Fiat X 1/9 1974 Service Manual Download Page 131

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Summary of Contents for X 1/9 1974

Page 1: ...c Serviqe manual 1 974 thru 197 8 3 2 ...

Page 2: ... HUME X 1I9 SERVICE MANUAL 1974 thru 1978 ...

Page 3: ... is used in conjunction with the first two c The last two digits indicate an assembly or task consisting of several parts This number identifies the sub group It refers to the sub group in both the Parts Catalog and the Service Time Schedule Find the information required as follows 1 Find the tab index page for the information on the first page of the manual 2 Find the group and sub group for the ...

Page 4: ...NCE 00 Page Engine Specifications 2 Chassis Specification 3 Electrical Specifications 3 Weights Performances 4 Dimensions 4 Capacities 5 Identifications 6 InSpections and Maintenance 8 Tune Up 9 Fiat Lubricant Specifications I4 00 ...

Page 5: ...Ill 1974 Section No 00 Page 1 General Information ...

Page 6: ...d with hot water header for mixture pre heating at idle Fuel filter in feed line from pump to carburetor Paper cartridge air cleaner with silencer LUBRICATDN SYSTEM Forced circulation by gear pump and pressure limiting valve Full flow cartridge oil filter Normal oil pressure 64 to 85 psi 4 5 to 6 kg cm at 212 F 100 C COOLING SYSTEM Radiator and expansion tank Water circulated by cen trifugal pump ...

Page 7: ...pinion type Ratio number of steering wheel turns about 3 corresponding rack travel 4 6 in 117mm Turning circle diam about 32 ft 10 in 10m Steering column of the breakaway mount type with 2 universal joints Independent and symmetric track rods to each wheel Sealed for life joints FRONT SUSPENSION Independent wheel type Lower control arms consisting of a cross rod and reaction strut Sealed for life ...

Page 8: ... fully laden 2 440 lbs Speed maximum on flat road with good surface run in and fully laden First gear 28 mph 45kph Second gear 47 mph 75kph Third gear 72 mph 115kph Fourth gear 103 mph 165 kph Reverse 31 mph 50kph DIMENSIONS METRIC mm 490 750 965 1 174 1335 1343 1570 2202 3900 in 19 3 29 5 38 0 46 1 52 5 52 9 61 8 86 7 153 5 The maximum height is referred to the unladen car ...

Page 9: ... front 0 160 0 160 1 3 pt DOT 3 Motor Vehicle Brake Fluid to rear 0 160 0 160 1 3 pt F M V S S No 116 Clutch control hydraulic system 0 180 0 180 2 5 pt Same as brake circuit Temperature Solvent in bottle Windshield washer bottle above 0 C 32 F down to 10 C 14 F below 10 C 14 F Pure water 3 plus high 50 quality wind shield washer 100 solvent TEMPERATURE UNIGRADE OIL MULTIGRADE OIL Below 15 C 5 F B...

Page 10: ...hed on crankcase flywheel end F M V Safety Standard 115 Tag This has type of vehicle and chassis number It is located on facia top between instrument cluster and windshield a nLﬂoAZmlIE 6 I b AUTI 3T ELMO CHAS IS JET MAOIIH Inn unlu I ALY WWI I llil 1 4 or PAH COLON Nolol C l l d e chassis Type and Identification Number This is punched on front trunk rear cross rail permanent structure right Side ...

Page 11: ...d number Engine type and number Number of spares Part number of the item being ordered as listed in Parts Catalog Orders are basically processed according to the part numbers F M V Regulation Conformity Tag _ This has air pollution con trol spec scations for correct engll lE tune up and adgustments It is located on lower side of engine hood CAR KEYS Two sets of two keys are supplied with each car ...

Page 12: ...ance adjust Spark plugs change lgnition distributor clean check and change if necessary cap and rotor change breaker contacts and condenser Carburetor check throttle choke valves and control linkages adjust as required Air pump filter change cartridge Exhaust emission control system check lines mani fold valves and air pump change as required Fue evaporative emission control check compo nents and ...

Page 13: ...024 in 0 5 to 0 6mm NOTE if you are going to check valve clearance leave plugs out until clearance is adjusted VALVE CLEARANCE Remove air cleaner Disconnect throttle rod 3 from control 4 on valve cover 1 Disconnect hoses to pro vide clearance Remove 6 nuts 2 holding cover Remove cover 1 1 Cover 2 Nuts 3 Throttle rod 4 Control Turn crankshaft until lobe on camshaft for valve being checked is pointi...

Page 14: ... move cap and rotor Clean and inspect cap and rotor Replace cap and rotor as necessary Lubricate distrib utor by adding a little oil thru wick 1 Wick 2 Contact points Check contact points 1 for wear and damage Check point gap 2 Gap 0 015 to 0 017 in 0 37 to 0 43mm Adjust point gap Check condenser 3 Replace as necessary NOTE Replacement of contact points should be per formed on the bench with the d...

Page 15: ...et to camshaft cover Disconnect hose 5 and hose to bottom of air cleaner from air cleaner Disconnect hose from carburetor cool ing fan Remove air cleaner Replace cartridge 1 Clean air cleaner NOTE Install air cleaner after adjusting carburetor 1 Cartridge 2 Air cleaner 3 Nuts 4 Nut 5 Hose ENGINE OIL With engine warm drain oil from engine Remove oil filter 1 Coat seal on filter with engine oil Thre...

Page 16: ...as scope and Dwell Tach Start car Allow engine time to warm up Using tach check idle speed Set idle speed at 850 rpm Adjust carburetor 1 Idle speed adjustment screw Using dwell meterl check dwell Dwell should be 55 Adjust contact points as necessary Using strobe light check ignition timing Timing should be 0 TDC If necessary loosen nut on distributor clamp and adjust distributor 1 0 TDC 2 5 3 10 ...

Page 17: ...about 10 advance Connect vacuum line to distributor Check that timing returns to O TDC in about 7 seconds 1 Vacuum line 2 Distributor Hook up exhaust analyzer Check CO reading on ana lyzer 00 should be 0 5 to 1 5 Adjust mixture metering screw 1 on carburetor as necessary 1 Mixture metering screw P I r _ ii J to ...

Page 18: ... 10 W W 901M Oil SAE 90 EP meets MlL L 2105 B Steering housing requirements ZC 90 Oil Mechanical transmission oil Transmission and differential SAE 90 not EP containing anti wear additives S A Oil Mineral antifreeze oil Hydraulic shock absorbers containing greasiness additives MR 2 Grease Lithium based grease Constant speed joint recess N L G I No 3 and protection boot MR 3 Grease Lithium based gr...

Page 19: ...rence 15 Gr loo ENGINE ASSEMBLY Power Plant Mounts 25 Gr 101 MAIN ENGINE COMPONENTS Crankcase and Cylinder Head 29 Oil Sump and Crankcase Covers 31 Crankshaft and Flywheel 39 Connecting Rods and Pistons 43 Camshaft Drive 41 Valve Mechanism 49 Gr 102 FUEL SYSTEM AND EXHAUST Fuel Tank and Lines 55 Fuel Pump and Lines 57 Carburetor and Air Cleaner 59 Exhaust Pipe 65 Exhaust Emission Control System 6 ...

Page 20: ...to 48 646 Thickness of standard big end bearing 0 0603 to 0 0606 1 531 to 1 538 Range of undersize big end bearings for service 0 010 0 020 0 254 0 508 0 030 0 040 0 762 1 016 Big end bearings fit clearance 0 0014 to 0 0034 0 036 to 0 086 Small end bore diameter 0 9425 to 0 9438 23 939 to 23 972 Small end bushing 0 0 0 9455 to 0 9465 24 016 to 20 041 Small end bushing fit interference 0 0017 to 0 ...

Page 21: ...ton pin range for service 0 0079 0 2 Piston ring thickness first compression ring 0 0582 to 0 0587 1 478 to 1 490 second oil ring 0 0779 to 0 0783 1 978 to 1 990 third oil ring with oilways and expander 0 1545 to 0 1553 3 925 to 3 947 Piston fit in bore measured at right angle to pin 1 08 27 5mm from piston skirt edge clearance of new parts 0 0020 to 0 0028 0 050 to 0 070 Piston pin in boss cleara...

Page 22: ... Max valve run out on a full turn guided on stem with dial indicator set at center of contact face 0 0012 0 03 Width of valve seats in cylinder head contact surface intake and exhaust about 0 0787 2 Inside diameter of valve seats in cyclinder head intake 1 1811 30 exhaust 1 0531 26 75 Lift on CIL of valve without play ____________________________________________ 0 3839 9 75 Diameter of tappet bore...

Page 23: ...4 48 535 to 48 550 Fit between bores in head and camshaft journals fit clearance drive end 0 0011 to 0 0028 0 029 to 0 070 intermediate drive side 0 0012 to 0 0028 0 030 to 0 070 middle 0 0012 to 0 0028 0 030 to 0 070 intermediate flywheel side 0 0012 to 0 0028 0 030 to 0 070 flywheel end 0 0012 to 0 0028 0 030 to 0 070 AUXILIARY SHAFT Diameter of bushing bores in crankcase drive end 1 5236 to 1 5...

Page 24: ... 8740 22 140 to 22 200 Rear main bearing seat thrust ring thickness 0 0909 to 0 0929 2 310 to 2 360 Thickness of oversize thrust rings 0 0959 to 0 0979 2 437 to 2 487 Crankshaft end play thrust ring installed clearance of new parts 0 0021 to 0 0104 0 055 to 0 265 Max misalignment of main bearing journals 0 0012 003 Max misalignment of crankpins to main bearings journals 0 014 10 35 Max out of roun...

Page 25: ...rector 0 079 2 00 0 077 1 95 Idle air corrector 0 043 1 10 0 28 0 70 Accelerator pump jet 0 020 0 50 Emulsion tube type F 30 Extra fuel device jet 0 027 0 70 Extra fuel device jet 0 033 0 85 Choke type throttle valve Partial opening of primary throttle valve choke on 0 035 to 0 394 0 90 to 10mm Needle valve seat 0 059 in 1 50mm Float valve distance between float and cover with gasket in vertical p...

Page 26: ...ull flow oil filter with by pass cartridge type Low oil pressure indicator sending unit electric Oil pressure at 185 F 85 C 64 to 85 4 psi 4 5 to 6 kglcm COOLING SYSTEM WATER PUMP Type centrifugal vane type Pump Drive Vee belt Fit between impeller vans and pump housing 0 031 to 0 051 in 0 8 to 1 3mm Radiator cooling fan drive electric motor Thermostat begins opening at 176 to 183 F 80 to 84 C open...

Page 27: ...Stud Nut bearing to belt tensroner support M 10 x 1 25 R 100 Znt 32 5 4 5 R 50 Znt Stud Nut Intake and exhaust manifold M 8 R 80 Znt 22 3 Bolt oil pump and fuel pump shaft driven gear M 10 x 1 25 R 120 61 8 5 R 50 Znt Stud Nut upper bracket to water pump M 8 R 80 Znt 18 2 5 R 50 Znt Bolt Nut alternator to lower support M 10 x 1 25 R 80 Znt 36 5 R 50 Znt Stud Nut alternator lower support to crankca...

Page 28: ...III 1974 Section No 10 Page 23 Engine Specifications LONGITUDINAL SECTION OF ENGINE THROUGH CYLINDERS ...

Page 29: ......

Page 30: ... air duct 1 Hose 2 Nuts 3 Hose 4 Cap 5 Fresh air duct Disconnect hose 1 between air pump 2 and filter Disconnect hose 3 from air pump Separate heater return hose 5 at coupling joint 4 Disconnect heater hose from pump Disconnect wires from alternator Remove 2 bolts holding louvered protection panel below carbon trap in rear firewall 1 Hose 2 Air pump 3 Hose 4 Coupling 5 Heater Hose Disconnect choke...

Page 31: ... hoses from tank at thermostat Remove tank Disconnect 2 hoses from thermostat Remove cotter pin holding rod from operating cylinder in clutch shaft Loosen 2 bolts 3 holding operating cylinder 2 to transmission Open bleed screw on cylinder and allow rod to retract Swing cylinder out of way 1 Expansion tank 2 Operating cylinder 3 Bolt Working under the car Remove remaining bolt holding louvered pane...

Page 32: ...shift linkage 4 Bolts 5 Shifting tube 0 Remove bolt holding ground strap 6 at body Straighten tabs on exhaust manifold flange Remove 4 nuts and locktab plates Remove 2 bolts 1 from upper bracket 4 at left end of muffler 2 Remove 2 nuts holding center support 3 for muffler to crossmember Remove muffler Remove 2 nuts and bolt holding upper bracket 4 to differential case Remove bracket Remove 3 bolts...

Page 33: ...s at top Straighten lock tabs on 2 bolts 2 on each end of lower crossmember 1 Loosen the bolts Lower car until engine is resting on a support Remove bolts thru lower crossmember 1 1 Crossmember 2 Bolts 3 Control Arm 4 Shims 5 Bracket 6 Bolts 7 Handbrake cable From above disconnect reaction rod 4 from bracket 3 on engine Remove bolt thru 2 front engine mount 1 Raise car slightly and rock engine tra...

Page 34: ...Accelerator rod 4 Fuel hoses 5 rack t Disconnect spark plug cables Disconnect vacuum hose for distributor from fitting in head Remove stop bolt 1 from accelerator cable Slide seal 3 off cable 2 Remove clip holding cable on valve cover 4 Remove cable 1 Stopbolt 2 Cable 3 Seal 4 Valvecover Disconnect water outlet hose 1 inlet hose 2 pump to union hose 3 and expansion tank hose 4 from union 5 Remove ...

Page 35: ...er bolt on alternator 5 Loosen bolt thru alternator adjusting bracket 6 Remove alternator and water pump drive belt 4 Remove 2 bolts thru rear of air pump 8 and support brackets 7 Loosen bolt thru top of air pump Move pump and remove drive belt Loosen nut on tensioner pulley 2 Remove timing belt 3 Remove lower bolt thru belt guard Remove cylinder head to crankcase bolts and nuts Remove cylinder he...

Page 36: ...dge check the head for distortion Lay the straightedge across the diagonals of the gasket surface and also lengthwise in the middle The gap between the head and the straightedge must not ex ceed 0 002 inch lf gap exceeds this reface the cylinder head gasket surface Do not remove more material than necessary Check depth of combustion chambers to make sure it has not been reduced below allowable lim...

Page 37: ... feed knob 5 Lock screw 6 Tool 7 Graduated scale 8 Angle adjustment knob Select a pilot which has minimum clearance between it and valve guide Place pilot in valve guide Place stone in mandrel Place mandrel in grinder Grind valve seats Make sure grinder is not turned on with stone in contact with seat Narrow seat width Install a 20 valve seat reamer on mandrel Insert mandrel on pilot Turn on grind...

Page 38: ...om valves Use wire brush If valve face is worn or damaged reface valves Install valve in grinder Set grinder for the specified angle of 45 30 5 upon completion of grinding Remove only enough material to true up surfaces After refacing check that the thickness of valve at edge of head is not less than 0 02 in 0 5mm If necessary to grind valve stem tip to remove traces of dishing remove only what is...

Page 39: ...tip just touches control surface of gauge If there is interference be tween stem and gauge reduce stem height by_ grinding 1 Gauge 2 Valve stem CYLINDER HEAD TORQUEING SEQUENCE Torque hold down bolts and nuts in sequence shown Torque bolts and nuts in gradual steps to 69 ft lbs 9 5kgm ...

Page 40: ...emery cloth wrapped around a hone Make Sure piston clearance in bore does not exceed 0 006 in 0 15mm 1 Dial gauge 2 Ringgauge Zero dial indicator using ring gauge A 96139 Check cylinder bores at three points both lengthwise and crosswise The bore class is indicated by letters stamped on the bottom of crankcase JiMEASURlENLEN L Z MEASUREMENT ﬂBLREMENL ill 1974 Section No 101 01 Page 35 ...

Page 41: ...Page 36 Cylinder bore diameter may vary from 3 3858 to 3 3878 in 86 000 to 86 050mm Bares are selected in 0 004 in 0 01mm classes F9500 73 590 __ﬂyﬂh _ _ aa nnn_ _ar oza _ _ __ ____ ___ ...

Page 42: ...r 20 Crankcase 2 Cover 12 Bolt and washer 21 Gasket 3 Washer 13 Gasket 22 Bolt and washer 4 Bolt 14 Nut 23 Cover 5 Gasket 15 Washer 24 Gasket 6 Cover 16 Bracket 25 Cover 7 Seal 17 Stud 26 Seal 8 Seal 18 Cover 27 Washer 9 Washer 19 Gasket 28 Bolt 10 Bolt Auxiliary shaft seal cover 1 Cover 2 Seal 3 Shaft ...

Page 43: ...her 3 Washer 6 Gasket 9 Bolt 4 3 _ _ _ _ Crankshaft oil seal flywheel end Arrows indicate that distance between cover gasket and crankshaft should be equal all around Crankshaft cover timing gear end Arrows show indexes for checking centering of cover with respect to crankshaft ...

Page 44: ...urnals crankpins and shoulder radius ham D Maximum allowable misalignment of journals and crankpins and diagram for checking flywheel contact surfaces with clutch disc and crankshaft flange A B C E points for checking alignment and squareness with respect to rotation axis D crankshaft flywhee clutch assembly balancing holes ...

Page 45: ...W Main data of crankshaft journals main bearings saddle bores and thrust rings Clearance between crankshaft journals and bearing _ should be 0 0020 to 0 0037 in 0 050 to 0 095mrn Torque cap screws for main bearings to 58 ft lbs 8kgm ...

Page 46: ...Ill 1974 Section No 101 03 Page 41 Crankshaft and Flywheel Check crankshaft and play End play should be 0 0021 to 0 0104 in 0 055 to 0 265mm If necessary install oversize thrust rings ...

Page 47: ...bore class 2 Piston class letter 3 Matching number of connecting rod to cylinder CHECKS Before assembling check weight of four pistons Pistons must have same weight within 10 088 02 12 59 If necessary remove metal from base of piston by milling Maximum metal than can be removed is 0 177 in 4 5mm Milling diameter should be limited to 2 775 in 70 5mm a 2 232 in 56 70mm nominal piston height h 2 055 ...

Page 48: ... 0 036 to 0 085mm Piston bore is 0 08 in 2mm offset When assembling piston to connecting rod make sure number on connecting rod faces away from side of piston bore offset Secure piston pin in piston with lockring 1 Auxiliary shaft 2 Location of connecting rod to cylinder matching number Before installing rings on pistons push rings down in groove Check clearance with feeler gauge See specification...

Page 49: ...lling connecting rod pin piston assembly in cylinder check alignment of big end and small end cHs measured at 4 92 in 125mm from shank Maximum allowable misalignment is 00039 in OJOmm 1 Piston assembly 2 Expansion blades 3 Square gauge Install assemblies in cylinders according to number stamped on conencting rods and caps Install them with numbers facing toward auxiliary shaft Torque big end cap n...

Page 50: ...I III I lglli _ I I_ A Iii I J 1 IIIIII S Iii Ii III IAIJII _ I y l jlccl1ulgl1 ll l I I I i A I I ...

Page 51: ...n lower bolt on alternator 4 Loosen bolt 5 thru alternator adjusting bracket 6 Remove water pump and alternator drive belt 3 Remove water pump drive pulley 2 from crankshaft Remove 2 bolts thru rear of air pump 8 and support brackets 7 Loosen bolt thru top of air pump Move pump and remove drive belt 1 Timing cover 2 Drive pulley 3 Drive belt 4 Alternator 5 Bolt 6 Adjusting bracket 7 Brackets 8 Air...

Page 52: ... Never push car backward in gear or allow engine to rock backyard while pushing car Slack will develop in belt allowing belt to jump timing 1 Camshaft pulley 2 Bolt 3 Lock nut 4 Idler pulley Place belt cover on car Make sure crankshaft timing mark is on T D C 3 Check that camshaft mark is exactly on pointer If good torque nut 2 on tensioner pulley 6 to 32 5 ft lbs Install pulley 4 on crankshaft In...

Page 53: ...cks 11 6 Upper cups 12 Inner spring Outer springs Lower cups Exhaust valve guide Exhaust valve Flat washer 13 14 15 16 17 Intake valve intake valve guide Oil seal Camshaft Welch plug A 48 550 48 350 48 535 48 335 48 150 48 135 l l 1 l 48 580 48 380 748380 47 980 29 9891 43 505 48 405 43 205 43 005 30 014 t O l _x 47 950 29 960 47 935 29 944 Main data on camshaft and bores in housing ...

Page 54: ...Page 50 AUXILIARY SHAFT 31 940 31 960 Main data of auxiliary shaft and bushing _ 35 593 35 618 ...

Page 55: ...eter and tappet bore diameter in housing Tappet clearance in bore should be 0 002 to 0 020 in 0 005 to 0 050mm III 1974 Section No 101 07 Page 51 _ 37 000 37 025 i ____ l 1 10 014 M _ 30 975 35 995 Valve guides are press fitted in their bores Interference should be 0 0025 to 0 0043 in 0 063 to 0 08mm Valve guides are available for service in the standard size and 0 008 in 0 2mm oversize ...

Page 56: ...HAUST Replace valve guides if scored or worn If clearance between valve guide and stem is excessive replace guide Use driver A 60153 to remove guide When installing guides use drive A 60153 and spacer A 60153 6A for intake valve guides Use driver A 60153 and spacer A 60153 63 for ex haust guides 1 Driver 2 Spacer for intake valve guide 3 Valve guide ...

Page 57: ...Ill 1974 Section No 101 07 Page 53 Valve Mechanism Repiacement guides have inner diameter prefinished to size If press fitting causes minor fault refinish guide Use reamer A 90310 ...

Page 58: ...ILEII TL I I E ...

Page 59: ...k and Lines Position 2 Air from ambient into tank Line trom carbon trap to carburetor downstream of throttle To carburetor bowl Lines between separator and fuel tank From fuel tank To activated carbon trap Fuel tank air inlet are 93 222 60 Position 3 safety Vapor from tank to ambient excess pressure in the tank Safety outlet Air filter To carburetor downstream of throttle Synthetic fllter Activate...

Page 60: ...l I r J ...

Page 61: ...k attachment screws 4 of upper and lower bodies and cover screw 1 for looseness Iines for clogging or deterioration filter for clogging or deterioration diaphragm and control lever springs for weakness or distortion rdiaphragm for hardening or cracking Oil control lever and pivot when reassembling Lightly coat new gaskets with grease Always use new gaskets 1 Cover screw 2 Lockwasher 3 Cover 4 Scre...

Page 62: ...5mm Install a thicker or thinner gasket 3 to meet this dimension After adjusting the dimension place gasket 3 on engine Place insulating support 4 on engine Place gasket 2 on support Install rod 5 in engine Install fuel pump NOTE Gaskets 3 are supplied in 0 012 0 027 and 0 047 in 0 3 0 7 and 1 2mm thickness 1 Pump support 5 2 Gasket between pump and s 3 Gasket betwet aqnogupport and crankcase I rt...

Page 63: ...able ball 7 Tang 8 Float arm 9 Float 10 Gasket IDLE SPEED ADJUSTMENT Connect a tachometer to engine Start engine and warm it up Check that idle Speed is according to specification on tag If necessary adjust idle speed screw IDLE co ADJUSTMENT Connect a tachometer to engine Insert sample probe of CO tester in tailpipe Start engine and warm it up Check that idle speed is according to specification t...

Page 64: ...screw Screw Accelerator pump cover Diaphragm Spnng Throttle shaft primary Bushing Lever Bushing Lockwasher Nut Spﬁng Ring Rod Spring Nut Lockwasher Washer Bushing Carburetor body Lever _ Cotter pm Secondary throttle stop screw Hose Throttle Screw Secondary throttle shaft Lever Lockwasher Nut Bushing Lever Spring Bushing Primary shaft lever Washer Spring Bushing Spring Lever Rod Lifter plug Lifter ...

Page 65: ...o 10204 Page 61 62 BE 57 51 71 72 53 65 22592 A Choke off B Choke on RECIRCULATING DEVICE ACCELERATING PUMP For mow 3v GASES 5 59 54 48 22693 Carburetor and Air Cleaner IDLE AND TRANSFER 36 15 18 fr 22694 15 20 45 22695 ...

Page 66: ...ixture calibrated bushing Idling mixture adjusting screw Primary throat transfer orifices Secondary well Secondary idling iet Secondary air passage calibrated bushing Fuel passage Secondary throat transfer orifices Duct conveying bowl vapors to activated carbon filter Suction duct gasoline vapors from activated carbon filter Cam controlling accelerator pump and clasing bowl vapors discharge duct 1...

Page 67: ...arburetor cooling fan 6 Remove 3 nuts 1 and washers holding cover 2 on air cleaner Remove cover Remove nut and washer holding bracket 9 on air cleaner to valve cover Disconnect by pass hose 8 from air cleaner Disconnect hose from bottom of air cleaner Remove 4 nuts holding air cleaner to carburetor Remove air cleaner and fresh air duct 1 Nuts 2 Air cleaner cover 3 Airline 4 Air duct 5 Clamp 6 Cool...

Page 68: ...h air duct 3 from fan duct 4 Remove 2 nuts right front side of support and 2 bolts left rear side of support holding support to car Remove fan and support 5 Remove 4 screws 7 holding fresh air duct to fan Remove 4 screws holding fan to support install in reverse order Make sure black wire from fan is under mounting nut for fan relay 1 Regulator 2 Fan relay 3 Fresh air duct 4 Fan Duct 5 Support 6 F...

Page 69: ...e 2 holding pipe 4 to flange 3 on exhaust manifold 1 Nuts 2 Lock late 3 Fla 4 Exhaust pipe p we Remove 2 bolts and washers holding bracket to top of exhaust pipe Remove 2 bolts 3 and washers holding exhaust pipe r 1 to crossrail 2 Remove exhaust pipe 1 Exhaust pipe 2 Crossrail 3 Bolts ...

Page 70: ...Page 66 EXHAUST PIPE WPP NE Intake manifold Bolt Washer Lockwasher Nut Support bracket Bolt Exhaust pipe Bolt Nut Lockplate Stud 16 ...

Page 71: ...take line with filter Pump discharge safety valve Air pump Intake manifold Exhaust manifold Diverter valve Vacuum line for diverter valve 6 6 0 226 Air distributor line Non return valve Vacuum line for carburetor diaphragm Air injector Vacuum control thermova Ive mmwm Distributor advance disphragm control unit ...

Page 72: ...ve belt Remove pump Install pump in reverse order I Hose 2 Timing cover 3 Air pump 4 Hose AIR INJECTION MANIFOLD REMOVAL AND INSTALLATION Remove air cleaner for access Remove bolt and nut holding clamp 1 on non return valve 2 to bracket on engine 1 Clamp 2 Non return valve Remove 2 bolts 2 holding manifold 1 to engine Disconenct 4 injectors from engine Remove manifold with non return valve 3 Remov...

Page 73: ...Filter Oil pump Gasket Sending unit Pipe Bushing Seal Gear 11 12 13 14 15 16 17 18 19 20 Shaft Pin Bushing Bushing Washer Dip stick Bolt Clamp Oil cap Gasket 21 22 23 24 25 26 27 28 29 Flame trap Hose Hose Clamp Switch Boot Boot Washer Bolt 30 31 32 33 34 35 36 37 38 Pipe Washer Bolt Gasket Washer Lockwasher Bolt Pipe Connector ...

Page 74: ...mshaft lobes and tappets 9 Oil pump 3 Camshaft 10 Oil pressure relief valve 4 Auxiliary units drive shaft 11 Oil pump suction pipe 5 Filterto engine components oil line 12 Oil return pipe 6 Oil pump and distributor drive gear oil duct 13 Oil mist outlet for cylinder walls 7 Full flow oil filter ...

Page 75: ...e 3 Flywheel an cover plate 4 Oil pump 5 Timing gear end cover plate INSPECTION Clean all parts Blow parts dry with compressed air Check housing 5 and cover 2 for cracks Check suction pipe and oil duct for clogging Blow clear with compressed air Make sure dirt and residues are removed from between relief valve 4 and pump housing 5 1 Pump shaft 2 Cover 3 Valve spring 4 Relief valve 5 Housing Check ...

Page 76: ...heck clearance between top face gears and cover mating face Clearance should be 0 008 to 0 041 in 0 020 to 0 105mm if more than 0 006 in 0 15mm replace gears or pump When oil pump is assembled turn drive shaft and check for binding OIL FILTER REPLACEMENT A clean filter is necessary to ensure good engine lubrication Remove filter Before installing coat seal with engine oil Thread filter on by hand ...

Page 77: ...cylinders See detail 4b At closed throttle the gasses are drawn into the intake manifold through the calibrated orifice of the control valve incorporated in the carburetor See detail 4a At wide open throttle part of the gasses are drawn into the intake manifold through the open duct of the control valve The remaining gasses flow directly to the clean side of the air filter 3 9 0 22610 ...

Page 78: ... 5 Il all Lam Jr I III _ I I l I I il l I wmﬂﬁ _ _ I p ...

Page 79: ...witch Remove bolt 3 and nut 2 holding crossrail 4 at each side Lower radiator out of car Be carefully of fan 1 Fan 2 Nut 3 Bolt 4 Crossrail 5 Hose INSPECTING COOLING SYSTEM Fill radiator and expansion tank Open heater controls Start car Open bleeder on top of radiator NOTE Bleeder is accessible from inside the front luggage compartment 1 Bleeder Connect tester to radiator cap Build up pressure Che...

Page 80: ......

Page 81: ...rt 1 for air pump to water pump Remove 4 bolts 6 holding water pump 2 to engine Remove pump 1 Support 2 Water um 3 Alternator 4 Nut 5 Pipe 1 gots Longitudinal section of water pump 1 Pump cover 2 Spacer 3 Screw 4 Coverto housing nuts 5 Bracket 6 Housing 7 Impeller 8 Seal 9 Snap ring 10 Gasket 11 Shoulder ring 12 Grommets 13 Ball bearingr 14 Pulley 15 Pump shaft NOTE Fit clearance between impeller ...

Page 82: ...DSTAT REMOVAL Drain enough water to lower level below union 1 Remove air cleaner Disconnect hose 2 from bottom of union Remove 3 bolts and washers holding cover 3 to union 1 Rernove thermostat and gaskets 1 Union 2 Hose 3 Cover ...

Page 83: ...the fan to power thru fuse L The fan continues to run until the temperature drops below 185 F 85 C EXPLDDED VIEW OF FAN REMOVAL 1 Fan motor 9 2 Fan 10 3 Washer 11 4 Nut 12 5 Plate 13 6 Washer 14 7 Lockwasher 15 8 Nut Gasket Conveyor Washer Lockwasher Nut Nut Lockwasher FAN RELAY 3 9 TEL r THERMAL SWITCH 30 51 TD FUSE Il L NJ T0 BATTERY as 35 B v FAN 3711 16 17 19 20 21 Washer Nut Relay Thermostati...

Page 84: ...Il l l l ...

Page 85: ... 81 Tool Equipment W A 60153 Remover and installer valve guides in cylinder head A 90310 Reamer valve guide bore _ V o A 96216 Gauge checking depth of combustion chambers A 96219 Gauge checking height of valve stem ...

Page 86: ...3 131 04 181 05 CLUTCH 18 SERVICE MANUAL SERVICE TIME Page SCHEDULE CODE Specifications Tightening Reference ___________________________________________________________ 83 Clutch Release Hydraulic Control 85 Master Cylinder 88 Operating Cylinder 89 Clutch 90 18 ...

Page 87: ...a minimum pressure plate displacement of 0 071 in 1 8mm 0 335 in 8 5mm Master cylinder bore 41 in Operating cylinder bore 13 4 in TIGHTENING REFERENCE THREAD TORQUE DESCRIPTION METR C MATERIAL FT LBS kgm Bolt clutch to flywheel M 6 R 100 Cdt 10 8 1 5 Bolt clutch release fork M 8 R 80 Znt 18 2 5 R 50 Znt shank Nut operating clnder pIston adjustment M 8 R 50 Incl Znt 18 2 5 Bolt operating cylinder _...

Page 88: ...Page B4 CLUTCH COVER AND CLUTCH DISC WITH LININGS ...

Page 89: ...te linings 0 335 in 8 5mm Release travel 5 in 127mm Lining I D 7 145 in 181 5mm Lining 0 0 A Lubrication points CLUTCH RELEASE HYDRAULIC CIRCUIT 1 Master cylinder 2 Operating cylinder 3 Nut and counter nut clutch release travel adjust ment a 6 692 170mm Pedal release travel SECTION THRU FORKED LEVER AND RELEASE SLEEVE A 1 in 28 5mm Declutching travel correspond ing to a driven plate displacement o...

Page 90: ...d of hose in container filled with fluid Loosen screw on operating cylinder Push pedal in and release it until all air bubbles stop stop Push pedal in and hold it down Remove hose Tighten bleeder screw Fill reservoir 1 Bleeder screw 2 Operating cylinder CLUTCH PEDAL RELEASE TRAVEL The clutch pedal travel should be about 6 692 in 170mm lf travel is not right loosen nut 1 Turn screw 2 out to reduce ...

Page 91: ...nsure proper adjustments the car must be driven on a road test 1 Operating cylinder 2 Adjustment not 3 Throw out bearing shaft CLUTCH RELEASE CONTROL COMPONENTS 1 Reservoir 14 Shaft 27 Clip 2 Bracket 15 Spring 28 Bolt 3 Lockwasher and nut 16 Nut 29 Cotter pin 4 Tube 17 Nut 30 Bracket 5 Master cylinder 18 Bolt 31 Washer 6 Clamp 19 Washer 32 Bolt 7 Washer 20 Operating cylinder 33 Fork 8 Throw out be...

Page 92: ...ner Connect hose to new cylinder Use new clamp Position cylinder on support plate Make sure rod is in cylinder Connect tube to cylinder Install bolts thru cylinder and brake cylinder Fill reservoir Operate clutch and check for leaks Bleed clutch control circuit Install steering column EXPLODED VIEW OF MASTER CYLINDER 1 Lockring 4 Gasket 2 Seal 5 Connector 3 Boot 6 Lockplate l Reservoir 2 Hose 3 Tu...

Page 93: ...on cylinder 2 on support plate 6 with rod thru shaft 1 Pry back on spring Install two bolts 4 and washers thru cylinder Install Split pin thru rod Place new gasket on union 3 Place union thru hose 5 Place another new gasket on union 3 Install union in cylinder Bleed cylinder Adjust cylinder Fill reservoir 1 Throw out bearing shaft 2 cylinder 3 Union 4 Bolt 5 Hose 6 Support plate EXPLODED VIEW OF O...

Page 94: ...ts Remove clutch When installing clutch place the protruding part of the hub next to the transmission Before tightening clutch to flywheel bolts center disc Use tool AJOZIO Torque bolts to 11 ft lbs 1 5kgm Reinstall transmission 1 Flywheel 2 Clutch assembly 3 Tool 18A Tool Equipment 70210 Pilot aligning driven plate ...

Page 95: ...E MANUAL SERVICE TIME SCHEDULE CODE 21 27 212 01 212 07 274 01 274 04 21 11 2711 Specifications Tightening Reference 91 Gr 212 TRANSMISSION Transmission Assembly 93 Outer Gearshift Controls 103 Gr 274 DIFFERENTIAL Axle Shafts 105 Differential Gear Train 109 Tool Equipment 114 21 27 ...

Page 96: ...No 212 01 Bpsodomstsr sprokat support soction 1 Longitudinal section of gearshift rod Longitudinal section of transmission lll 35 1 nmuum W Section through detent springs for gear control rods 22719 Soctlon through gear control lugs ...

Page 97: ...ts 2 Support Remove pin 3 holding rod 2 to gear shift lever 1 Remove dowl 4 bushing and washer Lift gearshift lever 1 out of car 1 Gearshift lever 2 Rod 3 Cotter pin 4 Bowl Remove bolt 1 and nut holding flexible rod 3 to transmission rod 2 Remove boot 4 Pull rod out of carfrom rear To install gearshift controls reverse the above procedure 1 Bolt 2 Transmission rod 3 Flexible rod 4 Boot ...

Page 98: ...r is in center of guide plate and is straight up and down Tighten bolts 2 1 Flexible rod 2 Bolts 3 Rod GEARSHIFT CONTROL ASSEMBLY 1 Dowel 7 Boot 2 Rubber bushing 8 Bolt 3 Washer 9 Guide 4 Cotter pin 10 Cap 5 Gearshift lever 11 Ball socket 6 Knob 12 Spring 13 14 15 16 17 18 Support Boot Plate Flexible rod Nut Lockwasher 18 E E E 9 K20 8 21 23 22 19 Bushing 20 Bolt 21 Plate 22 Bolt 23 Rod ...

Page 99: ...g ball joint for strut 3 in pillar Remove ball joint from pillar 1 Nut 2 Shock absorber 3 Stmt rod 4 Control arm 5 Nut Drain some oil from transmission Remove 3 bolts 1 and washers holding all seal boot 2 to differential Pull axle shaft and wheel hub out of differential 1 Bolts 2 Oil seal boot 3 Axle shaft Remove brake caliper 1 and support bracket from pillar Remove bolts holding plate 2 and disc...

Page 100: ...nut and washer Pull constant Speed joint out of hub Using a press remove hub from pillar Remove ring nut holding bearing in pillar Use tool A 57123 Remove hearing from pillar Use tool 8015 1 Lever 2 Socket 3 Ring nut tool 4 Pillar Install bearing in pillar Use tool 8015 Screw a new ring nut in pillar to hold bearing Torque nut to 43 ft lbs 6kgm Use tool A 57123 and torque wrench NOTE Always use a ...

Page 101: ...aft Move shaft in and out to make sure snap ring is in groove 1 Constant speed joint 2 Snap ring Grease constant speed joint sockets and boot Use no more than 3 025 of grease Install boot over joint install clamp Place axle shaft in differential Place ball joint of control arm 4 in pillar Secure ball joint with out 5 Place ball joint of strut rod 3 in pillar Secure ball joint with nut Install 2 bo...

Page 102: ... ring 10 Sealing ring 2 Circlip 5 Oil seal boot 8 Constant speed joint 11 Bushing 3 Axle shaft 6 Boot 9 Boot clamps Arrow indicates shoulder which boot 6 should be in contact with after installation Hub nut Washer Hub Bearing ring nut Bearing Constant speed joint Pillar TJE T PPEJl PE ...

Page 103: ...gear pinion gears and thrust washers 1 Side gears 2 Pinion gears 3 Driver 4 Pinion shaft 5 Half cases Wash all parts Check teeth for damage and wear Check contact pattern Check pinion shaft and pinion bores for damage Check side gears and counter bores in half cases for damage Check bearings for wear or damage Check thrust washers for wear or damage Repair or replace damaged parts 1 Bearing 2 Half...

Page 104: ...Page 110 DIFFERENTIAL SECTION ...

Page 105: ...inion shaft in place Install eight bolts Torque bolts to 51 ft lbs 7kgm Check backlash between side gears and pinions Backlash must not exceed 0 004 in 0 1mm Install two bearings on case Use proper driver on inner rings of bearings 1 Half case 2 Pinion shaft 3 Lock plate 4 Ring gear 5 Speedometer teething EXPLDDED VIEW OF DIFFERENTIAL ASSEMBLY 1 Bearing 5 Half case 2 Half case 6 Ring 3 Sun gear 7 ...

Page 106: ...ailable place outer ring of carrier bearing in its seat Place shims on top of bear ing Place retaining flange on shims Using feeler gauge measure clearance between flange and trans mission housing If clearance is not 0 003 to 0 005 in 0 08 to 0 12mm add or remove shims to obtain this clearance Install two nuts on studs thru flange and tighten nuts Tum transmission one full turn to set bearings Loo...

Page 107: ...rface Value on indicator is difference between distance P and height H Add 0 0031 in 0 08mm to value on indicator to determine thickness of shims Choose a shim with a thickness as close as possible to this value NOTE Shims are supplied in the following thicknesses 0 0196 0 0236 0 0275 0 0315 0 0354 0 0394 0 0433 in 0 50 0 60 0 70 0 80 0 90 1 00 1 10mm _ __ ﬂ __ _ _ 21771 Bearing Dial indicator Tra...

Page 108: ...Page 114 Place shim on outer ring of bearing Install cover Torque attaching nuts to 18 ft lbs 2 5kgm 21A 2 IA Tool Equipment AJOZM Compressor countershaft spring washers ...

Page 109: ...ERVICE TIME SCHEDULE CODE 33 331 02 331 30 32 331 31 331 33 331 35 33A Page Specifications Tightening Reference 115 Gr 331 WHEEL BRAKES Hydraulic Brake System 117 Front and Rear Wheel Brakes 119 Front Brake Calipers 121 Rear Brake Calipers 123 Hand Brake 125 Tool Equipment 125 33 ...

Page 110: ......

Page 111: ...STEM Master cylinder Hand brake lever Brake fluid reservoir Brake pedal Stop light switch Front brake calipers Rear brake T connection Rear brake calipers Hand brake indicator switch DCDHOO l hWM I FRONT WHEEL BRAKES HEAR WHEEL BRAKES I rr1 _ 1n ...

Page 112: ... Bleed brake system OVERHAUL Carefully inspect cylinder bore and piston surfaces They should have a mirror like finish without any kind of roughness The cylinder bore can be honed to prevent leaks or excessive wear of seals and pistons Do not increase size of bore 1 Washer 2 Bolt 3 Bolt 4 Washer 5 Switch 6 Master cylinder 7 Nut 8 Washer 9 Nut 10 Washer 11 Support EXPLODED VIEW OF MASTER CYLINDER 1...

Page 113: ...an container filled with brake fluid Loosen bleeder screw a few turns Press brake pedal quickly Release pedal and allow it to return slowly Repeat until all air bubbles stop Press brake pedal and hold it down Remove bleeder hose and tighten bleeder screw Clean up spilled fluid Install dust caps Repeat for other wheels Make sure fluid level in reservoirs are filled Caliper 2 Bleeder hose ...

Page 114: ... bolt 6 holding bracket 5 to caliper Remove union thru hose 4 Remove gaskets 1 Caliper 2 Brake Iinin 3 Spring 4 Hose 5 Bracket Bolt On rear brakes disconnect hose 1 from caliper 2 Remove gaskets Disconnect hand brake cable 3 from rear caliper 2 1 Hose 2 Caliper 3 Hand brake cable The minimum allowable thickness of brake linings is about 0 079 in 2mm Make sure new brake linings are the same type on...

Page 115: ...indicator reading is 0 0059 in 0 15mm If runout exceeds iimit or if disc is scored or dam aged reface disc Minimum thickness after refacing is 0 368 in 9 35mm Minimum thickness from wear is 0 354 in 9mm REFACING BRAKE DISC If disc is worn or has deep scores they can be refaced After refacing minimum thickness is 0 368 in 9 35mm ...

Page 116: ...6 Lining retainer spring 7 Cylinder housing 8 Dust boot 9 Piston 10 Seal 11 Bleeder screw and dust cap 12 Cylinder 13 Spring and dowel 14 Complete caliper OVERHAUL FRONT CALIPER Remove cover 5 Depress dowel using thin rod 3 Separate cylinder 2 from support 4 Apply compressed air to brake hose port 1 Blow piston out Remove seal 1 Brake hose port 2 Cylinder 3 Thin rod 4 Support 5 Cover ...

Page 117: ...r body Place spring and dowel in cylinder Slide support on cylinder Press dowel down and slide support over dowel Make sure dowel is seated in support 1 Cylinder 2 Piston 3 Cover 4 Seal Place springs 4 and linings on support bracket 5 Place caliper 3 on bracket Install locking blocks 2 and cotter pins 1 Connect hoses to caliper and reservoir Bleed brakes 1 Cotter pins 2 Locking blocks 3 Caliper 4 ...

Page 118: ...ing 13 6 Rubber boot 14 7 Locking ring 15 8 Spacer Hand brake shaft Pawl Plunger Spring washers Spring washers Seal Caliper cylinder 16 17 18 19 20 21 22 Piston Seal Dust boot Complete caliper Bleeder screw Bleeder boot Support bracket OVERHAUL REAR GALIPER Remove dust boot 1 Unscrew piston 3 from plunger Use screwdriver in slot in plunger Remove seal 1 Dust boot 2 Caliper 3 Piston 4 Seal ...

Page 119: ...plunger with grease 1 Shaft 2 Rubber boot 3 Sprin washers 4 Seal 5 Plunger 6 Pawl Locking ring 8 Caliper Install seal in caliper cylinder Screw piston 1 on plunger until it is seated MKE sure mark 2 on piston is on side of caliper with bleed fitting 5 Install rubber boot 4 Make sure boot is seated in groove in caliper 1 Piston boot 5 2 Mark Bleed fitting 3 Caliper 4 Rubber MARK Ail E WAT _ 0 ON 10...

Page 120: ...locked try to turn wheels manually Tighten locknut Release hand brake Check that wheels are free to turn 1 Lock nut 2 Adjusting nut HAN D BRAKE LINKAGE 1 Ratchet 9 Cable 2 Rod 10 Boot 3 Spring 11 Caliper 4 Button 12 Pulley 5 Rubber ring 13 Spacer 6 Lever 14 Gasket 7 Washer 15 Support 8 Bolt 16 Washer 17 18 19 20 21 22 23 24 Bolt Cable Lockwasher Nut Clamp Bolt Nuts Pin 25 26 27 28 29 30 31 32 Clip...

Page 121: ...Page 126 33A Tool Equipment A 56126 Wrench brake line connectors ...

Page 122: ...0 STEERING SYSTEM 41 SERVICE MANUAL 8 SERVICE TIME SCHEDULE CODE 41 412 01 412 02 412 10 41A Page Specifications Tightening Reference 12 Gr 412 STEERING SYSTEM Steering Gear 129 Steering Box 131 Steering Linkage 13B Tool Equipment 138 41 ...

Page 123: ...stable with fixed end ball joints outer wheel 28 inner wheel 32 40 Front wheel toe in car laden 0 0787 to 0 1575 in 2 to 4mm Steering column l Car laden two persons plus 44 lbs 20kg luggage with tire inflated to specified pressures TIGHTENING REFERENCE three sections with two universal joints THREAD TORQUE DESCRIPTION METRIC MATERIAL FT LBS kgm Nut steering wheel to column M 16 x 1 5 R 50 Znt shaf...

Page 124: ... 5 R 50 Sd Stab STEERING COLUMN AND GEAR DISASSEMBLED 1 Bolt 8 Steering wheel 15 Pad 22 Clamp 2 Washer 9 Nut 16 Gasket 23 Pad 3 Retainer 10 Bushing 17 Steering box 24 Clamp 4 Support 11 Steering column 18 Nut 25 Lockwasher 5 Nut 12 Bushing 19 Lockwasher 26 Nut 6 Lockwasher 13 Cover 20 Bolt 27 Pad 7 Washer 14 Screw 21 Shaft ...

Page 125: ...Ill 1974 Section Nu 412 01 Page 129 Steering Gear SECTION A A CROSS SECTION OF STEERING COLUMN ...

Page 126: ...ashers holding column at bottom of dash Slide shaft off steering box shaft Remove complete column from car 1 Nut 2 Bolt 3 Steering shaft Remove horn button Remove steering wheel nut and washer Remove steering wheel Remove bolt 1 and nut thru turn signal selector unit 2 Slide unit off shaft If necessary to separate lower shaft 3 from upper shaft remove bolt and nut holding universal joint 4 to lowe...

Page 127: ...nion shaft on steering box Remove three screws 2 holding gasket cover to steering box 1 Bolt 2 Screw 3 Universal joint Jack up car Remove wheels Remove nuts 1 holding ball joints in pillars Remove tie rods 2 from pillars 3 1 Nut 2 Tie rod 3 Pillar Remove four bolts 1 holding steering box 2 to body 1 Bolt 2 Steering box ...

Page 128: ...ints 8 Rubber pads 3 Lock nuts for adjustable ball joints 9 Steering housing 4 Rubber bellows 10 Spring 5 Rod and rack 11 Ball pin cup 6 Bushing A Travel 4 606 0 059 inches 117 i 1 5mm 60 1 ball joint stroking angle UNMODIFIED RACK AND STEERING GEAR CROSS SECTION ...

Page 129: ...62 1 Ball joints 6 Clamps 2 Ball joint heads 7 Resilient pads 3 Rubber bellows 8 Steering gear housing 4 Rod and rack 9 Ball joint socket 5 Bushing A Trave 4 606 1 0 059 inches 117 x 1 5mm oc BaI joint stroking angle 62 i 4 MODIFIED RACK AND STEERING GEAR CROSS SECTION ...

Page 130: ...efore remove only one joint when removing rack Place steering box in vice On modified box straighten stake on collar and ball joint Unthread ball joint 0n unmodified box straighten stakes on ring nuts 2 Unscrew nuts Slide off ball joints with sockets and springs Slide rack out of steering box Remove lower bearing for drive pinion 1 Rack 2 Ring nut 3 Adjustable head for ball joint 4 Ball pin NOTE A...

Page 131: ...pply enough force to the outer ring of tap bearing to take up all end play Measure distance X Determine shim thickness as follows Shim X 0 0020 to 0 0051 in X 0 05 to 0 13mm NOTE Shims are available in the following thickness 0 0047 0 0079 0 0098 0 0984 in 0 12 0 2 0 25 2 5mm install shims Coat gasket and bolts for cover plate with adhesive liquid install gasket plate 1 washers and bolts Install s...

Page 132: ... to 0 13mm NOTE rack yoke shims are available in 0 0039 and 0 0059 in 0 10 and 0 15mm thickness Assemble spring 5 and seal ring 7 on yoke 8 Coat surfaces of shims 4 with adhesive liquid install shims cover plate 6 and bolts on box STEERING BOX SECTION ACROSS DRIVE PINION Spﬂng 1 Drive pinion shaft 6 Yoke cover plate 2 Cover plate 7 Seal ring 3 Gasket 3 Rack yoke 4 Rack yoke shims 9 Rack 5 _ _ JEN ...

Page 133: ...ns Check that pins can describe a rotation cone with an apex angle of 60 1 1 Lock the heads in position with nuts 3 Stake heads as shown 1 Rack 2 Ring nut 3 Adjustable head for ball joint 4 Ball pin 5 Ground wire Slip boots over ball joints Slip ends of boots over steering box Position clamping screws as shown Fill steering box with oil as follows Turn steering fully to the right Jack car up on le...

Page 134: ...k is in front push car forward Measure distance again dimension B Dimension A must be 0 0787 to 0 1575 in greater than dimension B with a loaded car Adjust toe in as follows Loosen nut 1 Turn ball joint 2 in or out using wrench flats until proper toe in is obtained Do not change position of steering wheel spokes Tighten nut 1 1 Nut 2 Ball joint A 14219 Installer steering gear pinion shaft lower he...

Page 135: ...E TIME SCHEDULE CODE 44 443 01 443 02 443 05 443 06 443 10 443 16 44A Specifications Tightening Reference 139 Gr 443 SUSPENSION AND WHEELS Front Suspension 143 Front Shock Absorbers and Bars 149 Rear Suspension 153 Rear Shock Absorbers and Bars 151r Shock Absorbers 159 Wheels 163 Tool Equipment 166 44 ...

Page 136: ...ings Length under a load of 474 22 lbs 215 IOkg Minimum permissible load referred to above length Coil springs are divided into two classes color coded as follows yellow springs which under a load of 474 lbs 215kg haVe a length above green springs which under a load of 474 lbs 215kg have a length of 6 693 in 170mm 441 lbs 200kgl 6 693 in 170mm 6 693 in 170mm or less Shock Absorbers Type hydraulic ...

Page 137: ...ows yellow springs which under a load of 562 lbs 255kg have a length above green springs which under a load of 562 lbs 255kg have a length of Springs having same color code should be used 7 874 in 200mm 518 lbs 135kg 562 lbs 255kg 7 874 in 200mm 7 874 in 200mm or less Shock absorbers Type hydraulic telescopic double acting Pressure cylinder bore Length measured between upper face of dust shield an...

Page 138: ...hock absorber R 80 Znt Bolt to body upper mounting pad M 6 R 100 Cdt 7 2 1 Bolt brake caliper to steering knuckle M 10 x 1 25 R 80 Posf black 36 2 5 Stud bolt wheel M 12 x 1 25 C 35 R Bon Znt 50 6 7 black Nut self locking R 80 Znt Bolt front control arm to body M 10 x 1 25 R 100 Cdt 29 4 Nut self locking shock absorber to body R 80 Znt Bolt steering knuckle bolt M 10 x 1 25 R 100 Cdt 43 4 6 Nut sh...

Page 139: ...Bon 72 3 10 R 90 to 105 Nut for bolt clamp on R 50 Znt Bolt cross reaction rod SleeVe M 8 R 80 Znt 14 4 2 Nut self locking control arm pivot pin M 14 x 1 5 R 80 Znt Pin 72 3 10 R 80 Znt Nut self locking shock absorber top mounting M 12 x 1 25 R 80 Znt 43 4 6 Nut self locking shock absorber R 80 Znt Bolt to knuckle pillar bolt M 10 x 1 25 R 100 Znt 43 4 6 Bolt brake caliper to knuckle pillar M 10 x...

Page 140: ...et from brake fluid reservoir and disconnect brake fluid hose 2 from caliper 1 Caliper 2 Brake hose Remove wheel Remove bolts 1 and plate 2 holding strut to pillar 3 Remove bolt holding control arm 4 to bracket 5 1 Bolts 2 Plate 3 Pillar 4 Control arm 5 Bracket Remove nut 3 holding tie rod ball joint 1 to steering arm 2 Remove ball joint 1 Balljoint 2 Steering arm 3 Nut ...

Page 141: ...tched See Section 44 if hub bearing must be replaced see Wheels 443 16 When installing suspension do not fully tighten control arm attachments and sway bar attachments These bolts and nuts must be tightened with car under load 1 Shock absorber 2 Pillar 3 Control arm 4 Steering arm Place assembly in car Install washers and nut 2 on three bolts on top of shock absorber 1 Torque nuts to 8 ft lbs 1 kg...

Page 142: ... control arm and install nuts 1 Bolts 2 Plate 3 Pillar 4 Control arm 5 Bracket Place ball joint 1 of tie rod in pillar Install not 3 Install wheel Install brake caliper Lower car Fill brake fluid reservoir Bleed brakes 1 Ball joint 2 Steering arm 3 Nut Tighten nuts 1 2 and 3 and bolt 4 with car laden as follows NUT TORQUE 1 58 ft lbs 8kgm 2 51 ft lbs 7kgm 3 29 ft lbs 4kgm 4 bolt 29 ft lbs 4kgm ...

Page 143: ...Page 146 Model X 1 9 Section through shock absorber top mounting a o 4o to 4 20 camber I 3 13 about king pin inclinatiOn J P Data referred to laden car Front Suspension ...

Page 144: ... caster Caster unladen car 6 30 to 7 30 Adjust caster by adding or removing shims between reaction struts 2 and supports 1 Remove shims to increase caster If car has been in an accident set up equipment to check camber NOTE Camber cannot be adjusted and does not cause tire wear Camber unladen car 0 to 1 For toe in of front wheels see Steering Linkage 412 10 1 Support 2 Reaction strut ...

Page 145: ...ouching retainer 2 One screw at each end must be in the recess in retainer 2 Lower View of tool A 74241 1 Spring retainer clearance screws 2 Spring retainer 3 Coil spring Compress the spring Hold shock absorber stud with wrench A 57020 3 Remove nut attaching retainer 2 to shock absorber 1 Clearance screws 2 Upper retainer 3 Wrench ...

Page 146: ...rol arm rubber bushings Arrow shows stacking to be removed for removal of bushings Check ball joints for excessive play and damage to swivel and rubber boot If worn or damaged replace complete control arm EXPLODED VIEW OF CONTROL ARM COMPONENTS Nut Washer Washer Rubber bushing Control arm Rubber bushing Washer Spacer Bolt Nut Pillar E PEDpt NQP P PD t I t l ...

Page 147: ...ce bushing 1 and washer on tool 1 Bushing 2 Tool 3 Spacer 4 Control arm Place pilot on tool 1 Control arm 2 Tool 3 Pilotoftool 4 Washers 5 Rubber bushings Press bushing into control arm and stake spacer Use a press under a load of 2200 to 2600 lbs 1000 to 1200kg Stake one side and then the other 1 t1 I Centering pin 2 Fixture 3 Spacer centering oo ...

Page 148: ...ct bar for distortions If distortions are minor straighten bar If necessary replace bar Inspect rubber pad and ring for wear d hmmu EXPLODED VIEW OF STRUT BAR ATTACHMENTS TO BODY AND CONTROL ARM 1 Nut 6 Lockwasher 11 Lockwasher 15 Nut 2 Washer 7 Bolt 12 Bolt 16 Bolt 3 Cup 8 Rubber ring 13 Bolt 17 Washer 4 Rubber pad 9 Strut bar 14 Pillar 18 Support 5 Spacer 10 Lockplate ...

Page 149: ......

Page 150: ...per 1 Caliper 2 Hose 3 Parking brake cable Remove exhaust pipe Refer to 102 56 Note number of shims and position on control arm Remove nut washer and bolt 1 holdn arm 3 to bracket 2 at front of suspension Retain shims be tween arm and bracket 1 Bolt 2 Bracket 3 Control arm Remove nut washer and bolt 1 holding arm 3 to bracket 2 at rear of suspension Note number of shims and position Retain shims b...

Page 151: ...2 Axle shaft NOTE Always use a new hub nut Install shims as noted during removal Loosely attach arm 2 to brackets 3 Raise assembly and mount hub on constant speed joint Insert upper attachment of shock absorber 4 in holes in body install 3 nuts and spring washers Place washer on axle shaft Thread nut 1 on shaft Torque nut to 101 ft lbs l4kgm Stake nut Use tools A 74140 1 and A 74140 3 Install exha...

Page 152: ... ft lbs 10kgm 1 Shock absorber mounting nuts 2 Control arm front bolt 3 Control arm rear bolt REAR WHEEL ALIGNMENT Install and adjust alignment equipment Follow in structions provided with equipment Set up equipment to check camber Camber unladen car 1 10 to 2 10 Check toe in Toe in unladen car 0 360 to 0 510 9 to 13mm Adjust toe in by Iengthing or shorting reaction rod 1 Reaction rod ...

Page 153: ...Page 156 2 120 camber 3 a 12 king pin inclination 1 Data referred to iaden car 1 Shock absorber front mounting adjustment shims _ 2 Shock absorber rear mounting adjustment shims ...

Page 154: ...43 01 for infor mation on coil springs CONTROL ARM VIEW OF CONTROL ARM ATTACHMENT POINTS 1 Bolt 2 Support 3 Control arm 4 Ball Joint 5 Support 6 Pillar EXPLODED VIEW OF CONTROL ARM 1 Nut 5 Bolt 9 Bolt 13 Bushing 2 Washer 6 Nut 10 Pillar 14 Control arm 3 Washer 7 Washer 11 Nut 15 Bushing 4 Washer 8 Washer 12 Boot ...

Page 155: ...I M III IIII NII_ I II II II II II1III Illl ...

Page 156: ...hold ing absorbers 1 at top Remove two bolts and nuts 1 holding absorber 2 to pillar 3 l 1 l q L 1 Shock absorbers 2 Nuts Use Tool A 74241 to remove coil spring from absorber Refer to Front Suspension Components 443 01 Check absorbers for operation If absorbers fail to meet specifications replace them 1 Bolts 2 Shock absorbers 3 Pillar ...

Page 157: ...ock absorber Cup Washer Nut Nut Lockwasher Washer Pad Spacer Washer Thrust plate Rubber ring Nut REAR SHOCK ABSORBER ATTACHMENTS Bolt Nut Shock absorber Rubber pad Thrust plate Rubber ring Washer Spacer Pad Cup Washer Lockwasher Nut Washer Nut Page 160 ...

Page 158: ...cylinder 2 Threaded plug 3 Inner cylinder Method A Place stem 1 of inner cylinder 2 in vice Extend Cylinder Carefully and gently tap around and under valve 3 to remOve it Pour fluid into cylinder 2 until full Add remaining ﬂuid to outer cylinder 4 install valve 3 by carefully tapping it around edge insert cylinder 2 into cylinder 4 Assemble absorber using new ring seal 7 and Cap 6 Screw threaded p...

Page 159: ...using vice grips slowly pull stem 3 out to its full extension The piston will draw the oil into the cylinder Assemble absorber using new ring seal 6 and cap 5 Screw threaded plug 4 on absorber After assembling operate unit manually Extending and compressing it two or three times to bleed it 1 Outercylinder 2 Inner cylinder 3 Stem 4 Threaded plug 5 Cap 6 Ring seal ...

Page 160: ...isc 4 Plate 5 Calipers 6 Support bracket Remove nut 1 holding tie rod 2 to pillar 3 Remove ball joint from pillar Use tool Remove nut 4 holding control arm 5 to pillar 3 Remove ball joint from pillar Remove two nuts 6 and bolts holding shock absorbers 7 to pillar Remove pillar 1 Nut 2 Tie rod 3 Pillar 4 Nut 5 Control arm 6 Nut 7 Shock absorber Remove nut and washers holding hub to pillar Press hub...

Page 161: ...lar Use tool 8015 1 Tool 2 Pillar 3 Bearing Install bearing in pillar Use tool 8015 1 Tool 2 Bearing 3 Pillar Screw a new ring nut 2 in pillar Torque nut to 43 4 ft lbs 6kgm Use tool A 57123 and torque wrench NOTE Always use a new ring nut after disassembling pillar 1 Pillar 2 Ring nut 3 Tool ...

Page 162: ... ft lbs 14kgm Stake nut 1 Pillar 2 Hub 3 Driver 4 Tool Attach pillar to shock absorber with two bolts and nuts Attach control arm 5 to pillar 3 Install brake caliper and disc on hub Install wheel Lower car Attach tie rod 2 to pillar Torque nuts shown with car loaded Refer to Specifi cations 44 1 Nut 2 Tie rod 3 Pillar 4 Nut 5 Control arm 6 Nut 7 Shock absorber ...

Page 163: ...Page 166 Tool Equipment A 74241 Compressor coil springs n 15123 Wrench ring nut ﬂ 8015 Remover hub bearing ...

Page 164: ... TIME SCHEDULE CODE 55 551 01 552 01 553 01 554 01 555 03 Page Specifications 167 Wiring Diagram 174 Gr 551 IGNITION Engine Ignition 175 Gr 552 STARTING Engine Starting 179 Gr 553 ALTERNATOR Alternator 183 Gr 554 LIGHTING Lighting Fuses 185 Gr SSS ACCESSORIES Instruments and Controls 187 55 ...

Page 165: ...ation at 500Vdc about 50 M ohms Condenser capacity at 50 to 1000Hz 0 22 to 0 23 MF Opening angle 35 i 3 Closing angle 55 t 3 lGNlTION con MARELLI MARTINETTI TYPE BE 200 B c 52 3 Primary winding ohmic resistance at 68 F 20 C 3 1 to 3 4 ohms 3 to 3 3 ohms Secondary winding ohmic resistance at 68 F 20 C 5670 to 6930 ohms 6500 to 8000 ohms SPARK PLUGS Ac DELco MARELLI CHAMPION Type 42 x _s cw 78 LP N ...

Page 166: ...170 Torque developed 2 89 0 14 ft lbs 0 40 i 0 02Kgm Speed 1900 rpm Voltage 9 5 Stall test at 77 F 25 C Amperage 315 Torque developed 6 37 i 0 22 ft lbs 0 88 0 03kgrn Voltage 7 i 3 No load test at 77 F 25 C Amperage not above 30 Speed 7000 i 1000 rpm Voltage 11 9 lnner resistance on starting at 77 25 C 0 022 t 0 001 ohms Check of Mechanical Characteristics Brush pressure unworn 2 5 to 2 9 lbs 1 15...

Page 167: ...ive end FIMM A124 14V 44A Var 3 12 1 000 i 50 rpm 44A 53A approx 13 000 rpm clockwise Ratio engine alternator 1 2 Rectifier Diode Characteristics type Permanent normal current Reverse voltage Reverse current with 150V do at 266 F 130 C 6 Power 3 excitation 25A 1A 150V 150V 2mA 2mA Voltage Regulator Test and Setting Type Alternator speed for test and setting Battery capacity 2nd stage testing curre...

Page 168: ...her left side behind fuses UGHHNG SAE STANDARD Headlights high and low beams Sealed beam headlight unit 7031 Front parking and rear tail lights No 67 4cp Side marker lights front and rear No 158 2cp Front and rear turn signal stop back up and license plate lights NlBBRm Instrument cluster lighting Fuel reserve indicator Battery charge indicator Low oil pressure indicator High beams indicator Parki...

Page 169: ..._____________________________________________________________________________________ crank gear sweeps per minute low speed 48 high speed 75 brush pressure on glass 19 to 23 oz 550 to 650 gr FUSES FUSES 2 three Amp fuses 8 eight Amp fuses 2 sixteen Amp Fuses 1 eight Am fuse PROTECTED CIRCUITS in separate holder Stop lights Electric pump windshield washer Back up lights Fuel gage and fuel reserve ...

Page 170: ... HW Front right parking light Rear left side marker light 8 Am Front right side marker light License plate light one bulb only p Rear left tail light Cigar lighter 16 Amp Vehicular hazard warning signal and indicator L Engine fan motor 16 Amp Horns and relay M 3 Amp Retractable headlights con rol relay on closmg N 3 Amp Retractable headlights control relay on opening 28 3 Carburetor fan motor and ...

Page 171: ...128 3 Starter relay 40 ldeogram lighting potentiometer 65 2 Brake system effectiveness and hand brake ON indicator 128 4 Relay for carburetor fan motor unit 42 Turn signal indicator switch 66 Battery charge indicator i 161 Light source optical fiber illumination lg unit 42 1 High low beams change over switch 67 Parking and tail lights indicator cator switch etor fan relay 42 2 Wiper washer three p...

Page 172: ...roboscopic switch 5 Plug for distributor breaker The distributor is driven at one half engine speed To plot advance curve double both rpm and advance degrees Match curve against diagram shown in figure Check distributor contacts openings and closing angle open contact angle 35 1 3 dwell closed contact angle 55 1 3 Check that contact gap is 0 0145 to 0 0169 in 0 37 to 0 43mm Check that contact pres...

Page 173: ...act breaker points Washer Clip Rotor Spring contact Cap Clip 13 14 15 16 17 18 19 20 21 22 23 24 Washer Screw Rubber ring Spﬁng Cam Clip Washer Clip Washer Screw Vacuum valve Washer 25 26 27 28 29 30 31 32 33 34 35 36 Condenser Screw Washer Nut Lockwasher Fiber washer Terminal Bolt Washer Pin Seal Gear ...

Page 174: ...stance of primary winding Resistance at 68 F 20 C must be as follows Marelli Martinetti 3 1 to 3 4 ohms 3 to 3 3 ohms Check resistance of secondary winding Resistance at 68 F 20 C must be as follows Marelli Martinetti 5670 to 6930 ohms 6500 to 8000 ohms Ignition ...

Page 175: ... 1 ...

Page 176: ...Lift brushes 1 lightly Rest brush Spring ends against side face of brushes Remove nuts and washers holding brush holder support to frame Remove support Retain thrust washers on end of pin 1 Brush 2 Brush spring 3 Terminal 4 Pinion and head 5 Drive pinion 6 Frame 7 Commutator end head 8 Pole shoe mounting screws 9 Brush terminal clamping screw Slide frame off pinion end Remove cotter pin holding pi...

Page 177: ...n Rubber pin Fork pin Shifter fork Insulator Screw Plunger Spﬁng Nut PPPWHP QPP PL HH 2 Plain washers Sleeve spring Plain washers 3 Armature 6 Stop ring 9 Plain washers 12 13 14 15 16 17 18 19 20 21 22 27 Lockwasher Washer Solenoid Lockwasher N ut Washer Screw Bushing Screw Collar Screw 23 24 25 26 27 28 29 30 31 32 33 111213 14 15 Bush spring Brush Armature Nut Bolt Drive unit Ring Lockring Washe...

Page 178: ...unting screws 9 Brush terminal clamping screws REPLACING FIELD GOILS Disassemble starter to remove frame 4 Remove screws 3 and remove field coils 5 and pole shoes Heat replacement coils to 122 F 50 C Install coils and shoes Tighten screws 3 hard up to restore air space Check pole shoe inside diameter it must be between 2 175 and 2 182 in 55 25 to 55 42mm Reassemble starter 1 Coil terminal to brush...

Page 179: ...ection of stutter assembly SECTION A A SECTION 3 3 SECTION C C Cross section through plnlon Section through pole ghoul Section through commun drlua and ﬁeld winding tor and frame and View 01 brushes E 8443 8 12 Var 1 STARTER ASSEMBLY ...

Page 180: ...her Support Plate Screw Stator Support 11 12 13 14 15 16 17 18 20 Alternator Condenser Washer Screw Screw Lockwasher Washer Brush holder Seal Bearing Rotor 21 22 23 24 25 Washer 27 28 29 30 Ill 1974 Section No 553 01 Page 183 Clip Seal Plate Key Screw Bea ring Seal Lock washer Nut ...

Page 181: ......

Page 182: ...adlight adjustments should be made with the car unloaded at 16 ft 5m from the screen When using headlight alignment equipment refer to instruc tions provided Turn headlights on low beams Adjust horizontal alignment by turning screw 1 Adjustment screw Adjust vertical alignment by adjusting rod 1 Motor 2 Cap 3 Adjusting rod 9425 ...

Page 183: ... Headlight RETRACTABLE HEADLIGHT MOTOR REPLACEMENT Remove bolt 1 holding arm 2 to motor shaft Remove three bolts 3 and washers holding motor 5 Disconnect electrical connector Remove motor 5 When installing place ground wire for motor under mounting bolt 3 1 Bolt 2 Arm 3 Bolts 4 Cap 5 Motor 6 Adjusting rod FUSES Fuses A thru H 8 Amp Fuses I and L 16 Amp Fuses M and N 3 Amp Fuse in separate holder 8...

Page 184: ... button with lock Front trunk latch release handle ls housed in tray recess Heater outlet ﬂap Courtesy light switch Front ash tray Gearshift lever Cigar lighter I Lr as one 24 31 Hand brake lever To release thumb in the button on top of hand grip Choke knob Ideogram illumination intensity rheostat instrument cluster light switch Accelerator pedal Service brake pedal Clutch pedal Fusebox Oil pressu...

Page 185: ...s for the control box have been given number for reference C16 white conector 017 red con nector The wires are also numbered W1 thru W6 and R1 thru R6 The prOCedures refer to wire numbers in stead of color since some variation in wire color coding does occur The table below lists the wire colors and numbers being used at the time this manual was written RED CONNECTOR Cl7 WHITE CONNECTOR C16 R1 pin...

Page 186: ... With seat empty meter should read infinity 0 c Have someone sit in passenger s seat Meter should read 0 ohms d If any reading is faulty go to PASSENGER S SEAT SWITCH CIRCUIT 6 PASSENGER S SEAT BELT SWITCH a Leave black lead connected to ground Connect red lead to 1R in connector C17 b With belt retracted meter should read 0 ohms c Pull belt out and buckle it Meter should read infinity 7 d If any ...

Page 187: ...k ground connection 13 CONTROL BOX POWER CIRCUITS a Get voltmeter Connect black lead to ground Connect red lead to 4W in connector 016 Meter should read voltage lf meter does not read voltage check wire from connector 016 to instrument panel con hector Repair wire Connect red lead to 3W Meter should read voltage lf meter does not read voltage check that ignition key warning system works If system ...

Page 188: ... SCHEDULE CODE 70 71 701 02 701 05 701 08 701 09 701 18 701 20 701 23 701 27 711 01 General Information 191 Gr 701 BODY SHELL Instrument Panel 193 Body Shell 197 Hard Top 203 Doors 205 Windshield 209 Back Window 211 Luggage Compartment 213 Air Intakes and Lids 21 Gr 711 INTERIOR TRIM AND SEATS Front Seats 219 70 71 ...

Page 189: ... seats are adjustable bucket type with tiltable back for access to rear of seats Spare wheel housed behind passenger s seat Instrument panel has plastic padding Instruments and switches on driver s side Heat and air controls are in center panel Four adjustable out lets one at each end and two in center panel Interior trim and seats are imitation leather Arm rests in padded plastic on doors Rear vi...

Page 190: ...aura _ r _ I 7 lair F M I Iu r I HF J w L_umg 1d 3 ﬂ hF ur I I 21 n J _ x x I H I a r 4 Pm w ma n HF JﬁH HFL I im Tl H h_ anurmm h T H I ﬁller r Fﬂ ﬂ Hill I rultihrn ﬁ T I ...

Page 191: ...ectors and speedometer cable Remove instrument cluster 1 Screw 2 lnstrurnent cluster 3 Instrument panel Remove 4 screws 1 holding panel 2 on right side of instrument panel 3 Remove panel 2 Remove light switch from left side of instrument panel 1 Screw 2 Panel 3 Instrument Panel Remove 5 screws 1 thru bottom of steering column cover 2 Remove cover 1 Screws 2 Steering column cover ...

Page 192: ...lamps 3 on body Install 4 bolts lockwashers and washers 2 behind instrument cluster 2 behind panel on right side thru panel into body 1 Clips 2 Panel 3 Clamps Place instrument cluster 1 into position in panel Connect electrical connectors and speedometer cable to cluster Secure cluster with 5 screws 2 Install panel on right side of instrument panel with 4 screws Install steering column cover with ...

Page 193: ...Screw 33 Washer 4 Gasket 19 Lockwasher 34 Screw 5 Duct 20 Pin 35 Lockwasher 6 Gasket 21 Lock 36 Bolt 7 Rubber bushing 22 Lock cylinder 37 Washer 8 Rubber bushing 23 Latch 38 Spring clip 9 Screw 24 Duct 39 Hinge 10 Gasket 25 Hinge 40 Screw 11 Duct 26 Rubber bushing 41 Cover 12 Gasket 27 Screw 42 Cover 13 Spacer 28 Washer 43 Duct 14 Clip 29 Catch 44 Switch housing 15 Duct 30 Tray ...

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Page 195: ... body Alignment The body is of unitixed construction and therefore the body and underbody are one unit The alignment of front and rear wheels is the first thing to check Mis alignment is apparent when there is no parallel rela tionship between the axes of front and rear wheels or when rear wheels do not follow in the tracks of the front wheels You should first check to make sure the misalignment i...

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Page 197: ... 9567 in 55 5 mm 21850 In 477 5 mm 18 7992 In 52 mm 2047 in 429 mm 16 8898 in 418 mm 15 4567 In 408 mm 16 0630 In _ 406 mm 159843 In 405 mm 159449 In 399 5 mm 15 7283 In 378 mm 133313 In 354 mm 1 In 335 5 mm 13 2087 In 40 mm 333 mm 13 11o2 m 33 mm 302 mm 11 8898 in 31 mm 293 5 mm 11 5551 in 285 mm 290 5 mm 11 4370 in 23 mm 222 5 mm 8 7598 in 21 mm 220 mm 8 6614 in 17 mm 195 mm 7 6771 in 8 mm Refer...

Page 198: ...y seat 2 Wall 6 Cover 10 Framing 3 Nut 7 Bracket 11 Side panel 4 Lockwasher 8 Framing 12 Wall 1 Air intake wall 6 Joining element 11 Reinforcement 2 Air intake case 7 Framing 12 Reinforcement 3 Reinforcement 8 Joining element 13 Reinforcement 4 Framing 9 Reinforcement 14 Framing 5 Windshield framing 10 Framing 15 Joining element ...

Page 199: ...6 Joining element 10 Side panel 7 Side panel BODY SHELL OUTER COMPONENTS Panel Panel 17 Panel 2 Panel 10 Panel 18 Seat 3 Panel 11 Panel 19 Joining element 4 Channel 12 Panel 20 Joining element 5 Hood channel 13 Panel 21 Panel 6 Panel 14 Panel 22 Door opening panel 7 Windshield panel 15 Hood channel 23 Panel 8 Panel 16 Panel ...

Page 200: ...icker plate 2 and shifting plate 2 1 Screws 2 Stricker plate EXPLDDED VIEW OF HARD TOP COMPONENTS 1 Screw 8 Weather strip 15 Covering 2 Stricker plate 9 Weather strip 16 Plug 3 Screw 10 Hard top 17 Weather strip 4 Support 11 Lug 18 Moulding 5 Lock 12 Screw 19 Joint 6 Screw 13 Screw 20 Lock 7 Moulding 14 Stricker plate ...

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Page 202: ... 4 7 Plug Covering 2 Arm rest 3 Lock button Door handle 5 Cover 6 Window crank WINDOW ADJUSTMENT Loosen screws 1 2 places Rest window 2 on rubber pad 3 Set regulator handle in wide open position Tighten screws 1 hard After adjustment the glass must be able to run full length of its travel Control cable must wind and unwind properly on regulator pulley 1 To adjust tension of cable 1 loosen nut 2 on...

Page 203: ...able head 1 of tie rod 2 1 Adjustable head 2 Tie rod To adjust the inside door handle 1 loosen 3 screws 2 and shift the handle 1 1 Door handle 2 Screws To adjust stricker plate 1 for door lock mark its position Loosen 2 screws 2 and shift plate 1 1 Stricker plate 2 Screws ...

Page 204: ... 7 Pin 8 Lining 9 Door check 10 Hinge half 11 Pin 12 Bolt 13 Screw 14 15 16 17 18 19 20 21 22 23 24 25 26 Doors Handm Bok Lockwasher Washer Lever Lockwasher Lock Rod Rubberﬂng Knob Rod Nut Handle 27 28 29 30 31 32 33 34 35 36 37 38 Lock cylinder Pin Spﬁng Pawi Stricker plate Lockwasher Screw Screw Lockwasher Door Channel Rod ...

Page 205: ...s 8 Weather strip 9 Pillar 10 Pad 11 Weather strip 12 Clip 13 Plate 14 15 16 17 18 19 20 21 22 23 24 25 26 Screw Pad G lass Guide Plate Screw Weather strip Cover Boot Weather strip Channel Washer Lockwasher Screw Weather strip Pad Nut Washer Sheave Washer Bolt Lockwasher Nut Ornament Handle Window regulator ...

Page 206: ...ield weatherstrip and open ing fence Set glass in position in fence Center glass so that distance between glass and fence is even all around Place Spacers 1 to hold glass in position Check that glass is centered with respect to the fence Use gauges 4 Insert 4 or more spacers 3 to hold glass Glue spacers to opening fence Make sure they are right size to enable a continuous bead of adhesive to be ap...

Page 207: ...l to avoid variations in bead sections and air bubbles between bead and glass Place glass in fence resting it on the spacers Align taps on glass and car Remove taps Apply a thin coat 0 39 in 10mm wide of primer to outer edge of glass Apply outside weatherstrips Join end with butt joints Press strips until they are in place Use a spring type fixture to apply pressure to weatherstrips After 24 hours...

Page 208: ...ll rubber seal 1 around window towards center of window Slide seal out from under window 2 at edge Pull window down Remove top rubber seal Remove window Place rubber seal on top of window Place window in frame 3 and push it up into place Slide rubber seal 1 under window Make sure window is in center of seal and seal overlaps frame 3 1 Rubber seal 2 Window 3 Frame Install weatherstrip 2 with 6 bolt...

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Page 210: ...necessary After lid is positioned properly tighten bolts Install support rod 1 Lid 2 Bolts 3 Hinge 4 Support rod LID LOOK REPLACEMENT AND ADJUSTMENT Remove 4 screws and bolt holding grill 1 on right side of car Remove 2 bolts 3 and washers holding lock 2 in car Work lock out thru grill opening 1 Grill 2 Lock 3 Bolts Disconnect cable 1 from lock 3 Remove 2 nuts 2 and washers holding lock to bracket...

Page 211: ...ring washer 4 Washers 5 Lockwasher 6 Nut 7 Rod 8 Lock bracket 9 Washers 10 Bolt 24 11 12 13 14 15 16 17 18 19 20 Washer Latch cable Cable Spﬂng Lock Washer Lockwasher Nut Compartment rubber seal Bolt 21 22 23 24 25 26 27 28 29 30 Lockwasher Washer Lockwasher Nut Hinge Nut Hinge Bolt Washer Washer ...

Page 212: ...TMENT Remove 2 bolts 3 and 4 washers holding lock 4 in car Disconnect cable 1 from lock Disconnect plastic cable 2 from lock When installing lock position lock for proper operation Tighten 2 bolts NOTE The pull for the plastic cable is in engine compartment 1 Cable 2 Plastic cable 3 Bolts 4 Lock KEY LOCK REPLACEMENT Remove screws 2 holding cables in levers 1 Remove screw 3 holding assembly 4 in do...

Page 213: ...3 Handle 2 Lid 13 Washer 24 Washer 3 Hinge 14 Bolt 25 Fork 4 Washer 15 Cable 26 Screw 5 Lockwasher 16 Rubber ring 27 Washer 6 Bolt 17 Washer 28 Weather strip 7 Bolt 18 Lockwasher 29 Bushing 8 Lockwasher 19 Screw 30 Stay 9 Washer 20 Lockwasher 31 Pin 10 Lock 21 Screw 11 Spring 22 Lock cylinder ...

Page 214: ...ter pin washers and bushing 1 When installing lid check position Shift lid on hinges to obtain proper alignment Tighten bolts holding lid to hinges 1 Bushing 2 Prop 3 Hinge 4 Bolts 5 Lid LID LOOK REPLACEMENT AND ADJUSTMENT Remove 2 bolts 2 and 4 washers holding lock 1 in car Disconnect cable 3 from lock 1 When installing look position lock for proper operation Tighten 2 bolts 1 Lock 2 Bolts 3 Cabl...

Page 215: ...6 Hinge 7 Washer 8 Lock washer 9 Bolt 10 Center prop 11 Washer 12 Lid 13 Stricker plate 14 15 16 17 18 19 20 21 22 23 24 25 26 Bushing Cotter pin Grill Conveyor Gasket Gasket Wall Conveyor Bolt Lock Screw Screw Grill Screw Cable Cable Gasket Conveyor Gasket Air intake Wall Clip Screw Screw Washer ...

Page 216: ... from bracket under seat Disconnect connector for seat switch Raise lever Slide seat off floor tracks 1 Spring 2 Track 3 Connector 4 Bracket FRONT SEAT Fore and aft adjuster lever Seat release lever Back hinge Track Spﬁng Seat Belt interlock wires Front seat release lever FP PPPE J ...

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Page 218: ...tem 229 Ignition System 239 Radiator and Carburetor Cooling System ______________________________________________ 25 Seat Belt Interlock and Remove Key Warning System 26 Interior Lights 281 Exterior Lights 291 Instruments 31 Accessories 329 Fuses 339 ELECTRICAL SYSTEM TROUBLE SHOOTING ...

Page 219: ... Does Not Light With Ignition Switch On And Remains Off With Engine Running Engine Starts Battery Boils Over Lights Burn Out Repeatedly Battery Does Not Stay Charged m i i l I _ FUSE BOX 35 x VOLTAGE REGULATOR 5 DJ l BATTERY C_ o 0 000000 3 5 INSTRUMENT PANEL BATTERY CHARGE INDICATOR I mi i U_ _ ALTERNATOU l Page 221 PAGE 222 224 226 226 ...

Page 220: ... AND CHARGING SYSTEM BATTERY CHARGE INDICATOR STAYS ON AFTER ENGINE STARTS CHECK ALTERNATOR DRIVE REPAIR DRIVE IF OK CHECK VOLTAGE REPLACE AT ALTERNATOR ALTERNATOR IF OK CH ECK VOLTAGE AT CIRCUIT BOARD REPAIR WIRE IF OK CHECK CIRCUIT BOARD FOR DEFECTS ...

Page 221: ...ter lead to black violet wire at alternator BLACK LEAD Connect black lead to ground ALTERNATOR b if meter reads voltage go to step c If meter does not read voltage replace alternator c Remove 5 screws thru instrument panel Disconnect Speedometer cable from panel Do not disconnect connectors d Connect red meter lead to black violet wire in connector C7 Connect black lead to ground NOTE Connector C7...

Page 222: ...EM INDICATOR DOES NOT LIGHT WITH IGNITION SWITCH ON AND STAYS OFF WITH ENGINE RUNNING CHECK ALTERNATOR CIRCUIT TO GROUND CHECK CIRCUIT TO ALTERNATOR IF OK IF NOT IF OK REPLACE REPAIR WIRE ALTERNATOR REPLACE BULB IF OK JOB COMPLETE IF NOT OK CHECK CIRCUIT BOARD FOR DEFECTS ...

Page 223: ...go to step 3 Locate bulb holder for battery charge indicator Turn bulb holder to left and remove it from circuit board Pull bulb out of holder Install new bulb Install holder in circuit board Turn ignition switch on Check indicator If indicator is lit install in strument panel If indicatorvis not lit check connector C7 circuit board and bulb holder for defects Repair or replace defective part Go t...

Page 224: ...charge battery it cells are full charge battery Go to step b Get hydrometer Measure specific gravity of each cell If specific gravity is below 1 100 on any cell or cells check battery with a carbon pile load If battery O l go to step 2 If load test indicates battery is no good replace it Get multimeter Set up meter to measure amps Make sure all switches are off Close doors Disconnect battery posit...

Page 225: ...ARGING SYSTEM VOLTAGE ALERNATOR REGULATOR BATTERY D_ 3 WHITE BLACK _D_ ﬁll H l l 0F _ BLACK VI E 3 0 0L T CW STARTER0 J dz I LI _l 9 N 5 cs 4 a LIGHT BLUE m LIGHT BLUE RED BLACK L J FUSEA P Al I o 6 6 O 7 O O O BATTERY CHARGING C INDICATOR I5 54 J IGNITION SWITCH ...

Page 226: ...lI ul IIIIHIIIIIIIITln III iiul l 3 1 11 nil Ian 1 illrﬁ uL rm I __I u T E E II I I II I mm mm III I IJII I unl _ I 1II E I L I I I l J J i H r I h u _ I a I 2 ...

Page 227: ...AL SYSTEM TROUBLESHOOTING STARTING SYSTEM TABLE OF CONTENTS SECTION Starter Will Not Crank Engine Starter Cranks Slowly ﬂ BATTERY I IIIIGNITION 300003 U SWITCH _ _ __ I _ 32 Ué EEI w __ J Page 229 PAGE 230 235 ...

Page 228: ...OUT REPLACE IGNITION SWITCH REPAIR WIRING CHECK CONNECTIONS AT STARTER CHECK BATTERY CHECK GROUND FDR RELAY IF 0K CHECK OUTPUT OF RELAY REPLACE BATTERY IF NOT OK IF OK IF NOT OK CHECK CABLE T0 STARTER CHECK BATTERY TROUBLESHOOT SE AT BE LT SYSTEM CHECK VOLTAGE AT STARTER REPLACE RELAY REPLACE STARTER IF NOT OK IF OK REPLACE STARTER RECHARGE OR REPLACE BATTERY CHECK CONNECTIONS AT STARTER REPAIR WI...

Page 229: ...51 red wire of relay Connect black lead to ground Have someone start car If meter reads less than 8 volts go to step i If meter reads 8 volts or more get ohmmeter Connect red lead to terminal 86 light blue white wire Connect black lead to ground If meter reads 5 ohms or less go to step 9 If meter reads more than 5 ohms troubleshoot seat belt interlock system Get voltmeter Connect red lead of meter...

Page 230: ...3 Connect black lead to ground I Turn ignition switch to start If meter reads 8 volts or more repair red BLACK LEAD wire to relay 4 RED LEAD TO GROUND m If meter reads less than 8 volts check connector C12 for looseness dirt or CONNECTOR 12 corrosion Check red wire position 1 to ignition switch for breaks Repair or replace wire or connector n If wire and connector are good replace ignition switch ...

Page 231: ...Remove clean and tighten T0 BATTERY t Turn ignition switch to start If starter will not run replace starter BLACK M A TO RELAY __ _ Rem m I __ 3 a Check connections at starter terminals Remove clean and retighten c Check condition of battery with hydrometer If specific gravity of any cell is below 1 100 check battery with a carbon pile load If load test indicates battery is no good replace it P ﬂ ...

Page 232: ...als with a wire bristle brush Tighten connections 6 Check battery condition with hydrometer d If specific gravity of any cell is below 1 100 check battery with a carbon pile load If load test indicates battery is not good replace battery e If load test indicates battery is good recharge battery f If battery and cables check good starter is possibly shorted internally and must be removed and bench ...

Page 233: ... looseness or corrosion CONNECTOR C12 NOTE Connector 012 is located on right side of steering column under column cover It is a 4 pin connector e Repair or replace connector as necessary 1 Check terminals at starter for looseness or corrosion Clean and reinstall 9 if starter continues to crank slowly after each point has been checked and TO BATTERY found good condition may be caused by recently ov...

Page 234: ... 1 ...

Page 235: ...UBLESHOOTING Page 2373238 STARTING SYSTEM BATTERY DUDE 3 gum 8 5O _ co STARTER L1 Ea p TO INTERLOCK SYSTEM RED 37C 0 RED WHITE We l Ll ORANGE WHITE _ E 2 RED 85 3 W 0 II D CI2 m I I Z 3 O II III 30 0 LL 0 IGNITION 50 SWITCH ...

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Page 237: ...CONTENTS SECTION Engine Will Not Start Engine Misses at Idle Rough Idle Engine Runs But Lacks Power Or Misses at High Speeds Timing Ignition With Timing Light Engine Stalls l c t Ir 1 éﬂ IGNITION SV VITCH l I BATTERY I U U ua Page 239 FAG E 240 247 250 25 1 257 ...

Page 238: ...LUGS CLEAN OR REPLACE SPAR K PLUGS IF NOT OK CHECK CHECK AND REPLACE 7 SPARK AT DISTRIBUTOR CAP DISTRIBUTOR ROTOR OR LEADS 2 3 IF NOT OK REPLACE LEAD FROM COIL TO DISTRIBUTOR CHECK SPARK AT COIL HIGH TENSION TERMINAL 2 REPLACE COIL 4 IF NOT OK CHECK VOLTAGE AT COIL BATTERY TERMINAL 4 CHECK RESISTANCE 4 CHECK POINTS AND CONDENSER ADJUST TIMING 6 IF NOT OK CHECK VOLTAGE AT IGNITION SWITCH REPAIR WIR...

Page 239: ...ck for spark lf spark is strong troubleshoot fuel system If there is no spark or it appears weak go to step 2 2 3 Take coil to distributor lead out of distributor b Hold lead about 1 4 inch from engine Use insulated pliers c Crank engine and check for spark If spark is present 90 to step 3 d If spark is not present connect lead to distributor Disconnect lead from top of coil e Hold lead about 1 4 ...

Page 240: ...y examine distributor cap sockets for dirt corro sion or damaged terminals Check each end of the high tension lead also 4 a Connect coil lead to top of coil Disconnect remote starter switch from coil Turn ignition switch on b Get voltmeter Connect red meter lead to 3 terminal of coil Connect black lead to ground c Crank engine If meter does not read voltage go to step 5 d If meter reads voltage ge...

Page 241: ...t black lead to ground If meter reads voltage repair pink wire from connector 012 to connector C14 If meter does not read voltage check light blue red wire to ignition switch If wire is good replace ignition switch Remove distributor cap and rotor With ignition switch on crank engine with remote starter switch Watch points to see if they open and close fully lf points do not open and close fully g...

Page 242: ...s clean and tight at terminal Check black wire from coil to distributor for damage Replace wire if necessary If wire is good check points as directed in steps k thru 9 Then set the timing Crank engine until rubbing block is at peak of cam lobe Loosen breaker plate Iockscrew Insert screwdriver in adjust slot Adjust points so gap is 0 015 to 0 017 in 0 37 to 0 43mm when checked with feeler gage Tigh...

Page 243: ...ar accumulates mileage the distributor may wear and permit slight side play CHECK SIDE PLAY OF DISTRIBUTOR SHAFT q Measure tension of breaker moveable arm If less than 16 6 ounces replace breaker points MOVABLE BREAKER ARM 16 6 oumces a MINIMUM somel WORN TOO HOT REPLACE IMPROPER TYPE OILY CLEAN AND 7 3 Remove spark plugs Check condition REPLACE CHECK ENG NE b Clean or replace plugs if necessary S...

Page 244: ...STEM TROUBLESHOOTING Page 246 0 9 IGNITION SYSTEM Check gap Reset gap if necessary WIRE GAGE Reinstall plugs Connect leads 0 020 TO 0 024 If plugs were good or if engine still will not start troubleshoot fuel system ...

Page 245: ...ylinder is not located 90 to step 2 NOTE Misfiring is detected by no change in the idle RPM when lead is shorted or removed c Remove plug Check plug for dirt damage and gap If plug is good 90 to step d If plug is not good clean gap or replace plug 1 Remove plug from firing cylinder Reverse plugs and reinstall e Start engine See if misfiring is in cylinder with suspect plug by repeating shorting in...

Page 246: ...pitting or improper gap CHECK FOR ERACKS 0 b If point condition and gap are good check spark plug leads distributor cap and rotor for defects Replace any defective part AND DRY a c If leads cap and rotor are good check for side play in distributor shaft Remove distributor for overhaul or replacement if excessive play is de tected CHECK SIDE PLAY OF DISTRIBUTOR SHAFT ...

Page 247: ...blue red wire from B terminal of coil f Connect red meter lead to top of coil Connect black lead to 3 terminal of coil Resistance should be as follows 3 BLACK LEAD Coil Resistance Ohms 3 TERMWAL Marelli 5 670 to 6 930 Martinetti 6 500 to 8 000 g If coil resistance is not within range specified replace it If test is good replace condenser h Restart engine and check idle speed If missing is still ap...

Page 248: ...step 2 c if advance does not return check springs Connect or replace damaged or disconnected springs Check return operation d If springs appear good remove them Move mechanism by hand and check for binding If binding is felt distributor must be replaced NOTE When replacing distributor be sure to note position of rotor before removal New distributor must be installed in exact same position Check ti...

Page 249: ...ct point at which points just start to open is sure I Tighten distributor lock nut Be careful not to move distributor while tightening lock nut on coupling of crankcase If point gap was set properly ignition should be timed at this _ point h Reinstall plug and lead i Reinstall distributor cap TIMING IGNITION WITH TIMING LIGHT La Slide No 1 spark plug lead caver back on lead b Connect one lead of t...

Page 250: ...y and cover shall appear in line _ MARKS ALIGNED 59 i If marks are not in line turn distributor body until alignment is good j Tighten nut on clamp for distributor on crankcase Recheck timing after tightening k If engine still lacks pDWer or misses at high speed check CARBURETION AND FUEL SUPPLY or go to ENGINE MISSES AT IDLE LOCK NUT omtnmutoe coupuNG ENGINE STALLS 1 a Check battery terminals for...

Page 251: ...rosion dirt or moisture Replace if defective CONNECTIONS DISTRIBUTOR H T LEAD COIL TERMINALS c Check primary wire to ignition switch Wire to coil must not be bare at any TO IGNITION SWITCH point d If condition still occurs check CARBURETION or COMPRESSION If these are good repeat procedures under ENGINE WILL NOT START LT BLU El BLACK WIRE t ...

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Page 253: ...ELECTRICAL SYSTEM TROUBLESHOOTING Page 2551 256 IGNITION SYSTEM HIGH TENSION LEADS DISTRIBUTOR CONDENSER 3 A H A COIL II 1 BATTERY 1 SPARK PLUGS 1 CI4 JEI 13 BROWN r 1_ LT BLUE RED IGNITION SWITCH ...

Page 254: ...Iiﬂugaiii inlllilllsﬂuﬂﬂal _ F I I II II Iﬁlml all Ii l I I II I 4 I l lII r l ll llli I II I L I I I ...

Page 255: ...iator Cooling Fan Will Not Run 259 Radiator Cooling Fan Runs All The Time 260 Carburetor Cooling Fan Will Not Run 261 Carburetor Cooling Fan Runs All The Time 262 THERMOSTATIC SWITCH COOLING FAN COOLING FAN RELAY II I II I I BATTERY FU_ SE BOX 00003 U CE ___ I 6 13 I CARBURETOR CARBURETOR THERMOSTATIC H SWITCH CARBURETOR __ FAN RELAY ...

Page 256: ...S IF NOT OK IF REPLACE CHECK FUSE IF OK JUMPER THERMO FAN RUNS STATIC SWITCH FAN DOES NOT RUN CHECK VOLTAGE IF NOT OK TO FAN RELAY IF OK CHECK RELAY F NOT 0 IF OK CHECK GROUND IF NOT OK CIRCUIT IF OK REPLACE FAN F 00 0 _ _ FUSE O REPLACE SWITCH REPAIR WIRE REPLACE RELAY REPAIR WIRE ...

Page 257: ...d meter lead to terminal 86 light blue black wirel of cooling fan relay Connect black lead to ground NOTE Cooling fan relay is mounted in compartment for left head light motor It is the forward relay lf meter reads voltage go to step 2 If meter does not read voltage repair light blue black wire from relay to connector C7 Connect red meter lead to terminal 30 51 violet wire of relay Connect black l...

Page 258: ...t is located above the cooling fan i If meter reads voltage go to step j lf meter does not read voltage repair light blue wire from connector C21 to relay 1 Get ohmmeter Connect red lead to black wire in connector C21 Connect black lead to ground k If meter reads more than 5 ohms repair black lead to ground I If meter reads 5 ohms or less check wires to fan for defects Repair wires or replace fan ...

Page 259: ...onnect jumper to terminals on switch If fan runs replace switch If fan SWITCH does not run 90 to step d Leave jumper on switch d Get voltmeter Connect red meter lead to terminal 30 51 brown wire of SEEING FAN RELAY carburetor cooling fan Connect black lead to ground NOTE we ff The relay for the cooling fan is located on support for carbu ll BLACK LEAD retor cooling fan BROWN WIRES e If meter reads...

Page 260: ...tion Go to fan motor Check red wire from fan to relay for defects If wire is damaged repair wire Check black wire from fan to ground If wire is damaged repair wire NOTE Wire is grounded at relay mount Check ground terminal for dirt corrosion or looseness Clean and tighten ground terminal Repair ground wire If wires and ground terminal are good replace fan motor CARBURETOR COOLING FAN RUNS ALL THE ...

Page 261: ...OOTING Page 2631264 RADIATOR AND CARBURETOR COOLING SYSTEMS c Disconnect gray red wire from terminal 85 of relay If fan still runs re FAN RELAY place relay 1 If fan stops repair gray red wire from relay to switch ﬂ GRAY REL WIRE ...

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Page 263: ...RMOSTATIC _I_ SWITCH WHITE BLACK Y BLACK _ _L CARBURETOR BLACK COOLING __ FAN RE LIGHT BLUE 87 37 0 ___C_ WHITE BLACK 85 CARBURETOR I ENG NE COOLING FAN COOLING RELAY GREY RED LIGHT BLUE BLACK FAN C 86 RELAY TE BLACK VIOLET C 30 5I 30 5 WHIJT LIGHT BLUE BLACK BR WN C7 LIGHT BLUE BLACK T FUSE L H FUSE A ﬁx 1 IGNITION SWITCH I TRED ...

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Page 265: ...rcuit Faulty 270 Seat Belt Indicator and Buzzer Circuit Faulty 272 Starter Relay Circuit Faulty 273 By Pass Switch Circuit Faulty 274 Key Warning Buzzer Will Not Work 276 Key Warning Buzzer Will Not Stop With Door Closed and Key In 277 f _ _ SEAT BELT TRANSMISSION SWITCHW ﬂ__ SEAT BELT ALARM BUZZER RELAY H III SEAT BE LT U__ Sistine BUTTON SWITCH STARTER _ _ __ RELAY I SEAT SWITCH 6 SEAT BELT SWIT...

Page 266: ...tor C17 NOTE CONNECTOR UNDER Connector C9 is a 6 pin connector it is behind center console SEAT d If meter reads infinity or test light goes out replace switch in driver s seat 2 a Disconnect connector under driver s seat Using jumper wire connect 2 CONNECTOR UNDER wires in connector together SEAT b If meter reads 0 ohms or test light comes on replace switch in driver s seat JUMPER c If meter read...

Page 267: ...wﬁOomm CONNECTORUNDER or light remains on repair pink yellow wire to connector C9 and to con RUG nector 017 NOTE Connector C9 is a 6 pin connector It is behind center console PASSENGER S SEAT CIRCUIT FAULTY 1 a If meter did not read 0 ohms or test light is out with someone in seat 90 to step 2 b if meter did not read infinity W or test light is on with seat empty disconnect connector under passeng...

Page 268: ...0 HJUMPER ohms or light comes on replace switch in seat belt d if meter reads infinity or test light remains out repair white red wire to T0 GROUND connector C9 and to Connector C17 NOTE Connector 09 is a 6 pin connector It is behind center console 2 a Disconnect connector behind spare wheel passenger s seat If meter reads 0 CONNECTOR UNDER ohms or light remains on with belt pulled out repair whit...

Page 269: ...a 6 pin connector It is behind center console Disconnect connector C22 NOTE Connector 022 is a 2 pin connector It is located on bottom forward side of engine If meter does not read infinity W or test light remains on repair green white wire from connector C22 to connector C9 and to connector C17 NOTE Connector 09 is a 6 pin connector It is behind the center console If meter reads infinity or test ...

Page 270: ...meter reads 0 ohms go to step 9 If meter does not read 0 ohms repair black wire to ground or ground connection g Disconnect blue red wire from terminal 85 of relay Connect red meter lead to wire Connect black lead to ground h If meter reads 0 ohms replace relay If meter does not read 0 ohms repair blue red wire from relay to connector CB NOTE Connector CS is middle connector at instrument panel It...

Page 271: ... an 8 pin connector If indicator does not go out repair blue red wire from connector C16 to connector C6 and to buzzer relay STARTER RELAY CIRCUIT FAULTY 1 3 b Go to starter relay in drop tray area Get jumper Connect jumper to terminal 86 light blue white wire of starter rela Connect other end of jumper to ground Try to start car If car will start repair light blue white wire from relay to connect...

Page 272: ...tch to connector C9 and to connector C16 NOTE JUMPER Connector 09 is a 6 pin connector It is behind center console TO GROUND e Disconnect black violet wire from by pass switch Using jumper connect BY PASS SWITCH wires together 1 If meter reads 0 ohms or test light comes on replace by pass switch 9 If meter reads infinity or test light does not come on repair black violet wire to ground or ground c...

Page 273: ...STEM I IF NOT OK IF NOT OK IF 0K CHECK DOOR JAM SWITCH IF OK IF OK IF NOT OK CHECK VOLTAGE AT BUZZER REPAIR WIRE REPLACE SWITCH IF OK IF NOT OK CHECK IGNITION SWITCH CHECK GROUND TO BUZZER IF NOT OK REPLACE SWITCH IF NOT OK CHECK VOLTAGE FROM FUSE BOX IF OK REPLACE BUZZER REPAIR WIRE To RELAY REPAIR WIRE TO RELAY REPAIR WIRE TO FUSE BOX ...

Page 274: ...NOTE Buzzer is located on left side of driver s footwell d If meter reads voltage go to step e If meter does not read voltage go to step 9 TERMINAL4 l BLACK LEAD TO GROUND e Get ohmmeter Connect red meter lead to terminal 3 white black wire RED LEAD Connect black lead to ground f If meter reads 5 ohms or less replace buzzer If meter reads more than 5 ohms repair white black wire to buzzer relay _ ...

Page 275: ...If meter reads voltage repair red white wire position 1 from connector RED LEAD C15 to buzzer If meter does not read voltage repair red wire position 2 from connector 015 to fuse box BLACK LEAD Open door Remove jam switch Make sure wire does not touch metal If buzzer does not stop repair white black wire from switch to relay and to buzzer GROUND If buzzer stops check jam switch for dirt or corrosi...

Page 276: ...JL JLJ UUL JUL WHITE BLACK 16 017 I DOOR GRAY DRIVER s SWITCH SEAT BELT BROWN WHITE __ _ YELLOW SWITCH RED I RAY BLACK 3 GRAY K _ PASSENGER S LIGHT BLJE BLACK C8 _ _ DRIVER S SEAT WH TEI SEAT SWITCH WHITE RED I WHITE RED SWITCH __ J I BLACK VIOLET PINK YELLOW J PASSENGER S SEAT BELT T SWITCH WHITE BLACK 3 WHITE BLACK TRANSMISSION T SW TCH C22 09 L GHT BLUE BLACK GREEN WHITE 3 GREENNVHITE 3 13 GREE...

Page 277: ...Will Not Light Optical Fiber Illumination Will Not Work Vehicle Warning Indicator Light Will Not Work Direction Indicator Light Will Not Work COURTESY LIGHT COURTESY LIGHT SIINITCH JAM SIWITCH C19 9 s34 C _ __ ﬁrm I HAZARD WARNING INDICATOR Page 281 PAGE 283 284 285 286 287 288 HAND BRAKE SWITCH I INSTRUMENT PANEL LIGHITS SWITCH JAM SWITCH I i EINSTRUMENT PANEL HAND BRAKE ON INDICATOR l5 ...

Page 278: ... COURTESY LIGHT NOT ON WITH DOOR OPEN CHECK DOORS IF NEITHER DOOR WORKS LIGHT REPAIR WIRE FROMSWITCH TO CONNECTOR IFNOT OK IF OK IF LIGHT WORKS WITH EITHER DOOR CHECK JAM SWITCH IF OK IF NOT REPAIR WIRE IF OK REPLACE SWITCH IF NOT OK REPAIR WIRE REPLACE SWITCH ...

Page 279: ...ks check screw switch and door pillar for dirt and corrosion Clean as necessary Install switch If light will not work replace switch Check fuse in separate holder Replace fuse if blown If fuse is good check bulb in light Replace bulb if defective If bulb is good get voltmeter Connect red meter lead to violet white wire at light Connect black lead to ground If meter reads voltage go to step f If me...

Page 280: ... meter reads 5 ohms or less 90 to step e If meter reads more than 5 ohms check orange white wire from connector C14 to switch at hand brake Check ground at switch NOTE The hand brake switch can be checked by removing cover over hand brake Remove 5 screws thru instrument panel Disconnect 3 connectors and speedometer cable Pull panel out Replace bulb Connect connectors to panel If indicator is not l...

Page 281: ... pin connector for the instrument panel Connector C10 is a 6 pin connector under the steering column INSTRUMENT PANEL CONNECTOR ca COVET BLACK WIRE 2 a If lights work on high setting but not low go to step 3 BROWN WIRE b If lights do not work at all pull panel light switch out c Get voltmeter Connect red meter lead to terminal I brown wire of switch Connect black lead to ground d If meter does not...

Page 282: ...ch b If only switch lights or heater panel light is out replace bulb NOTE Optical fiber bulb is located behind center console on left side below heater c If only one or two switch lights are out replace optical fiber for that L are switch d Check cigar lighter light If light is on go to step 2 e If light is off check fuse G If fuse is good repair yellow black wire from rh eostat to fuse box 0 0 a ...

Page 283: ...ect black lead to ground NOTE Connector CS is an 8 pin connector f If meter does not read voltage go to step 2 If meter reads voltage check connector and circuit board for defects Repair or replace board or connector as necessary 2 a Find warning light flasher Get voltmeter NOTE Warning light flasher is mounted forward of fuse box under rug b Connect red meter lead to terminal P yellow red wire of...

Page 284: ...nnector C6 Connect black lead to ground NOTE Connector CS is an 8 pin connector f If meter does not read voltage go to step h g If meter reads voltage check connector circuit board and bulb holder for defects Repair or replace parts as necessary h Find directional flasher NOTE Flasher is mounted in a clip above the fuse box i Connect red meter lead to terminal P violet white wire of flasher Con ne...

Page 285: ...c7 Z i g 0 Z 2 c3 2 W E O O O O _I c m S g I E m m E E o O o 0 LA I qLI AU AU E 2 INT Q INSTRUMENT Q g 2 0 CLUSTER 3 g m LIGHT m m o SWITCH o J IGNITION CREE C9 m SWITCH JAM E SWITCH E I E BLACK G l BLACK E YELLOW E LACK O 2 PARKING m BRAKE SWITCH YELLOW BLACK n I __ _ __C A I 7 E JAM PANEL I U LIGHT I SW TCH g 023 RHEOSTAT I YELLOW RED __J VOLET WHITE VIOLET WHITE _ 2 WHITE BLACK WHITE BLACK C J ...

Page 286: ...ights Will Not Work 307 Back Up Lights Will Not Work 308 Vehicle Warning Lights Will Not Work 309 Directional Lights Will Not Work 310 LICENSE PLATE LIGHT BACK UP LIGHT PARKING LIGHT DIRECTIONAL INDICATOR i SIDE MARKER TG IQ I I BACK UP LIGHT SWITCHI DIRECTIONAL SWITCH HAZARD WARNING HIGH LOW ISWITCH BEAM SWITCH OUTER I E LIGHTING SWITCH LT i I 2 BRAKE LIGHT_ 13 0 SWITICH I WARNING HAZARD DIRECTIO...

Page 287: ...K BOTH HIGH BEAMS AND INDICATOR CHECK LOW BEAMS CHECK FUSE INDICATOR OUT CHECK PARKING LIGHT INDICATOR IF NOT OK IF NOT OK TROUBLESHOOT LOW BEAMS TROUBLESHOOT PARKING LIGHTS CHECK HIGH LOW BEAM SWITCH IF NOT OK CHECK BULB REPLACE BULB REPLACE LAMP IF BAD OD IF GO REPLACE SWITCH REPAIR WIRING TO FUSE BOX REPAIR WIRING ...

Page 288: ...r from steering column CONNECTOR C5 b Find connector C5 Get voltmeter GREEN wm E NOTE RED Connector C5 is an 8 pin connector It is located on left side LEAD of steering column c Connect red meter lead to green wire in connector Connect black lead to ground d If meter does not read voltage check green wire to switch If wire is good replace switch e If meter reads voltage check connector for defects...

Page 289: ...onnect 3 connectors and speedometer cable c Turn socket for indicator to left Remove bulb Install new bulb Connect connectors to panel d If indicator is lit install instrument panel e If indicator is not lit disconnect connector CB Get voltmeter NOTE Connector CS is an 8 pin Connector f Connect red meter lead to green black wire in connector Connect black lead to ground 9 If mater does not read vo...

Page 290: ...ue wire from fuse box to terminal 87 of left motor relay If meter does not read voltage connect red meter lead to gray yellow wire in back of fuse N Connect black lead to ground If meter reads voltage repair gray yellow wire from fuse box to connector C19 If meter does not read voltage check fuse box and brown wire from fuse G to fuse N for defects If left motor will not work go to step f If right...

Page 291: ...and connector are good replace motor If only left motor will not work go to step e If right motor will not work get voltmeter Connect red meter lead to green white wire in connector C20 Connect black lead to ground NOTE Connector C20 is a 4 pin connector It is in compartment for right motor If meter reads voltage go to step e If meter does not read voltage repair green white wire from connector 02...

Page 292: ...If meter does not read voltage repair gray black wire from relay to con Rector e If meter reads voltage get ohmmeter Set outer lighting switch off f Connect red meter lead to terminal 86 black wire of relay Connect black lead to ground 9 If meter reads 5 ohms or less replace relay h If meter reads more than 5 ohms check black wire from terminal 86 to terminal 87b and to ground Page 297 QELAY TEST ...

Page 293: ...MS ONE BEAM BOTH BEAMS OUT OUT CHECK PARKING LIGHT INDICATO IF NOT OK IF I IF NOT OK IF OK CHECK VOLTAGE TURN ON HIGH AT IGNITION BEAMS SWITCH IF NOT OK IF 0K IF OK IF NOT OK REPLACE LAMP REPAIR WIRING REPLACE IGN T ON SWITCH CHECK HIGH LOW BEAM SWITCH CHECK OUTER LIGHTING SWITCH IF OK REPLACE SWITCH REPAIR WIRING REPLACE SWITCH ...

Page 294: ...e 3 screws thru trim and remove trim Loosen 3 screws thru frame and turn frame to left Remove frame and lamp install new lamp Place frame on screws and turn frame to right Place trim on and install 3 screWs Get voltmeter Disconnect plug from lamp Connect red meter lead to gray wire right beam or gray black wire left beam Connect black lead to ground If meter does not read voltage repair wire to fu...

Page 295: ... does not read voltage replace switch 9 If meter reads voltage repair green wire from switch to connector C5 TO GROUND I RED 5 a Pull outer lighting switch out Make sure wires do not touch panel BLACK R ED LEAD b Get voltmeter Connect red meter lead to terminal H black wire of switch Connect black lead to ground c If meter does not read voltage go to step e d If meter reads voltage replace switch ...

Page 296: ...o o T _ S 393 _l I _ 5 C no 1 BLACK 5 5 S e E 4 Z Z 2 1 2 Z x Z IJJ Lu o In Lu 0 I EE BEE EjEE 5 mm c Q Dean 0000 new c1lK ww l 7 JCI9 I km 1020 I J JU c3 g g ﬂ GRAY YELLOW E z E 5 5 GRAY L GRAY BLACK 5 I g m 3 BLACK GREEN WHITE GREEN WHITE 9 c 0 E GREEN I n O O I l GREEN BLACK HIGH BEAM INDICATOR 06 O O a FUSES 8 8 O O K o o E _ E M _ a E g In n P E 0 WHITE LIGHT BLUE BROWN GREEN GREEN B ROWN BLA...

Page 297: ...ation or all of the right side marker and parking lights left PARKING LIGHT license plate light and left front parking and side marker lights are out go INDICATOR to step 5 f If only parking light indicator light is out go to step 6 SOCKET The rear side marker lights are reached from inside the trunk Pull bulb holder out of fender Pull bulb out of holder Replace bulb If new bulb will not Work go t...

Page 298: ... go to step m m If bulb did not work check socket for dirt corrosion or defect Check wires to next light for break Repair or replace any damaged part 3 a Pull outer lighting switch out of dash panel Make sure wires do not touch switch housing b Get voltmeter Connect red meter lead to terminal L brown wire of switch Connect black lead to ground c If meter reads voltage repair brown wire from switch...

Page 299: ...ht and right license plate light are out repair yellow red wire from side marker to parking light CONNECTOR C14 If right front parking and side marker lights are out check connector C4 BLACK LEAD for tightness NOTE Connector C4 is a 3 pin connector It is in the left headlight motor compartment TO GROUND If connector is good get ohmmeter Connect red meter lead to black wires in connector Connect bl...

Page 300: ... is lit and other lights are out check connector C2 for tightness NOTE Connector CZ is a 3 pin connector It is in left headlight motor BLACK compartment LEAD If connector is good get ohmmeter Connect red meter lead to black wires in connector Connect black lead to ground BLACK WIRE If meter reads 3 ohms or less repair yellow black wire from connector CZ to connector C6 If meter reads more than 3 o...

Page 301: ... a red 8 pin connector It is behind center console f Connect red meter lead to red wire in connector Connect black lead to BLACK LEAD ground 9 If meter reads voltage repair red wire from connector 014 to left brake light h If meter does not read voltage check connector C14 for defects If con RED LEAD nector is good repair red wire from connector to brake light switch T0 GR OIJND 2 a Remove 4 screw...

Page 302: ...t black lead to ground NOTE Connector C14 is a red 8 pin connector It is behind center console If meter reads voltage 90 to step d If meter does not read voltage repair light blue white wire from connector C14 to fuse box Locate connector for back up light switch Get jumper NOTE Connector for back up light switch is located on left forward side of transmission It is a 2 pin connector Connect jumpe...

Page 303: ...t red meter lead to terminal H red wire of hazard switch Connect black lead to ground BLACK LEAD c If meter reads voltage go to step e d If meter does not read voltage check cigar lighter for operation If lighter e Connect red meter lead to terminal V red wire of switch Connect black lead to ground f If meter does not read voltage replace hazard switch g If meter reads voltage go to hazard warning...

Page 304: ... directional switch for one side and then the other b If none of the directional lights are working 90 to step 2 c If only one side is not working 90 to step 4 d If only one light is not working go to step 5 2 3 Check brake lights If brake lights do not work go to BRAKE LIGHTS BLACK troubleshooting l b If lights work pull hazard switch out Get voltmeter c Connect red meter lead to terminal I 2 ora...

Page 305: ... connect CS Connect black lead to ground NOTE Connect 05 is an 8 pin connector If meter reads voltage check violet wire and connector from directional switch If connector and wires are good replace switch If meter does not read voltage repair violet wire from connector to flasher If one side is not working turn hazard switch on If lights are working check connector 05 and wires from directional sw...

Page 306: ...ll lens c If not working turn on parking lights If parking lights do not work ground wire or ground connection is bad Troubleshoot PARKING LlGHTS d If parking lights work remove bulb Get voltmeter Hold red meter lead to BULB SOCKET center contact Hold black lead to ground e If meter reads voltage replace socket f If meter does not read voltage repair wire from socket to connector RED LEAD BLACK LE...

Page 307: ... O J a g I E 5 5 g I j 3 2 03 as E R 2 5 g 5 j 5 I 5 EnI 3 WHITE i D D 3 LIGHT BLUE WHITE E L iﬁEAMS LIGHTBLUE __ LIGHT BLUE B LACK LIGHTB 3 OJ CIGAR LUE z z 8 LIGHTER C9 ICI4 R 5 E g m f f j S O i x E o E B E 3 um I I I U 3 _ I E 3 33 3 HAZ R co 1 __I I 1 H V A D e _ S m comm 6 WARNING g I 5 DIRECTION 5 I E 5 3 SWITCH El 3 _l INDICATOR 2 9 2 2 9 E SWITCH G T c5 3 J 4 I I H BLUE INSTRUMENT PANEL 9...

Page 308: ...LACK J BLAICK l BLACK BLACK YELLOW RED YELLOW BLACK _ _ I I I BROWN i I I FUSES I I H 06 I I Y V YELLOW BLACK YELLOW BLACK I BLACK 2 0 cos 3 I O O In 0 O I ILL NA I I I I x I m BRIEFING O 0 S 85 S SWITCH E g a I E 9 E I j I j I w w w I IGNITION SWITCH A C14 UMENT PANEL SIDE SIDE MARKER YELLOW RED_ MARKER YELLOW RED PARKING C LIGHT BLAcK _L INDICATOR ITC E1 VIOLET BLACK 3 9 I hYELLOW BLACK YELLOW B...

Page 309: ...ng Inoperative Oil Pressure Gage Inoperative Low Oil Pressure Warning Inoperative Tachometer Inoperative OIL PRESSURE_WATER TEMPERATURE SENDING UNIT SENDING UNIT ___ I Q I FUEL GAGE SENDING UNIT LOW OIL PRESSURE LOW FUEL FUEL GAGE ND CATOR 11 j TACHOlI IETER I I WATER OIL PRESSURE u INDICATOR GAGE DJ Page 317 PAG E 318 320 321 322 324 325 ...

Page 310: ...ROUBLESHOOTING Page 318 INSTRUMENTS INSTRUMENTS IF NOT OK IF OK CHECK POWER TO INSTRUMENT IF NOT OK IF OK REPAIR WIRE TO FUSEBOX CHECK CIRCUIT TO SENDING UNIT IF NOT OK u 0K REPAIR WIRE REPLACE TO SENDING UNIT INSTRUMENT ...

Page 311: ...hot disconnect connector 013 Check gage If gage moves to cold repair green wire from connector C13 to sending unit If gage does not move to cold connect connector 013 Remove 5 screws thru instrument panel Pull panel out Disconnect con nector C6 NOTE Connector CS is an 8 pin connector it gage moves to cold repair green wire from connector C6 to connector C13 If gage does not move check connector an...

Page 312: ... to ground Check gage Gage should read empty with wire disconnected and full with wire touched to ground if gage reads properly replace sending unit If gage does not read properly locate connector C13 Get jumper NOTE Connector 013 is a white 8 pin connector It is behind center console If gage reads full all the time go to step 2 If gage reads empty connect jumper to light blue yellow wire in conne...

Page 313: ... WARNING INOPERATIVE 1 a b C Disconnect 4 hoses from top of fuel tank Remove 4 screws thru cover Remove cover Disconnect red black wire from terminal W of sending unit Touch wire to ground Check indicator Warning light should go out with wire disconnected and come on with wire touched to ground If light works properly replace sending unit If light did not work properly locate connector C14 Get jum...

Page 314: ... black wire from connector C14 to sending unit CONNECTOR C14 c if light did not go out connect connector 014 Remove 5 screws thru RED BLACK instrument panel Pull panel out WIRE d Disconnect connector C6 Check light NOTE Connector CS is an 8 pin connector e if light goes out repair red black wire from connector C6 to connector C14 f If light did not go out check circuit board and bulb holder for de...

Page 315: ... circuit board and gage Replace defective part 2 a Connect jumper between gray black wire in connector C13 and ground b If gage moves towards high pressure repair gray black wire from connector C13 to connector for sending unit c If gage did not move remove 5 Screws thru instrument panel Pull panel out I Connect jumper between gray black wire in connector CB and ground NOTE Connector CB is a 6 pin...

Page 316: ...et jumper NOTE Connector C13 is a white 8 pin connector It is behind center console e If light is out all the time go to step 2 If light is on all the time discon nect connector f If light goes out repair gray yellow wire from connector C13 to sending unit CONNECTOR C13 9 If light stays on remove 5 screws thru instrument panel Pull panel out CONNECTOR C7 h Check connector C7 circuit board and bulb...

Page 317: ...r readings are good go to step e If readings are not good check green black wire to distributor Find connector C13 Connect red meter lead to brown white wire in connector Connect black lead to ground NOTE Connector C13 is a white 8 pin connector It is behind center console Increase and decrease engine speed If meter readings increase and decrease go to step it If readings are not good repair brown...

Page 318: ......

Page 319: ...4 Lu n It I c no 0 o 0 ORANGE 013 SEAT BELT J U U J ALARM RELAY _ _I Lu 3 E 5 a E 3 3 Lu 2 E Z i g E z 31 z a L a 0 L m o o w o I ca c7 I O o O 0 O O O C O l O O O Q _ LI 0 Z RED BLACK g LIGHT BLUE YELLOW c14 WATER TEMPERATURE OIL PRE URE GAUGE RED BLACK FUEL GAGE SENDING UNIT LIGHT BLUE YELLOW I I GAUGE 06 ACHOMETER GAUGE L W OIL PRESSURE LOW FUEL IN ICATOR INDICATOR INSTRUMENT PANEL ...

Page 320: ...owing Horn Will Not Blow Windshield Washer Pump Will Not Work Windshield Wipers Will Not Work Heater Fan Will Not Work FAN SWITCH WINDSHIELD WIPER AND WASHER SWITCH HORN BUTTON SWITCH C 5 2 WASHER 13 PUMP L _ __ _ _ 33 q m MOTOR WINDSHIELD WIPER l MOTOR I I l Page 329 PAG E 331 332 333 333 335 ...

Page 321: ...STEM TROUBLESHOOTING Page 330 ACCESSORIES ACCESSORIES IF NOT OK IF 0K CHECK VOLTAGE REPAIR WIRE AT ACCESSORY IF NOT OK IF NOT OK CHECK GROUND AT ACCESSORY REPLACE SWITCH IF OK IF NOT OK REPLACE ACCESSORY REPAIR WIRE ...

Page 322: ...owing replace horn switch HORNS WILL NOT BLOW 1 3 b If only one horn will not blow go to step 2 Check instrument panel lights If lights will not work repair black wire from connector C10 to ground NOTE Connector C10 is located under steering column cover it is a 6 pin connector If both horns will not blow check fuse L Replace fuse if blown lf fuse is good get voltmeter Connect red meter lead to te...

Page 323: ...ove cover JUMPER k Connect a jumper between gray black wire in connector C5 and black BLACK WIRE wires in connector C10 NOTE Connector C5 is an 8 pin connector Connection C10 is a 6 pin connector I If horns blow check gray black wire from connector C5 and black violet wire from connector C10 to horn button Check horn button Repair or replace parts or wires as necessary m If horns do not blow repai...

Page 324: ...e pump If meter reads more than 5 ohms repair black wire from pump to connec tor C18 for Windshield Wiper motor BLACK l l ILEAD RED Klm 5 LEAD TO GROUND 2 3 Remove 5 screws in steering column cover Remove cover RED LEAD b Connect red meter lead to green black wire in separate connector Connect BLACK LEAD black lead to ground c If meter reads voltage repair green black wire from connector to pump d...

Page 325: ...ter does not read voltage check wires to switch If wires are good replace switch If meter reads voltage repair red wire low speed or gray wire high speed from connector C18 to wiper motor connector 018 Remove 4 screws and bolt holding grill on left side in front of windshield Remove grill NOTE Connector 018 is located under grill it is a 6 pin connector Connect red meter lead to orange wires in co...

Page 326: ...her does not work operate the seat belt system buzzer If buzzer does not work go to SEAT BELT INTER LOCK troubleshooting I If buzzer works repair orange wire from terminal 86 of buzzer relay to connector C10 HEATER FAN WILL NOT WORK 1 a If fan works in one speed but not the other go to step 2 b If fan will not work turn on hazard warning lights If lights will not work go to HAZARD WARNING LIGHTS t...

Page 327: ...to that speed Get voltmeter BLACK RED WIRE Pull switch out Make sure wires do not touch panel LEAD c Connect red meter lead to red wire high speed or light blue black wire low speed at switch Connect black lead to ground d if meter reads voltage go to step e If meter does not read voltage replace switch HIGH SPEED TO GROUND RED LIGHT BLUE LEAD BLACK WlRE ILOW SPEED e If meter reads voltage find co...

Page 328: ...T BLUE WHITE T T GRAY I VIOLET 5 3 q 2 3 C F D I O GREEN BLACI ORANGE BLACK BUZ ORANGE J ZER WHITE BLACK I RELAY LIGHT BLUE WHITE I RED I f 0 CS uRAY CIo K STOPLIGHT ORANGE KO ﬂy GREEN BLACK SWITCH YELLOW BLACK V OLE BLACK BLACK x 1 WHITE ORANGE RED VEHICULAR HAZARD RAY cs E3 Clo Wr G WARNING SWITCH m 1 w w v t ORANGE WIRER WASHER 4 E SWITCIII o _I o I a E I g 0 g j O J O m AL HEATER r r 0 0 FAN P...

Page 329: ...e Turned On Fuse D Blows When High Beams Are Turned On Fuse E Blows When Headlights Are Turned On Fuse F Blows When Headlights Are Turned On Fuse G Blows Repeatedly Fuse H Blows Repeatedly Fuse l Blows Repeatedly Fuse L Blows Repeatedly Fuse M Blows Repeatedly Fuse N Blows Repeatedly Page 339 PAGE 341 348 349 350 350 350 351 353 354 355 356 356 ...

Page 330: ...t side marker light Rear right tail light Front left side marker light License plate light one bulb only Front right parking light Front right side marker light Rear left tail light Cigar lighter Vehicular hazard warning signal and indicator Engine fan motor Horn and relay Retractable headlights control relay on closing Retractable headlights control relay on opening Fuel gage and indicator Engine...

Page 331: ...ter lead to wires Connect black lead to ground if meter reads 9 ohms or more go to step 3 If meter reads less than 9 ohms go to step 2 With meter connected to wires disconnect connector 016 from seat belt interlock control box NOTE Connector C16 is a red 6 pin connector lf meter reads 9 ohms or more replace control box If meter reads less than 9 ohms remove 4 screws thru steering column cover Remo...

Page 332: ...directional indicator flasher terminal k If meter reads 9 ohms or more replace flasher lf meter reads less than 9 ohms repair orange wire from flasher to switch an FEASI IE l Full fan switch out of panel Disconnect orange wire from fan switch FAN m If meter reads 9 ohms or more replace switch SWITCH ORANGE WIRE n if meter reads less than 9 ohms disconnect connector C18 for windshield CONNECTOR C18...

Page 333: ... Disconnect orange wires from terminal 86 of buzzer relay If meter reads infinity 0 replace relay u If meter does not read infinity wiring is defective NOTE One orange wire goes to brake light switch hazard switch and fan switch The other wire goes to buzzer relay connector C10 C18 C7 and 016 ORANGE WIRE 3 3 Connect orange wires to fuse box Disconnect light b ue white wire from wag EVLI RE fuse bo...

Page 334: ...short to ground If rneter reads less than 3 ohms on either wire and the wires look good replace motor Remove grill on left side in front of windshield Disconnect connecter C18 for windshield wiper motor Connect red meter lead to red wire in connector Connect black lead to ground If meter reads infinity go to step d lf meter does not read infinity go to step f Connect red meter lead to gray wire in...

Page 335: ... switch If meter reads less than 3 oh ms disconnect connector C14 NOTE Connector 014 is an 8 pin connector It is behind the center console lf meter reads less than 3 ohms repair red wire from connector C14 to brake switch If meter reads 3 ohms or more connect connector C14 Remove 4 nuts and washers holding left tail light assembly in car Discon nect red wires from assembly If meter reads 3 ohms or...

Page 336: ... Connector 05 is an 8 pin connector If meter reads more than 1 ohm go to step 10 If meter reads 1 ohm or less disconnect connector C15 NOTE Connector C15 is a 2 pin connector It is behind the center console lf meter reads more than 2 ohms go to step 9 If meter reads 2 ohms or less go to step i Connect connector 015 Disconnect light blue black wire from left rear directional indicator If meter read...

Page 337: ...onnector C15 to light If meter reads more than 2 ohms replace light if meter reads 2 ohms or less disconnect connector C4 If meter reads infinity check light blue wire from connector C4 to light NOTE Connector C4 is a 3 pin connector It is in compartment for right headlight motor lf meter does not read infinity disconnect light blue wire from hazard flasher lf meter reads infinity replace flasher ...

Page 338: ...tor lf meter does not read infinity repair red wire from fuse box to connector C11 and to connector C16 Disconnect light blue wire from fuse box Connect red meter lead to light blue wire Connect black lead to ground Disconnect light blue wire from terminal 87 of relay left headlight If meter reads more than 20 ohms replace relay if meter reads less than 20 ohms disconnect light blue wire from term...

Page 339: ...c Remove 5 screws thru instrument panel Pull panel out Disconnect Con nector C6 from instrument panel d If meter reads infinity check connector and circuit board for a short to ground e If meter does not read infinity repair green black wire from fuse box to connector CS INSTRUMENT PANEL 2 3 Disconnect large green black wire from fuse box Connect red meter lead GREENIBLACK to wire Connect black le...

Page 340: ...NED ON 1 3 Disconnect plug from left headlight Check plug for short b If plug is good check fuse box for short at gray black wire c If fuse box is good repair gray black wire from fuse box to plug FUSE F BLOWS WHEN HEADLIGHTS ARE TURNED ON 1 3 Disconnect plug from right headlight Check plug for short b If plug is good check fuse box for short at gray wire c if fuse box is good repair gray wire fro...

Page 341: ... lf meter reads less than 4 ohms go to step 3 NOTE Connector C14 is a red 8 pin connector It is behind center con sole If meter reads 4 ohms or more connect 014 Disconnect connector for left license plate light If meter reads less than 4 ohms go to step e If meter reads 4 ohms or more replace license plate light Remove right rear tail light assembly Disconnect yellow black wires If meter reads 4 o...

Page 342: ... socket c Remove left front parking light Check yellow black wire from connector YELLOW BLACK CZ to light assembly ﬂ w RE d If wire is good replace assembly e If meter reads less than 4 ohms remove 5 screws thru instrument panel CONNECTOR C 6 Pull panel out f Disconnect connector CB If meter reads infinity check connector and circuit board for defects 9 If meter does not read infinity wireing is d...

Page 343: ...t side marker light f If meter reads infinity replace side marker light socket If meter does not read infinity repair yellow red wire from fuse box to connector 014 C4 and front right side marker light 2 a Connect connector C14 Disconnect yellow red wires from left rear side marker light If meter reads 1 ohm or more replace light socket b If meter reads less than 1 ohm remove left tail light assem...

Page 344: ...ect red wire from terminal V of hazard switch Connect red meter lead to wire Connect black lead to ground R ED c If meter reads 10 ohms or more replace hazard switch LEAD TO HAZARD GROUND SWITCH If meter reads less than 10 ohms disconnect red wire from hazard flasher e If meter reads infinity go to step f If meter does not read infinity repair red wire from switch to flasher f Connect red wire to ...

Page 345: ... blue wires Connect black lead to ground b If meter reads 3 ohms or more replace relay If meter reads less than 3 ohms disconnect connector C21 NOTE Connector C21 is a 2 pin connector It is above the fan motor c If meter reads infinity check wire to fan motor lf wire is good replace motor I If meter does not read infinity repair light blue wire to connector C21 3 a Disconnect light blue wires from...

Page 346: ...nect gray yellow wire from fuse N Connect red meter lead to wire Connect black lead to ground b Disconnect connector C19 If meter reads infinity go to step 2 NOTE Connector C19 is a 4 pin connector It is in compartment for left headlight motor c If meter does not read infinity disconnect connector C20 lf meter reads infinity go to step 2 If meter does not read infinity repair gray Yellow wire from...

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