wipe with the cloth. 3 Refitting is 3 reversal of removal, but make sure that the brushes ‘move freely in theirholders. 8 On completion, refit the alternator as described in Section 8, and _adust the drivebelt tension as described in Chapter 2, Section 12, Tai! ( the slternatorrear cover~ 10.12 Unserawings regulator/brushbox type alternator assembly secuting screw Magnets Micali ype altertator Fig. 11.1 Bosch type alternator regulator/brush box assembly 4 Regulatoriorush securing screws (Sec 10) box 5 Regulator A Brushes 10.13 Measuring brush length - Magnet Marelli type alternator 190 Chapter 11 Electrical system Fig. 11.2 Exploded view of Mitsubishi type alternator (Sec 10) A Pulley F Driveendhousing 8 Fen Bearing © Ticrspacer 1 Bearing reainor D Throughbott J Dusteap E Dustshiolt Lucas type alternators 7 Remave the thvee-screws securing the regulatar/brush box a5- sembly tothe rearof the alternator. 8 Tip the outside edye of the assembly upwards, and withdraws it from its Ipeation. Biseonnect the wiring plug and withdraw the as- ‘sembly from the alternator, 9 Ifthe length of either brush is less than the minimum given in the Specifications, the complete reguiatoribrush box assernbly must be renewed. 10. Proceed as described in paragraphs 4 to. inclusive, # Marelli type alternators 11 Unscrew the secixing nuts and remove the rear cover from the altermatoriphotal. 12 Remove the two securing screws. and withdrew the regu- {stor?orush box assembly (photo 13. Ifthe tength of either brush s less than the minimum given in the Specifications, the complete regulatoribrush box assembly must be enewed (photo) 14 Proceed as described in paragraphs 4 to 6 Inchsive (photo Mitsubishi type alternators 18 Unscrew the pulley out. To prevent the shaft ratating, Insert an ‘Allen kein the end of the shat. 16 Remove the spring washer, pulley, fan, spacer and dust shield, 17 _Seribe an alignment mark afong the length of the altemator to {ocittate reassembly of the drive end housing, starer and rear housing. 18 Unscrew the through-bolts and withdraw the drive end housing frorn the nator shat. 19 Remove the seal and spacer from the rotor shaft 20. Remave the-rator from the rear housing and the stator. This may ‘equire the application of local heat to the reer housing using 2 large folderinytan Dosctueea heat gun as this mayresltn damage othe 21. Unscrew the four securing bolts and withdraw the diode packista- tor assembly from the rear housing. K Thin spacer 0 Rearend housing L. Rotor P Diode pack M Seal R Brush box N Bearing S Stator 22 _Unsolder the stator leads from the diode pack terminals. Uso a pair ‘of pliers when unsoldering to act as a heat sink, otherwise damage to the diodes may occur. 2. If the length of either brush is fess than the minimum given in the ‘Specifications, the brush box must be renewed. 24. To renew the brush box, unsolder the connection to the diode pack, and solder the connection to the new brush box. Use e peir of iers 08 a heat sink to avold damage to the diodes. Examine the surfaces of the slip rings. Clean them with a fuel moistened cloth, orf necessary fine glasspaper and then the cloth. 26 Solder the stator leads to the diode pack terminals, again using @ pair of pliers as a heat sin. 10.14 Sip ings (arrowed) ~ Magnetti Mareli type alternator Chapter 11 Electrical system 191 27. Refit the diode packistator assembly to the rear housing and ‘igien the securing bolts. 2 Insert thin red (an Allen key i Weal through the hole In the rear housing tothold the brushes n the retracted position. 29 _ Fit the rotor to the rear housing and then remove the temporary ‘od torelease thetbnushes. 30 Resssemble the remsining Components by reversing the dis- manting operations. Meke sure that the scribed marks made during dsmentiing ae aligned. 31. Proceed as described in paragraph 6. 11 Starter motor— general description ‘Thestarter motor is mounted atthe frontofthe cylinder block, andie -af the pre-engaged typo, i the drive pinion is broutst ito mesh with thetiywheo ting gear before the main cunentis applied. When the startr switch Is operated, curent flows feo the battery ‘o the solenoid which is mounted on tho Sartor motor body. The plunger in tha soleneic| moves inwards, so causing.» centraly pivoted ‘ever to push the eve pinion into mesh with ha Rywhe! ring goer. ‘When the solenoid plunger reaches the end ofits travel, it closes an intemal contact and the ful stering eurent flows ta the starter field ‘i, The armature ls then able to rotate the crankshalt, so starting the egine. ‘Aspecialreewhea cic |sfted to the starter drive pinion, sothat 48 900n a the-ongine stots up, itdoes not drive the starter moter, When the starr swith is released, the solenoid is de-onergised, anda spring endves the plunger back to is est postion. This operates thepivoted lever fo withdrew the drive pinion rom engagement with the fywheel ring gear. 12 Starter motor ~ testing in-ths vehicle ‘Note: Refer to Section 2 before proceeding 1. Hf tho starter motor falls to turn the engine when the switch is ‘operated, essuming that ongine seizure le not the problem, there are several other possible reasons: fe) The botteryisfovity (6) Theelectrical connections between the switch, solenoid, battery ‘and starter motor are somewhere failing to poss the necessary ‘urrent from the battery through the starter (0 eorth fe) The solenoid switch i foukty (The starter motor i mechanioaly or lectricaly defective (€) Thestarter motor pinion andlor Mymtree/ring gear is badly worn, and in néed of replacement 2 To check the battery, switch on the headlamps. If they dim after a few seconds, then the battery isin # Gischanged state. f the lamps glow yighly, operate the startersinitch and see what happens tothe lamps. iTthey dim, then powers reaching tse motor, but fling to tora. tthe slater turns slowly, proceed to the next check, 2, when the starter ewitch is operated. the lamps stay bright, hen Insufficient power is reaching the motor. Disconnect the battery and the strtersclenoid power connections, end the engine earth strap, then ‘thoroughly lean and refit them. Smear petroleum jelly around the battery connections to preventcorrosion. Corroded connections atethe ‘most comimon cause of eloctrical malfunctions. 4 ifthe preceding checks and clesning tasks have been carried out ‘yithaut success, a clicking noise will probably have been heard each ‘ime the starter swnch was operated. This indicates that the solenoid Switch was operating, ut it Goes Not necesearily follow that the main ‘contacts were closing propery (if no licking has been heard from the: ‘solenoid, itis certainly detective. The solenoid oan be checked by comecting a voltmeter across the rain ceble connection on the sale oid and earth, When the switch s.opersted, there should be @ reading ‘onthe voltmeter. If there is no reading, the solenoid unit is faulty, and should be renewed 5. ffthesterter motor operates, but does not turn the engine, then itis: {ikely thatthe starter pinion andlor fiyavhee ring gear are badly worn, in which case the starter motor will normally be noisy in operation. 6 Finally, if it is established that the solenoid is not faulty, and that ‘twelve volis is reaching the starter, then thé motor itself is feulty, and ‘should be removed for inspection, 18. Starter motor - removal and refitting 1. The starter motor is loceted atthe front ofthe eylinder block. To remove the motor, proceed as follow. 2" Disconnect the battery negatvs eed. 3. Dieconnect the wiring from the starter motor. twill be necessary to Unscrew the seating ut in order to disconnect the mein feed wie (photo). 4 Unscrew the three securing bolt, noting tat the top belt also secutes @ witing harness bracket, end withdrew the starter motor (photo. r 5 Reliting i reversal of eamoval, ensuring thatthe wiring hamess bracket isi position on the relevant securing Balt 19.4 Withdrawing the starter motor Ks 142 Disconnecting th field winding from the solenoid terminal 14.3C... then unhook the armature from the sctuating acm 146A Femove the through-bots... housiig 14 Starter motor — overhaul 1._With the startermotorsemavedifram the vehicle, legn all dirt from the exterior, then proceed as follows. 2. Remove the nut and washer securing the fiet winding lead to the solenoid terminal, ond unhook the fead from the terminal (photo). 3._Remove the three securing nuts and withdraw the solenoid yoke and the solenoid return spring, thenunhook the solenoid ermeture from the actuatingarm and remove the armature (photos). 4 Remove the two screws secwting the commutator end housing cap, then remove the cap (photo) 5 Wipe any grease trom the'armature shaft, and remove the C-clip ‘2nd shims) from the end of the shaft (photo, & Unscrew the two through-bolts and lift off the commutator end housing (photos) 7. Recover the ceramic washer from the end of the armature shaft (photo). 8 Carefully separate the drive end housing and armature from the 14.68... and liftoff the commutator end Be ‘145 Removing the C-clip from the end of the Sonoran 147 Recover the end of the armature amie washer from the vyoke, tapping apan with a softfaced hammer if necessary. 9 Remove the rubber insert from the drive end housing, then with- draw thearmatureassembiy, complete withthe actuating arm, fromthe dive end housing (photo). 1 Unhook the actuating arm from the drive pinion flange. 11 To remove the brushes, carefully unhook the springs from the brush plate using pat of pliers then side the brushes fom the brush plate photos), 12 To remove tha dive pinion from the armature shaft drive the collar down thashaft using asuitable grit, to expose theC-iip. Remove tha cipher ts groove, and sige the colar and drive pinion from tha shaft (potas). 13. Examine the components and renew as necessary. 14_ Ifthe brushes hove worn to less than the specified minimum lenath, renew them 8a set. To renew the brushes, the leads must be ‘nsoldared tearm the torminals on the brush plate, and tha leeds of the new brushes must be soldered to the terminals. Banat refit the brush springs ath stage. 18 The soramutator face should be clean and free from buent spos. Chapter 11 Electrical system 193 "I 49 Withdrawing the armature assembly row the chive ond bausing 14124 Drive the collar down the shaft. i retaining C-cip. here necessary burrish with fine glasspaper not emery) and wipe wi fet moistened oth fthecommutater isin verybadeandiiontt Gn be skimmed on a lathe provided its diameter is not reduced tcesively recutting the insulation slots, take care not to cut nto the tommutator metal 48 Accurate checking of the armature, commutator and field coi Yindngsandinsulation requites the use of special test equipment. Ifthe fanet motor was inoperative when removed from the vehicle, and the fvius checks have not highlighted the problem, then it can be Inumed tho theres @contouity er insulator fault andthe unit should “renewed. 17 Commence reassembly by siding the drive pinion end colar onto fearmature shat Ft the C-lp into ts groove, and then use a suitable pletto draw the collarover the clip. TW Refit the actuating atm to the dive pinion flange, then eet the nature assembly and actuating arr tothe drive end housing -Reftthe ruthaer insert to the drive end housing (abot). 2 Guide the yoke and brush plate over tho armature. 41 Guide the brush plate overtne commutator, and then carefully refit Jedush springs using a duitale pact plas. Tess a tricky operetion fsome patience may be required. 22. With tha brush plate correctly located, tap the yoke into position Inte chive end housing, ensuring fast the lug on the yoke engages tb corresponding eu-outin te delve end housing (photo). A Beit the oeremie washerto the endothe enmature shaft 4 Gude re commutator end housing into position atthe same time sing the rubber insulate nto the cut-out inthe housing, Secure the fofutsor end housing with the two through-bolts. Refithe shims and the C:cip tothe end ofthe armature shaft ‘Apply alte ahiorn based grease tothe endothe armawure shaft, Bereft the commutator end housing cap and wecure with the two ces, “ookthe solenoid armature over the actuating erminthe drive end 2. Feft the solenoid return spring, ensuring that itis correctyYocet- ten guide the solenoid yoke over the armature, nbting that the ls on the rear of the yoke should be positioned one above the 14,11 Unhook the springs, 140128 .. and remove the crivepinion 14,198... and slide the broshes from the brush piste ‘\8.19 Reftting the mibber inser roth drive end housing 1422 Thelug on the yolk must engage with the cut-out in he dive end housing ‘other wen the stater motor is ited tothe engine. Seoare the yoke ‘withthe three ruts 28. Reconnect the field winding ead to the solenoid terminal ond ‘secure with the nut and washer. 15. Fuses and relays - general 1._The fuses and main relays are located ina pane! positioned beneath the driver's side lower facia panel (photo) Circuit protected Hazard warning lamps Hom, cigarette lighter, brake lamps Windscreen wipers. Tailgate wiper Instrument pane! ilumingtion, left-hand tal lamp, right- hand nurnber plate lamp, right-hand sidelamp, right-hand trailer tal omap Instrument panel ilumination, Circuit protected right-hand tal lamp, leftsbandl number plate lamp, tefi-hand sidelarme, left-hand traler tall lamp Right-hand headiamp ditped beam Left-hand headlamp dipped beam Right-hand headlamp mainbeam Left-hand headlamp maintieam, main beam warning lamp Rear fog lamps, taller rear fag amps, rear fog amps warning leroy Heated rear window, heated rear Window wertng amp, hateaoor mirrorelements Heater blower motor Rodiator cooling fan Instrument pane! power supoly, windscreen and tailgate washer pumps, multi-function sta swutete Tlumination, ceversing lamps, fuck cutoff solenoid 75A, Gourtery lero, uageun compartment ne 750, Direction indicator lamps 208, Central door locking systarn Not fitted to UK models 7 Circuit protected Direction indicatorthazard warning flasher amps Horns} Heated rear window Starter motor Intermittent windscreen wipe Rear fog lamps Headlamp dipped beam Headlamp main beam Sidelamps 11.4 Fuse and relay locations in main panel ~ DGT models ‘Sec 15) For details of fuses refer to key for Fig. 11.3 ireult protected Notused Direction ingicatorhazard waxing flosher lamps Notused Notused Homie) Hosted rear window ‘Starter motor Notused Intermittent windscreen wipe esr fog lamps Headiomp dipped boam Headlamp mein beam Sidelomos Central door locking control module Not used Chapter 11 Electrical system 15.1 Main fuse and relay panel 2 The fuselrelay panel can be lowered for access by pulling the lever at Yherear ofthe panel, 3. Thecircuits protected by the various fuses are marked on the inside ‘f tha panel cover, and are shown in Figs. 11.8 and 11.4, togettor with the relay locations. 4 Toremovea fuse orrelay, lowerthe panel and pullthe relevanthuse lor relay from the panel 3. Belore renewing a blown fuse, trace anil rectly the cause, and ‘Shays fitafuse of the correct rating. Never substitute afuse of a higher rating, or meke temporary repairs using wire OF metal fol, 2s more Serious damage or even fire could result. 8 Oncertain models, additional fuses and relay, including those for ‘the inlet manifold heater, electric windows powor supply, and head- lamp washiwipe circuits are located in a secondary pane! t0 the tight the main paneiphoto). 7 Whore applicable, the sunroof motor relay Is located belhind the sunroof ator in the rook. The relay can be unplugged after remaving She courtesy lamp r008 ganél Mth reference to Section 22 16 Ignition switch and lock eylinder - removaland refi Ignition suite 1 Disconnect the battery negative lead. 2. Remove the lower steering column shroud, with reference to Chap- ter 19, Section 82 fnecessary. 3 Inger the janition key and turn itto position “AMAR”. 44 Extract the two ignition switch securing screws, then withdraw the ‘witch and disconnect the wing plugs (photc). 5 Donot tum the key orthe switch operating pininthe columnswitch housing whilstahe switch is removed. 6 Rofiting isa reversal of removal Look eylinder 7 Proved bs described ia paragraphs 1 and2 8 Insert the ignition key and turmit to position “MAR”. Using serewdiver, working tough the satin the rer of helock housing. Sepress the retaining lugane withdrew the lock oyinder Using the key (photo), 10 Da net tum the ignition switch operating pin in the column switch ‘housing whilst ebook clings i removed. Wasted, the evinder eon be removed from is housing ater semoving tre erwip trom the ond ofthe cylinder. ¥2'" Reassombly and refiting fs rovers of dismantling Und remove. 17. Multi-function stalk switches - removal and refitting 1 Olsconnect the battery negative esd. 2 Remove thesteering column shrouds with reference to Chapter 10, ‘Section 32 iFrecessary. 164 Extracting an ignition switch securing screw (steering eoluma removed) 116.3 Removing the ignition switch lock cylinder (steering column temaved) Chapter 11 Electrical system 117.34 Removing a multi-function stalk switch (retaining lug arrowed) . 3. Depress the retaining lugs at the top and bottom of the relevant ‘switch, then pul the switch from the housing and disconnect the wiring plug (photos) 4 Refitting is @ reversal of removal 18 Facis panel switches - removal and refitting Heater blower motor switch Removal snd refitting of the heater blower motor switch is described in Chapter 10, Section 37. Instrumentpanelswsitehes (models with digitatinstru- ment panel) 2. Reter to Section 31, Hazaxel warning flasher switch 3) Referto Section 18. 19 Hezard warning flasher switch - removal and refitting 1. Disconnect the battery nagative lead. 2 Remeve the steering colurin shrouds with reference to Chapter 10, Section 32 if necessary. 3. Pull the switch from the housing on the steering column, then

    You might also like