Lancia Beta montecarlo Shop Manual Download Page 224

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SEC 10

Air System

Air compressors - Tanks - Valves - Pipes - Units

(Not Fitted to This Vehicle)

Summary of Contents for Beta montecarlo

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Page 4: ...ter details the operations at the bench for overhauling subassemblies that may be remo ved directly from the car Chapter 2 or from the full assembly at the work bench during general overhaul operation...

Page 5: ...out on the car Reading through Chapter 2 operations in the Section 07 index we find 0720200 R R front suspension pageO72 1 GENERAL RECOMMENDATIONS Before carrying out any operation make sure that all...

Page 6: ...ly visible on bearings that can be disassembled on others marks will be visible by examining races between balls against the light b scoring of balls caused by foreign matter abrasion in the presence...

Page 7: ...IV BETA MONTECARLO SHOP MANUAL FOREWORD IDENTI FICATION OF CAR Fig 1 Position of chassis serial number Fig 3 Beta Montecarlo TYPES f...

Page 8: ...56 mm Rear track laden r 2300 mm Wheelbase laden 1040 kg Kerb weight 1230 kg Weight fully laden 800 kg Towable weight PERFORMANCE Speeds in the various gears at 6000 rpm Final drive ratio Third 1 522...

Page 9: ...celeration with minimum load and changing gear as required Sec standing 400 m 16 standing 1000 m 30 2 0 100 k p h 9 3 Specifications and ata Engine 134 AS OOO Number of cylinders 4 84 Cylinder bore mm...

Page 10: ...22 Boot release control 23 Direction indicators switch 24 Side lights switch Fig 5 Instrument cluster 1 Speedometer with trip and total distance recorders 2 Hazard signalling system warning light if...

Page 11: ...TECARLO SHOP MANUAL FOREWORD var SCORPION Position of chassis serial number Position of car data plate Beta SCORPION TYPES Identification numbers DESCRIPTION Drive Car Drive 137 AS 6 134 AS O31 6 Beta...

Page 12: ...HTS Overall length 156 10 in Overall width 66 77 in Overall height unladen 46 85 in Front track laden in 55 59 Rear track laden 57 32 In Wheelbase laden 99 55 in Ibs 2 400 r Kerb weight without option...

Page 13: ...SCORPION Specifications and data Engine 134 031 6 Number of cylinders 4 Cylinder bore 3 31 Total capacity cu in 107 13 Compression ratio 8 0 to 1 Max power output SAE net HP 81 Max torque SAE net Ibs...

Page 14: ...Brake pedal 24 Clutch pedal 25 Fuse box 26 Boot release control 27 Main and low beams control Instruments and controls y 1 Trip distance recorder zero reset 2 Speedometer with trip and total di stance...

Page 15: ...contacts rotor cable terminals and replacing the spark plug cable terminal guards Checking or timing the ignition Do for Scorpion cars Strobe lamp ignition timing check Removing and refitting the igni...

Page 16: ...G R system alarm Removing and refitting accessory gearbox Removal and refitting of the electronic speedometer Fuel System 0120900 01 2 5 0121100 01 2 5 01 2 3 01 2 6 01 2 6 01 2 6 01 2 7 Variant Scorp...

Page 17: ...ng the valve tappet clearance Checking and setting the valve gear timing including checking the ignition timing Renewing the timing belt including valve gear timing and checking the ignition timing Re...

Page 18: ...t gears ancillary units drive shaft gear and coolant pump from the engine at the bench Removing and refitting the oil sump oil pump connecting rods pistons from the engine at the bench including relat...

Page 19: ...0 0143300 0143400 Removing and refitting the camshaft housings from the cylinder head on the bench Disassembling and reassembling the cylinder head including checking the cylinder head surface for fla...

Page 20: ...C Q Q C 0 CI U o C t W O o E ea Q o o c o I Q c c 0 I 0 Q C O 0 o 0 0 N 0 o t tO 0 N o t o t o t c o u Q c c o u Q o o O u Q c 0 o E QJ O ca 0 E QJ QJ C ca c ca QJ 5 ca O E QJ 0 c u c o 2 g Q o 2 c o...

Page 21: ...Q 1J CII Q J U Q c 8 Q c u Q c CII U 8 J CII Q Q c r CI c Q Q c Q CII U o o N O N n c c 0 J o O 0 C J a c J c O t t Q co c o 0 t a o co 5 c t 0 co c 0 c Q 0 c a c Q 0 Q c 0 co t Q co u 1 1 O o 0 t O...

Page 22: ...c CQ c a 0 5 0 0 E 0 Q LL E ca O t O ca QJ c t J QJ O C QJt t cOca QJ c QJ c E JC QJ c O QJ QJ QJt ca t o JcaoQJ c J t o cao E L J u O 0 E 3 0 Q 3 0 QJ 0 c 0 QJ o E QJ 1 o 0 00 N 0 Q tJ t 0 I 0 I 0 0...

Page 23: ...E C t 0 s o o O N 0 u Q Q u Ec co L c E Q Q co 0 c V C 0 Q I C co c co C ICV C CO COo CQ C O O C C OQ I CQ Q I U v 0 V OQ C OC C t C Q I 0 U U 0 CO C co 0 C 0 0 00 u m c s o o c c 21 21 Q E Q C C c c...

Page 24: ...c E I O c Q c Q c co Q E c c Q CI c Q I O Q 0 I O O c Q c I C O C Q C c c 19 o 0 Q J 1 0 e 0 0 Q o E Q C Q 0 0 o u Q 0 0 c o B J c co c o Q li o 0 N c O 0 u Q c 61 c w cg J Q o c QJ oS 0 QJ 0 QJ c O 1...

Page 25: ...I U U 0 c 10 tJ 0 10 0 0 tJ tJ 10 J C t t ta Q C Q 0 r t ta Q r Q 0 2 o c ta ta CJ Q Q CJ CJ CJ 0 co Q Q Q JQ CO J c CO Q t C Q Q c 0 Q c c CO Q c Cot Q a c 0 J 3 J Q Q c u CO u 0 O 0 u E 0 t 61 t III...

Page 26: ...c Q Q c Q J ca c c C c u ca Q ca Q c 2 Q u u c c Q 0 Q c Q C c Q c Q O u u QI c c g u c g C P c O u g Q Q Q c u C x c w 0 Q t c t Q t 0 Q Q tJ 0 t 3 E O O o c u Q Q u o Q E CQ o a t o o 00 00 N 0 o o...

Page 27: ...Q co 0 co C C c 2 c g J co c 0 I co o E co c I C cQ 0 J Q co c c c 8 a o o o o N M N V to O Q Q 0 0 E J 0 0 c 0 c 2 Q Q u Q u c 0 Q I u c c Q c m u m 0 Q C Q c m c Q m O u E t Q Q a o 0 0 t 0 e c 00 c...

Page 28: ...tJ Q tJtJQ Q O Q a 0 o c tJ tJ 0 0 0 0 0 c 0 o E 0 oc o o 0 ID N O dl c 0 0 r 0 0 0 c 61 c U1 c cn 0 E QJ c 0 c 0 0 QJ 0 0 cn QJ 1 J 0 c u o E 0 c 0 u 0 0 u O w o 0 M 0 U N 0 3 0 c 0 0 0 5 ca 0 o 2 w...

Page 29: ...c 0 a 0 0 Q C c 0 Q 0 E Q a o 0 1 v N 0 0 0 0 0 o u 0 CQ 5 c CQ 8 u cv Q 01 Q CV cV Q ro CV Q U Q 0 CI c 10 Q r Q 0 Q c 0 c LlJ a aj t t c c ro ro ro ro Q Q u u Q Q iO i5 t w Q t C u q o 0 0 0 LC to...

Page 30: ...t c ca ca 0 ca c t 0 t ca c C 0 ca E t o Q 0 Q o caO 0 0 ca ca t t C Q ca c t c ca cao E Q 0 0 O Q Q 3 to E o I ii CI C QJCtO C c 51 c E W L o 0 N O N 5 O C Q Q CI C C C QC Q a CO Q C 3 Q O A C J Q a...

Page 31: ...C Q Q tJ J J c CO 0 l c CII c o 9 c E C1 c c E CII c U O CII 0 l c CII C 2 c U o 0 N N N 0 ciI t O 0 0 0 0 E 0 t CJ 0 O LL Q 0 Q 0 E ca c ca O Q Q Q C c Q ca J Q 0 E Q Q c a o o 0 I I N N N o t 0 0 0...

Page 32: ...Q3 oc c 0 o c 0 0 CI 0 C E 0 C 0 C 0 0 U C on C co Q r Q C c u Q C J a C Q C c 0 co Q Q u O co E ii Q Q a a o 0 0 0 r r M N v O O CI C E in O to Q Q Q C 0 O E Q CO J U c Q Q to C CQ Q ClQ Q Q c 0 O to...

Page 33: ...J co co Q Q Q Q CO tt Ir O M 00 N 0 c Q o c 01 0 C E Q J C Q C 0 Q t C J 0 0 E o co Q Q C u 0 0 Q 0 Q co u c Q co c u o E 0 0 cn 0 0 0 1 cn t 0 u 0 QJ 0 CQ QJ CQ c t CQ QJ CQ 5 QJ o o r 00 N 0 E Q a...

Page 34: ...c Q 0 ca u Q Q E c J o 0 r 8 o 0 0 0 0 0 N r 0 M N q q 0 n n 0 QJ c J J c c QJ c ca O J ca QJ 0 QJ J c C QJ c ca ca J J c QJ J caca O J c E QJ g a I O 00 E 00 o 0 Q 0 tJ tJ 0 Q Q Q tJ x Q w c c O ca...

Page 35: ...0 E 0 0 Z ci E J 00 c 0 O o QJ 0 c 0 QJ o E QJ o 0 00 N O 0 c 81 c 0 0 0 0 x 0 w c CQ Q CI J Q W CQ CQ W U Q CQ Q u c CQ Q i3 Q 0 0 CQ J 0 o 0 0 0 N n Q c u Q Q c Q 0 c tJ Q C C c Q co co Q 0 Q 0 Q tJ...

Page 36: ...0 c Q 10 5 iO Q E u C j o c Q O tJ c x o w tl 0 c c 0 s U C1 C Q 9 C U tI U a C U U c E 0 0 U Q c u u Q Q C1 a c C JQ Q Q c SI c Q Q Q Q t x o w c o o 00 00 N O O CI C C 9 C CI C C O 0 U 0 0 C C O C C...

Page 37: ...Q c c c Q J Q Q ua oCEa 0 I 0 1 0 QJ 0 0 O J 0 0 QJ ro C c J C QJ J QJ ro a 0 E J 0 o 0 0 0 0 0 0 r L L L N N N n n n c E c 0 ci QJ E QJ c QJ c 0 c o 0 QJ u o c QJ E c QJ a n c 0 O o u c 5 0 QJ cu QJ...

Page 38: ...I Cl u Q c Q J lL 5 o 0 0 c 0 Q 0 I tJ Q c c 0 tJ 0 c c 6 o 0 0 0 e J 0 Q c co O 1 0 Q 1 c 1 C1 CO t tJ 0 t 1 a 1 Q Q c E Q CO r u tJ o 0 I I N N N I 0 0 0 C t 0 0 t a t ca w I Q c E co c CJ co O Qj Q...

Page 39: ...THE SPARK PLUG TERMINAL GUARDS Fig 01 211 Positioning the stand Fit the covers 88083051 and proceed as follows Disconnect the cables from the spark plugs and from the distributor cap Remove the bolts...

Page 40: ...the car over the pit fit the covers 88083051 and proceed as follows the marks in line the lamp does not come on set the ignition distributor as follows Removing Slacken the ignition distributor retain...

Page 41: ...rom the spark plugs and the high voltage cable from the distributor cap Remove the bolts and lift off the ignition distributor cap complete with the cables Disconnect the ignition distributor low volt...

Page 42: ...overs 88083051 and proceed as follows Removing Operating inside the engine compartment remove the spare wheel Drain the fuel tank by means of the fuel pump or a suitable substitute Fig 01 217 Fuel gau...

Page 43: ...ir intake Remove the cleaner casing mounting bolts and lift off the casing 0121700 CLEANING OR REPLACING THE AIR CLEA NER ELEMENT Fit the covers 88083051 and then proceed as follows Refitting Inspect...

Page 44: ...ort bracket Refitting Refit in the reverse order to the removal 0122200 3 CLEANING THE CARBURETTOR FLOAT CHAMBER BLO NG THE JETS AND SET TING THE SLOW RUNNING MECHANISM Fit the covers 88083051 and the...

Page 45: ...ox and set it on one side Remove the bolts 3 and lift off the carbu rettor cover 4 1 Refit by reversing the removal operations 1 To check fuel level see 1641150 Fig 01 2112 Carburettor air intake 01 2...

Page 46: ...ork 5 then turn the coil housing in anti clockwise direction until the marks 6 are in line Complete the refitting of the remaining parts reversing the removal operations When refitting has been comple...

Page 47: ...moving Remove the spare wheel from the engine compartment also remove the heat shield SCORPION only Remove the bolts securing the choke control box to the carburet tor cover then remove the box Slacke...

Page 48: ...securing the exhaust piping to the exhaust manifold then remove the bolts 10 and take out the complete as sembly Drive the car over the pit and then proceed as follows At the bench Remove the nuts 1...

Page 49: ...RADIATOR Drive the car over the pit fit the covers 88083051 drain off the coolant as described at 01 2 4650 and proceed as follows Removing Operating from the pit remove mounting bolts and nuts and ta...

Page 50: ...ne compartment loosen the bolts securing the sheave to the pump loosen the alternator drive belt completely remove the securing bolts and remove the sheave Remove the clamping nuts and detach the cool...

Page 51: ...CHECKING THE THERMOSWITCH SOlE NoID SWITCH AND MOTOR DRIVEN FAN Fig 01 2127 Blender thermostat Refitting Refit the reverse order to the removal Top up the coolant level and then deaerate as described...

Page 52: ...ut tem perature Refitting Refit in reverse order to the removal opera tion taking care to fit a new thermoswitch washer Top up the coolant level and deaerate the cir cuit 0125110 CHECKING WORKING COND...

Page 53: ...e the test temperature gauge and refit the transmitter Reconnect disconnected wires Top up the coolant level and deaerate the circuit 1 Should the motor driven fan fail to cut in and cut out at the re...

Page 54: ...coolant has gone up to about 85 90 C and the temperature of the oil to 85 C then check that pressure gauge 88095453 is showing the correct pressure 88091134 88091135 Torque spanners 0126000 Working b...

Page 55: ...and take off the ignition distributor Turn the crankshaft to the point where the camshaft lobe that controls the tappet being controlled is turned upwards and perpendicu lar to the shim then locate o...

Page 56: ...it 88013040 To measure the thickness of the shim to be employed proceed as follows Add the thickness of the removed shim to the measured valve clearance then subtract the clearance specified for the v...

Page 57: ...wheel from the engine compartment also remove the heat shield SCORPION only Fig 01 2 35 View of engine from above Remove the screws 3 and the pipe union 4 Turn the crankshaft in working direction cloc...

Page 58: ...eference rnarkjng refit the fixture 88013042 and then refit the timing belt Lo Senthe nut 2 so as to tighten the belt again then tighten the bolt 1 and the nut 2 remove the fixture 88013042 and turn t...

Page 59: ...with the markings 2 Loosen timing belt stretcher as described at 0126800 Remove the timing belt Fit the timing checking fixture 88013042 and time the valve gear then refit the timing belt as described...

Page 60: ...the housing seal Remove the bolts 1 and 2 and take off the spring Check the spring for load proceeding as described at 01 30520 Remove the nut 3 and the support complete with stretcher ring If the st...

Page 61: ...t 88097827 and set it on the stand 88097120 as shown in the figure then remove the loosened wheel Fig 01 2142 Retainer 88013151 for locking camshaft drive gears Fig 01 2 44 Positioning of retainer 880...

Page 62: ...er 88013347 and refit the flywheel guard Refit the arm and bar without tightening bolts 1 and 2 and bolts 3 fit the wheel and lower the car then tighten the bolts 1 and 2 and the bolts 3 at the specif...

Page 63: ...t temperature gauge transmitter and from the thermoswitch and the slow running cut off cable and lay them aside Remove the fluid to heater inlet coupling remove the bolts 1 and take off the box 2 sett...

Page 64: ...es from the carburet tor Carefully clean the engine block mating surface Apply the gasket to the cylinder head Fit the cylinder head and secure it tightening the bolts in the order and at the torque s...

Page 65: ...move the spark plugs and disconnect the high voltage lead from the ignition coil Starting from cylinder No 1 fit the pressure gauge recorder 88015453 to the spark plug port Operate the starter motor t...

Page 66: ...removal SPECIAL TOOLS REQUIRED 88032052 Fixture for removing mounting buffer 18809827 Jack bracket 01 28300 REPLACING THE CRANKSHAFT FRONT OIL SEAL Drive the car over the pit fit the covers 88083651 d...

Page 67: ...iming belt guard cover Remove the bolts 1 and 2 securing the stabilizer bar to the arm remove the bolts 3 and take off the arm 4 Fig 01 2157 Engine from above Remove the bolts 3 followed by the pipe u...

Page 68: ...on the cover using the appropriate tool Refitting Carefully clean the cover mating surface and the oil seal seat then fit the new gasket and refit the cover SPECIAL TOOLS REQUIRED 88097120 Stand 88013...

Page 69: ...01 2 7500 Refit the timing belt and time the valve gear as described at 01 26800 Refit the remaining parts in the reverse order f SPECIAL TOOLS REQUIRED 88013151 Ancillary units drive locking tool 880...

Page 70: ...one at the press Fig 01 2165 Positioning flywheel locking tool 88013347 Reassembling Refit the rear oil seal cover to the engine block after fitting a new gasket Complete the operation by refitting t...

Page 71: ...ach the connection 1 detach the high and low voltage cables 2 and 3 from the coil then remove the securing nuts and take off the coil Remove the slow running cut off cable 4 and remove the cables 5 an...

Page 72: ...bove the car secure the engine to lifting hook 88017362 and cable 88097251 set as shown in fig 01 2 and take up the slack Slacken the clamps 1 2 3 4 5 and 8 remove the mounti ng bolts and remove the c...

Page 73: ...ngine on the bed Fig 01 2n2 Engine mounting Remove the bolts 1 and nuts 2 and then take off the mounting 3 Above the car Fit cradle 88027068A to the gearbox and then insert the trolley jack so that th...

Page 74: ...S REQUIRED 88017363 Engine gearbox unit lifting arms 88017362 Engine lifting hook 88097251 Cable 88027058 Gearbox support 88017364 Bed for detached engine gearbox unit 88013347 Crankshaft locking fixt...

Page 75: ...ting Remove the engine from bed 88017364 carefully wash the outside and dry with air pressure then remove the covers When the wash is completed or after repair jobs have been carried out refit the ign...

Page 76: ...450 Stand 88017364 Bed 0130250 REMOVING AND REFITTING THE TIMING BELT TIMING THE VALVE GEAR AND CHECKING THE VALVE TAPPET CLEARANCE WITH ENGINE AT THE BENCH Fig 01 313 Engine from the top Carry out th...

Page 77: ...s 88013344 Finish off by performing the operations described at 01 301 00 and 01 3001 0 TOOLS REQUIRED 88013344 Handles 88013042 Timing gear retaining fixture 88095770 Feeler gauge Make sure that the...

Page 78: ...by carrying out the operations described at 01 30250 01 301 00 and 01 3001 0 Refitting Carefully clean the engine block top surface TOOLS REQUIRED 88015038 Gauge 88095770 Feeler gauge 88013042 Timing...

Page 79: ...88095122 Fig 01 3 9 locking tappets with shim extraction tool 88013036 Measure the thickness of the shim with the dial gauge and the surface plate supplied with the trolley 88013055 and kit 88013040...

Page 80: ...s TOOLS REQUIRED 88013036 Tappet retaining tool 88013038 Pliers 88013055 Shim trolley 0130520 Fig 01 3112 Fitting the Aywheel Locking Tool 88013147 REMOVING AND REFITTING THE TIMING BELT STRETCHER SPR...

Page 81: ...on the tool surface Should the pointer tip overshoot the tool reference mark when the snap Iock is applied the belt stretcher spring must be scrapped Remove the bolts 1 and the sheave 2 then take off...

Page 82: ...efit the coolant pump fitting a new gasket then tighten bolts 12 and refit the sheave 11 Apply camshaft drive gear retaining fixture 88013042 and clamp it to the cylinder head Complete by carrying out...

Page 83: ...he shells and subsequent checks show that the pins are acceptable simply replace the shells Fig 01 3118 Measuring the crankpins Using a centesimal dial gauge 88095467 or 88095466 check that the crankp...

Page 84: ...e gudgeon pin circlips and then remove the g dgeon pins and lift off the conrods by means of tool 88012209 Check that the gudgeon pin surfaces are perfectly smooth and show no signs of scoring or seiz...

Page 85: ...rings Grip the con rod assy in a lead jawed vice rest the installer 88012211 against the piston and screw in the threaEied pin until the circlip has been fitted in its seat Refitting Set the engine o...

Page 86: ...h bearing shell from the conrod then measure the width of the flattened Plastigage which will either be stuck to the shell or to the crankpin at its widest point To read the thickness use the scale st...

Page 87: ...curing the sheave to the crankshaft and then remove the sheave i1 Fig 01 3131 Removing ancillary units drive shaft from engine block Remove nut 1 bracket 2 and cover 3 Unscrew bolts 4 and remove the o...

Page 88: ...nto contact with it is not scored In the presence of light scoring simply dress the surface with emery cloth 240 grit size Otherwise reface the flywheel see 01 32400 Use a micrometer to check that the...

Page 89: ...to the pump fitting Then tighten the cap mounting bolts to the specified torque loading During this operation take care not to turn the crankshaft so damaging the Plastigage and making clearance measu...

Page 90: ...ave 8 and tighten the bolts 9 Refit the sheave to the crankshaft and tighten the mounting nut to the specified torque loading then remove tool 88013347 and fit handles 88013344 on the flywheel Complet...

Page 91: ...ller diameter bearing in its seat and then fit the front bearing making sure that the bearing oilways coincide with those on the crankcase f Fig 01 3138 Removing the Ancillary Units Drive Shaft Front...

Page 92: ...6 drive out the oil pump drive gear bushing and then carefully clean the bushing seat and make sure that the crankcase oilway is not clogged Turn che crankcase 180 on the stand and install the new bus...

Page 93: ...the minimum permissible dimension the flywheel will have to be replaced Prior to refacing the flywheel carry out the following checks Lie the flywheel on a surface plate with the clutch mating surface...

Page 94: ...pin to the spindle To reface the clutch mating surface so that it is perfectly perpendicular to the rotation axis Grip a cylindrical or hexagonal rod of diameter 25 30 mm and length 150 200 mm in the...

Page 95: ...OD ALIGNMENT Proceed as follows Stage 1 checking small end and big end axes for parallelism r Grip the conrod to be checked in a vice provided with lead covered jaws fit the mandrel 88015231 A to the...

Page 96: ...t side according to the dial pointer shift Then repeat the checking operation Stage 2 checking con rod small and big end axes for coplanarity Fit spindle 88015231 B in the small end bushing to the poi...

Page 97: ...ng 0133100 REPLACING CONNECTING ROD SMALL END BUSHING Using tool 88012212 install the new bushing making sure that the lubrication hole registers with that in the conrad small end Using the small conr...

Page 98: ...ice Grip the distributor in a lead jawed vice remove the mounting screws and take off the cap Dress the rotor contact and the outside and inside contacts of the cap with fine abrasive paper Check the...

Page 99: ...e or excessive wear If any of these faults is encountered replace the complete automatic advance assembly Check that the breaker points do not present burn marks or holes if they do replace the set Cl...

Page 100: ...temperature falls the spiral spring contracts and the yoke rotates in the reverse direction thus closing the throttle This movement is countered by screw 1 of fig 01 4 13 which engages with sector 2 f...

Page 101: ...er abruptly so that the throttles settle properly repeat this operation a few times before tightening the screws that hold the throttle to the shaft Use the same procedure for the secondary choke thro...

Page 102: ...icrogauge glass tube at the point where the 0 head jet has been fitted the height reached by the fluid in the microgauge Checking the accelerating pump jet from adapter Disconnect the A end 88015383 a...

Page 103: ...off device Holding the jet vertically the same position as when it is fitted to the carburet tor apply the adapter 8 end so that it adheres perfectly to the jet outlet In these conditions the leak on...

Page 104: ...emove the fixing screws take off the rich mixture control body 4 and replace the gasket 5 Refit the cut off device and rich mixture control in the reverse order to removal then refit the float chamber...

Page 105: ...mpressed air Carefully clean the areas where leaks have been detected and the edges of the tank and cover with a flame and wire brush If necessary straighten out the tank cover and any tube gills that...

Page 106: ...dy is acceptable Removing the bolts 1 and take off the intake assembly 2 remove the bolts 3 and take off the cover 4 Remove the pump body from the vice Excessive clearance could be caused by wear on t...

Page 107: ...tions Reassembling Lubricate the inner parts and reassemble the oil pump in the reverse order to the removal TOOLS REQUIRED Fig 01 4 18 Measuring the end float between gears and pump body surface 8809...

Page 108: ...ppets off the housings being sure to place them so that they wi II be put back in exactly the same position at refitting Carefully wash all parts removed with paraffin Visually check that tappets and...

Page 109: ...t the valves Fig 01 4 20 Checking the cylinder head for flatness Check the head surface for flatness after smearing the surface plate with engineer s blue Confine the operation to the outer edge of th...

Page 110: ...the mating surface between valves and seats does not vary Insert the 8 00 mm pilot stem forming part of the grinder outfit 88016011 in the valve guide concerned Then fit the wheel 88014533 45 and ref...

Page 111: ...part with wheel 88014112 75 This operation is not necessary on the exhaust valve seats because their internal diameter is at right angles to the top surface the specified width for surface Fs can ther...

Page 112: ...dge of the gauge if there is not use grinder 88016006 to remove the material necessary to obtain the specified clearance Wash down the cylinder head and valves with paraffin TOOL REaulRED Allow the cy...

Page 113: ...inder head off the support Refit the thermistor and excess temperature switch Complete by carrying out the jobs described at 01 42700 Fig 01 4 30 Gauging combustion chamber depth TOOLS REQUIRED 880150...

Page 114: ...uring nuts remove the rear cover 1 and take out the camshaft Using tool 88012315 extract the oil seal from its seating Wash removed components with paraffin and dry with compressed air Carefully check...

Page 115: ...TION STROKE WITH A STROBOSCOPIC LAMP i Fit the covers 8803051 and proceed as follows Remove the spare wheel and heat shield Take off the engine compartment lid as described at 1522700 Connect up equip...

Page 116: ...BUTOR AND TIMING THE IGNITION Fit the covers follows 88083051 and proceed as Fig 01 214 Setting of timing gearsduring the ignition phase With the crankshaft in this position the holes 1 in the gears s...

Page 117: ...TING GAS TANK VENTILATION VALVE Fit the covers 88093051 and proceed as follows Remove the spare wheel and heat shield Fig 01 2 5 Air cleaner Slacken the clamp 1 withdraw the pipe 2 unclip the retainer...

Page 118: ...efit in the reverse order Fit the covers 88083051 and proceed as follows Remove the spare wheel and heat shield 0120720 REMOVING AND REFITTING THE AIR PUMP Fit the covers 88083051 and proceed as follo...

Page 119: ...1134 Torque wrench 0120730 Fig 01 2111 Removing air pump R EMOVING AND REFITTING DIVERTER VALVE THREE WAY VALVE AND THREE WAY ELECTROVALVE Unscrew the nut 1 and the bolt 2 and remove the belt 3 Withdr...

Page 120: ...lexible piping as shown in the figure complete refitting in the reverse order to removal Unfasten the nuts 1 unscrew the couplings 2 by means of wrench 88011461 and then disconnect the hose 3 At the b...

Page 121: ...the bolts 6 and remove the complete valve 7 At the bench remove the bolt 8 and separate the pipe 9 from the valve 7 Replace any worn parts and refit in the reverse order to removal 0120790 REMOVING AN...

Page 122: ...VALVE Fit the covers 88083051 and proceed as follows Unhook the spring 2 withdraw the split pin 3 unfasten the bolts 4 and remove the cylinder 5 Withdraw the electric cables and remove the push button...

Page 123: ...CEMENT OF FAST IDLER DIAPHRAGM BODY Fit the covers 88083051 and proceed as follows r With ref to Fig 01 2 21 Slacken the clamp 1 and remove the pipe Fig 01 2124 Fast idler hand control Press the butto...

Page 124: ...emoval and tighten the bolt 6 to the specified torque loading and put back the ring nut 5 seal 0120880 Fig 01 2 26 Anti pollution data plates REMOVING AND REFITTING ACCESSORY GEARBOX Fit covers 880830...

Page 125: ...accessory gearbox 5 Unscrew the nuts 2 and 3 and the bolt 4 Take off the bracket 5 complete with the solenoi d 6 Refitting Refit in the reverse order to removal 01 2 0890 REMOVAL AND REFITTING OF THE...

Page 126: ...d then take off the tank simultaneously unfastening bolts 8 shown in the previous figure and the lower securing bolt two mechanics are needed for this operation Remove the fuel level gauge transmitter...

Page 127: ...hanism Slacken clamp 1 and slide off the pipe Remove the air intake cover unscrew the nuts 2 slide off the oil vapourbreather pipes and remove the air intake F it gasket 1 so that the reference marks...

Page 128: ...2 36 Setting the slow running mechanism First set the primary choke throttle by means of bolt 1 until the engine runs steadily Then set bolt 2 to obtain a mixture at which tne engine turns fastest an...

Page 129: ...mplete by refitting the remaining parts in the reverse order When the refitting operation is completed adjust the idle running mechanism as described at 01 2 2300 Remove cables 7 and 8 Remove pipes 1...

Page 130: ...pipe assembly Unscrew bolts 1 2 and detach the tail silencer 3 from the intermediate pipe 4 the front pipe 5 and the main silencer 6 Refitting Refit in the reverse order Fig 01 2 41 Removal of exhaust...

Page 131: ...r clamping bracket and withdraw the coolant pump control belt and alternator Fig 01 2144 Removing the exhaust pipe from the manifold Unfasten the pins 1 and remove the exhaust pipe from the manifold W...

Page 132: ...ig 01 2149 Carburet tor air intake Fig 01 2147 Removing air to exhaust manifold pipe with tool Slacken the clamp 1 and withdraw the pipe Remove the air intake cover unscrew the nuts 2 withdraw the oil...

Page 133: ...draw it along with the spacer 3 Remove the bolts securing the cylinder head and remove it for partial overhaul of the head see 01 42700 Refitting Clean the cylinder head mating surface thoroughly and...

Page 134: ...p belt with tool 88013053 and torque wrench 88091134 set at the specified torque loading Refit the remaining parts in the reverse order to remova I Refill with coolant and deaerate as described at 01...

Page 135: ...d Slacken the clamp 1 slide off the pipe 2 unhook the sprtngs 3 and remove the cover 4 Unscrew the bolts and take off the cleaner body Detach the air intake on the carburet tor Fig 01 2155 Removal of...

Page 136: ...Disconnect the cylinder 1 and take off the coil 2 Take off leads 3 4 5 6 and 7 Unscrew nuts 8 9 and bolt 11 Remove pipe 10 Unscrew nuts 12 and bolt 13 Remove the guard 14 Slip off pipes 15 16 Fig 01...

Page 137: ...e used to collect the water and re insert the drain plugs Take off the oil filter support as described at para 01 2 6000 Take off the servo unit vacuum hose Fig 01 2162 Removal of starter motor leads...

Page 138: ...h reference mark 2 Remount the gearbox on the engine and tighten the mounting bolts to the correct torque loading Refit the remaining parts in the reveerse order On completion fill and vent the coolin...

Page 139: ...2 1 022 1 02 2 2 02 2 2 02 2 3 02 2 3 02 2 4 02 20100 Checking and adjusting the clutch pedal travel 022 0700 Removing and refitting the clutch pedal 022 0900 Replacing the clutch release bearing 02 2...

Page 140: ...I 0 01 I 0 J 0 U 0 0 X 0 U II 0 c u u 0 c 0 0 L 9 u 0 c u I u 0 0 s Q c Q c J u O 01 c 0 c ro o E Q OC o o 0 N N O I C c u 0 I 5 c o a u 0 c u j u O ro c rr c u u t 0 0 0 c 0 u 1 c u Q E Q Q 0 0 Q 0...

Page 141: ...0 N 0 c J J u 0 c Q E C J O C 0 c o J J 5 o 0 J c i Q Q 0 0 Q c Q u x Q 0 u Q Q c 0 u b c u J u 1 0 0 0 0 0 u 0 Q u c Q u 0 o 0 0 N N O O c J Q 0 0 Q 01 c 10 U 01 C J Q o 0 u C c 10 0 J cn 10 Q 0 O O...

Page 142: ...lts 5 and remove the master cylinder 6 together with the plate 7 and the push rod 8 Fig 02211 Adjustment of clutch pedal travel If adjustment is necessary loosen the nut 1 and turn nut 2 in the direct...

Page 143: ...withdraw the bearing 1 Remove the gearbox as described at 03 2 2500 and proceed as follows 0221000 REMOVAL AND REFITTING OF CLUTCH not including removal and refitting of gearbox Remove the gearbox as...

Page 144: ...88023030 to centre the disc when remounting the clutch Refit the gearbox as described at para 03 2 2500 TOOL REQUIRED 88023036 Fixture TOOLS REQUIRED 88013347 Fixture to lock flywheel 88023030 Fixtur...

Page 145: ...uld result in letting air Take a glass container and fill it with a small quantity of fluid Place one end of a 30 40 cm flexible hose preferably made of transparent plastic in the liquid in the contai...

Page 146: ...and refitting the gearbox front and rear mounting buffers 032 2200 Removing and refitting the gearbox rear cover and renewing the gasket 0322300 Renewing the diff side gear oil seal 0322500 Removing...

Page 147: ...1 ca 0 1 c o Q ca Q 0 9 I I 0 c Q 0 O I Q 0 E J 0 0 c Q c 0 O S ro c O C1 0 C c oro C 0 A C1 y f c C1 C1C1 U c 0 C1 tJ c c C1 ro O C1 Q tJ tJ Q c c tJ r o roroc OC ro E C1 ro C1 F C1 ro C 0 E t C1 E c...

Page 148: ...I I 0 Q I l O u u 0 o o v o M M O 0 0 c Q Q 0 b J 0 c Q 0 o o o V V 0 c J I E I 0 01l C O I In 0 I 0 t o o L N N M O x 0 0 0 0 0 0 c 0 0 c o E 0 rr 0 c o co c cn 0 c c ro E Q c O co c O CI a o t c u...

Page 149: ...C C 1 C CQ ca Q C J C C ca C C ro C Q ca 0 c E 1 C ca Q c 1 In Q 0 Q Q ro Q 0 ro Q 01 Q 0 V 4 4 0 c 0 S In ro 1 0 1 0 iii E o In ro 1 0 o 0 3 Q 0 Vi X O 0 co Q 0 c 0 co Q 0 Q c Q rr o o M N N M O Q 0...

Page 150: ...he lock nut and unscrew the knob 1 then remove the bolt 3 and take off the trim panel 2 Above the car Remove the bolts holding the gear lever support to the tunnel Remove the spare wheel Disconnect th...

Page 151: ...that the gearbox is in neutral Take off the rear air duct Slacken bolts H of the rear rod 8 and connect gear engagement lever 0 to lever G If this is not possible slacken bolts L adjust the length of...

Page 152: ...worn TOOLS REQUIRED r Refitting Refit the parts in the reverse order using pliers 88539061 for refitting the control and idler levers 88022122 Tool 03 2 1300 REMOVAL AND RENEWAL OF GEARBOX FRONT AND R...

Page 153: ...300 RENEWAL OF DIFFERENTIAL SIDE GEAR OIL SEALS Stand the vehicle over the pit and proceed as follows Unscrew the respective mounting nuts and remove bolts 1 and 2 Take off the bracket 3 with its buff...

Page 154: ...f the left hand seal is carried out in the same way after raising the gearbox on a pillar lift so as to take the strain off the left suspension and facilitate uncrimping of the flange mounting ring nu...

Page 155: ...he figure Remove the starter motor as described at 14 2 6900 Fig 03 2111 Removal of rear arm and torsion bar Remove the left and rjght half shafts from the differential flange Detach the hand brake ca...

Page 156: ...etween gearbox and engine Refitting Refit the gearbox in the reverse order tightening bolts and nuts to their respective torque loadings remember that left rear arm securing bolts should be tightened...

Page 157: ...se lever 3 to engage any other forward gear Use spanner 88021074 to unscrew ring nuts 1 and 2 Watch for the snap release of the rollers 4 Slide off the fork 5 ana the assembly consisting of the hub 6...

Page 158: ...an ner 88021075 to release bushing 13 unscrew bolts 14 and tap the gearbox casing with a mallet until it can be removed as shown below Fig 03 316 Gear selector rods and reverse gear shaft Fig 03 3 7 r...

Page 159: ...e shaft in the position shown in the photo To remove the oil seal from the clutch release sleeve support proceed as follows Fig 03 319 Tool 88022102 for disassembly of selector rod retainers Fig 03311...

Page 160: ...nd renew as necessary Change all snap rings and seals oil seals Orings etc Reassembly Fig 03 3114 Retainer on 3rd and 4th gear selector rod Replace the gear selector shaft in the gearbox casing see fi...

Page 161: ...third rod Tighten bolt 6 to the correct torque loading and disengage 2nd gear to make it easier to insert the gear selector into the locks later Lubricate shaft 1 and remount gear 2 with its teeth le...

Page 162: ...ven shafts at the same time together with the gear 9 and the assembly consisting of the inside bushing gear 6 synchroniser sleeve 7 hub 8 and fork 5 Position the pawls springs and rollers Mount the co...

Page 163: ...sassembly Use lead jaws to hold the driven shaft in a vice Fig 033 22 Clutch release sleeve and bearing r Turn the assembly to bring the gearbox casing upside down Use driver 88022080 to insert the oi...

Page 164: ...ss Overhaul and checks Clean all disassembled parts throughly Sheck the sleeves and hubs for wear particularly the teeth and renew all parts as required Check the coupling of the synchronisers on thei...

Page 165: ...Dr Beta Montecarlo 03 0020 Fig 03 3 28 Replacing front bearing circlip with installer 88022107 Fig 033130 Remounting the release rollers Remount the sleeve 4 with the fork groove downwards Then posit...

Page 166: ...ages are plastic do not heat but insert with tool 88062503 7th modification Reassemble as described in para 03 30100 88022106 Half rings for extraction of driven shaft rear bearing 88092034 Extractor...

Page 167: ...03 3 35 Checking end float between side gear and pinion r Apply tool 88023412 unscrew the ring nut with spanner 88021411 and remove flange 1 Unscrew bolts 2 and remove the cover 3 and shim Remove the...

Page 168: ...he differential on the support smear Blue Stop on the support to cover mating surfaces and then tighten the nuts to the correct torque loading Clean all disassembled parts thoroughly eck the gear teet...

Page 169: ...torque of differential bearings with a torque spanner Turn the assembly remove the handle of tool 88023411 and use torque meter 88095138 together with socket 8802141 1 to mea re the rolling torque of...

Page 170: ...para 0330100 scale of the meter is in cm kg the figure 10 on the instrument corresponds to 0 1 metre per kg If the rolling torque is known and a torque meter is not available the weight to be applied...

Page 171: ...ter f 1 r Unscrew bolt 1 and disconnect the contro 2 Undo the connection 3 unscrew bolt 4 and take off the lead 5 Undo bolt 6 and collect the plate 7 Then unscrew the ring nut 8 and take off the count...

Page 172: ...nd take off the cylinder 6 Disconnect the cylinder 7 and take off the lead 8 Undo bolt 9 and collect the plate 10 Undo bolt 5 see fig 032 4 Slacken the bolts holding the left rear wheel From below the...

Page 173: ...rm detached previously Remove the metal sheet between the gearbox and the engine Refitting Refit the gearbox in the reverse order and tighteen all nuts and bolts to the correct torque loadings remembe...

Page 174: ...1 Troubles probable causes checkings and operations to be carried out CHAPTER 2 page 042 1 042 1 042 2 04 2 0100 Removal and refitting a front wheel drive shaft 04 2 0120 Renewal of a constant veloci...

Page 175: ...U m a z 0 1 w u u w z 1 J u I w I u w J m m O a 0 u o o Q J Q 0 Q c E 8 0 ro C Q C ro c 0 s c ro D J 0 O ro oQ J 0 1Q C roc ro u Q ro orn J D 0 01 c 0 Q 0 c ro ro ro I I 0 E Q 0 a S o o O N 0 c o in E...

Page 176: ...o fig 04 2 2 when replacing A in fact must coincide with A If it coincides with 8 the joint will be locked From below the vehicle Lift the back of the vehicle unscrew bolts 1 and remove the drive shaf...

Page 177: ...le Fig 042 3 Release of bearing to hub nut Lift the back of the vehicle and rest it on trestle 88097120 Unscrew the bolts holding the joint to the flange and move the joint to one side Apply tool 8805...

Page 178: ...SEC 05 Axle Housings Axle housing Step down and differential gears Not Fitted to This Vehicle...

Page 179: ...SEC 06 Axle Beams Front and rear axle shafts and transverse reaction bar Not Fitted to This Vehicle...

Page 180: ...n 07 2 2000 Removing and refitting the rear suspension crossmember 0722200 Renewing the rear stabilizer bar silent blocks 0722300 Removing and refitting the rear stabilizer bar 0722310 Renewing the re...

Page 181: ...c CI tJ c o c c 10 10 O tJ CI c f oc IOc 0 f o c E ro E f CI f f CI f 0 f f f f IOc Ec I0 O CI 10 Q I Q o o q 1 0 a I 8 E aJ a J J D O I CaJaJ u c O C1 O roC ro aJ aJ E c c aJ aJ I D S C aJ ro cC U I...

Page 182: ...Q c c cn 0 J u cn 0 c c co O Q u CHAPTER 1 o o M N r O c 0 0 C C 0 0 C co co O co 0 0 E O 0 co a t o 0 N 0 Q 0 Q o u E s D Q c c Q Q a o 0 N N N 0 Q 0 0 c Q 0 c c Q 0 E o Q 0 o o M N N r o c 0 ro 0 E...

Page 183: ...Q t1J a Do Q CC Q c c C C O D t1J t1J O LL ro 0 Q 0 9 cn c O 0 0 cn o u ro 2 s 0 Q c c Q Q a o o V N r O E L 0 0 Q 3 c Q c Q c J Q Q C o o Q Q Q CJ Q c CJ ro O 0 Q CJ c c 0 ro v Q ro c Q o a tJ J c Q...

Page 184: ...stud bolts of the wheel concerned lift the vehicle from inside the pit with a pillar lift r Fig 07 2 3 Front suspension Fig 07 211 Lifting the car Take off the wheel and unscrew nuts 5 Refitting Reass...

Page 185: ...lete with silent blocks and spacers Fig 07 2 4 Front suspension arm Fig 07 215 Rear view of arm anchorage rod Refitting Reassemble in the reverse order Make sure that the same number of spaces part 10...

Page 186: ...Seee fig 07 2 6 From the pit remove the cooling air duct the brackets 2 and the clamps 4 and take off the stabiliser bar 1 Fig 07217 Front stabiliser bar Fig 07 216 Front suspension with stabiliser ba...

Page 187: ...tabiliser bar Refitting Reassemble in the reverse order With the vehicle at its standing load tighten parts 1 2 3 and 5 to the torque loadings shown Fig 07 218 Rear stabiliser bar 07 2 2400 Refitting...

Page 188: ...ew of attachment of strut to body and the bolts shown as 2 in fig 072 12 Fig 072 12 Arm and rear transverse rod Unscrew bolt 6 from the arm 7 and slide off the rod 8 disassemble the ball joint 4 from...

Page 189: ...arms to the body bracket Remove the pin 5 holding the rod to the arm and then slide off the arm from its attachment to the body and the swivel In this operation the rod remains clamped to the swivel r...

Page 190: ...fully down Stand the vehicle over the pit and proceed as follows Lift the vehicle and rest it on trestles Remove the centre 1 and side 2 clamps holding the stabiliser bar 3 Remove the rubber band 4 U...

Page 191: ...rm of tool 88042132 r TOOLS REQUIRED 88042132 Front arm silent block extractor inserter Fig 07 411 Extractor for forcing out silent block pin 0741000 and using the press remove the silent block from i...

Page 192: ...g 10 thrust plate 11 and bumper 13 88043127 Suspension disassembly and reassembly fixture 88041158 Spanner to hold the cup during unlocking and locking of telescopic strut nut 0741100 DISASSEMBLY AND...

Page 193: ...nut lock spanner 88033425 Guide pin for reassembly of suspension 0741200 DISASSEMBL y AND REASSEMBL Y OF A FRONT OR REAR TELESCOPIC STRUT Proceed as follows Disassembly Clean the strut with water and...

Page 194: ...valve Remove the valve Remove the strut from the vice turn it over and collect the oil it contains then slide the complete stem out from the strut Check the disassembled parts and replace for wear or...

Page 195: ...ER 2 08 2 01 DO Removing and refitting of swivel complete with flange and front wheel hub bearing 08 2 04DO Removing and refitting the rear carrier complete with hub wheel and bearing page 082 1 082 1...

Page 196: ...i E 1 J 1 J c ro c ro c ro 0 ro ro VI 0 c 0 E E VI cr cr o o 0 o v 00 O 0 Q u c ro ro 0 O c Q Q s CI Q c C 0 C C O Q c c 0 Q Q c O 1 CI C U Q Q c Q U t 0 QJ QJ 01 1 U 1 2 ca ro 08 WHEELS Q I t t Q 1...

Page 197: ...J c O ro t C J c a ro 0 0 0 J c E Q c c Q C u a HUBS o o 0 N N r O TYRES CHAPTER Q 0 Q c Q E c o C c f Q o a C 0 Q 0 c a C W C E 0 0 Q CO O Q C E Q a Q CI Q C c JQ CO C Q 0 o CO uroQ 0 p Ca ro 0 0 0 u...

Page 198: ...on trestles and take off the wheel Unscrew the two bolts holding the brake caliper Remove caliper complete with carrier and place it to one side Unscrew the two bolts holding the brake disc and remov...

Page 199: ...bolts holding strut to carrier nut 11 nut 3 bolts holding brake disc bolts holding brake caliper carrier nut holding wheel bearing Use removing tool 88062036 to drive off the pin 4 and the pin holding...

Page 200: ...in a vice and unscrew the nut holding the bearing the washer the guard and the cup sealing the guard use a press to drive off the hub from the swivel Note the bearing and ring nut must always be rene...

Page 201: ...hub 1 Use a press and installer 88062503 to insert the hub on the swivel If the inner race is left on the hub during this operation two grooves at 180 from each other and no more than 2 mm deep must...

Page 202: ...nut with spanner 88051173 and crimp it Use a press and installer 88022080 to insert the hub in the carrier TOOLS REQUIRED 0395 Fig 08418 Detachment of bearing from carrier Use a press and removing to...

Page 203: ...rk the position of the tyre with respect to the rim and remove the wheel from the balancing machine Deflate the tyre and turn it 45 with respect to the rim I nflate the tyre and fit the wheel on the b...

Page 204: ...and proceed as before applying a counterweight of the value indicated on the instrument at the highest point of the inside of the rim as indicated by the luminous arrow 8 Again check the balance of t...

Page 205: ...Removal adjustment and refitting of the brake pedal 09 2 3700 Removal and refitting of a front or rear brake caliper 0924100 Removal and refitting of a brake caliper carrier 09 2 4500 Removal and ref...

Page 206: ...a LL 0 l l 0 c o l 0 O IC c u l l E 0 c E o ro 0 3 c 0 c E l l c a 1O 00 00 00 0 N 0 0 00 E o 1 III Q c 0 la 0 c 0 1 o 0 III III III Q O 0 J 0 0 t Q Q J u c u 0 c Q ro ro C c ro J ro ro c 0 Q a c 0 0...

Page 207: ...0 0 c t 0 0 ro o o 0 q N 0 0 C c Q c Q O C O c Q J C C C C Q c ro u u u u 0 Q CIJ 0 0 Q CIJ Q u CIJ 1 u J c o 0 C c i Cl C c u ro C ro ro O Cl E Cl a o o 0 1 N 0 0 Q 0 c u Q II E c Q u Q c Q c cn C c...

Page 208: ...1 I C E 0 CfI I 01 0 01 0 S 1 Q 0 Q 0 0 aJ c o 0 c o ro aJ V c 0 aJ ro u u aJ aJ aJ 0 Q E o 0 1 Y N 0 0 o o 00 0 v 0 0 c o ro C1I 0 C1I C1 0 C ro U ro U C C1I O ro C U U C 0 O ro O O ro D D U ro roC1l...

Page 209: ...oceed as follows Removal Reassembly From below the vehicle take off the lower engine guard unscrew bolts 1 and 2 remove the anchor piece 4 from the Reassemble in the reverse order and adjust the brake...

Page 210: ...para 09 2 1300 Check that the hand brake telltale comes on after 2 3 clicks of lever travel and goes off when the 1ever is fully released Overhaul of the hand brake linkage is described at para 094 1...

Page 211: ...sed Refitting Refit in the reverse order and tighten parts 5 to the correct torque loading On completion bleed the hudraulic circuits as described at para 09 2 5300 TOOL REaulRED 0921700 88023032 Tool...

Page 212: ...the brake circuit is described at para 0925300 0922200 REMOVAL ADJUSTMENT AND REFITTING OF THE BRAKE PEDAL not including removal and refitting of the pedal support Fig 09 217 Servo unit and brake flui...

Page 213: ...off when the brake pedal is at rest Fig 09 2 9 Pedal support complete with controls Unscrew the nut 2 holding pedals 4 and 5 and bolt 7 Slide off the bush 6 and the two pedals Unhook the spring 3 Take...

Page 214: ...the pit and rest it on trestles Take off the wheel Remove the pin 5 unscrew the hose 7 from the union 6 and collect the brake fluid Fig 09 2113 Attachment of hand brake cable to rear caliper Refittin...

Page 215: ...oval of brake fluid hose from union r Fig 09 2117 Front caliper carrier Note removal of a rear carrier also requires the detachment of the hand brake cable from the lever ref 2 in fig 092 13 and disco...

Page 216: ...5 take off the spacer 4 and withdraw the disc 1 Removal Slacken the wheel stud bolts Jack the vehicle onto trestles and take off the wheels Front wheels set gauge as shown in fig 09 2 18 to check tha...

Page 217: ...otos below Fig 09 2121 Caliper carrier and friction pad Fig 09 2122 Caliper and spring for pads Fig 09 2119 Checking the angle of the front brake disc to the axis of rotation Refitting Clean the disc...

Page 218: ...hose should run upwards as shown in fig 09 2 25 Press he brake pedaj down quickly and slacken the bleed screw 1 A mixture of fluid and air will pass up the hose Hold the pedal down and tighten the bl...

Page 219: ...e system for leaks Repeat these operations on the other brake calipers On each occasion make sure that there is enough fluid in the reservoir If a certain degree of sponginess remains when the brake p...

Page 220: ...pump body and the outside of the pistons have a shiny surface and are free from scratches etc Replace if necessary Refitting Reassemble the pistons Renew the seals if necessary Replace the front circ...

Page 221: ...parts Disassembly Remove the carrier as described at para 092 4100 and mount it in a lead jawed vice Remove the dust guard 3 unscrew the cylinder and use a jet of compressed air through the brake fluf...

Page 222: ...cularly the seal housings Use a soft brush or a paint brush for this purpose Blowdry with compressed air Check that the piston and cylinder are from signs of abrasion and binding If not the caliper an...

Page 223: ...and the toothed sector 4 Overhaul Check all parts and renew as necessary if worn or damaged Reassembly Reassemble in the reverse order Grease the toothed sector On completion check that the sector an...

Page 224: ...SEC 10 Air System Air compressors Tanks Valves Pipes Units Not Fitted to This Vehicle...

Page 225: ...SEC 11 Frame Frame or subframes for mechanical assemblies Not Fitted to This Vehicle...

Page 226: ...cket 12 2 1400 Removal and refitting of pedal support assembly 122 1600 Removal and refitting of jointed steering column from and on its jacket 1221700 Renewal of jointed section of steering column 12...

Page 227: ...1 0 I ro O 0 o 0 N N 0 c Q O c CI C Q Q V E Q oc Q Q Q V CI E a C Q c Q J c 0 Oc Q o 0 V 0 c J J 0 Q Q E a c a Q V uoa a o 0 0 N 0 II Q J II II Q 0 Q u Q O u c Q j 0 Q u Q 0 O aJ aJ I c o CJ aJ aJ a...

Page 228: ...NN O J C c C1 ro u J c J c O Cii c 0 O c J C1 c c O ro O C1 LL c o o r O N r o co Q O E Q CI C c C CO O Q C i c Q c C Q Oc a C iii CO c c C Q COa C Q c co JEo C Q 0 C E C c coco Q 0 a a 0 o o o v r o...

Page 229: ...O cn 1 cn U w U w Z w t u w J m t m O cx Ii I c 1 J t IL c s Q E O c Q Q C E c Q Q c C s Q IJ C C Q c c u c C CJ Q c c c u Q Q a cn c cn 0 0 0 0 c Q c C o Q Q Q c t E Q 0 u 0 u a Q QJ E o QJ 0 0 c QJ...

Page 230: ...e reference marks on both the steering wheel and the steering column Remove the steering wheel With the front wheels pointing straight ahead and the spokes of the steering wheel horizontal refit all p...

Page 231: ...and disconnect the hoses from the pumps Detach the brake light switch leads Remove the support complete with pedals Refitting Refit the pedal support in the reverse order On completion bleed the brak...

Page 232: ...tted with a crosspiece as shown in fig Remove the jointed steering column jacket as described at para 12 2 1300 and proceed as follows Removal Use pillar drill 88096828 and a 6 mm drill to bore and re...

Page 233: ...two and position the worm accordingly Refit in the reverse order Tighten all bolts and nuts to the correct torque loading Check and if necessary correct the toe out as described at para 12 2 0010 TOOL...

Page 234: ...stands and take off the wheel 1224000 REMOVAL AND REFITTING OF SWIVEL COMPLETE WITH FLANGE AND BEARING FOR FRONT WHEEL HUBS Stand the vehicle over the pit fit covers 88083051 and proceed as follows Re...

Page 235: ...with carrier and fix it to one side unscrew the two bolts holding the brake disc and remove the disc Unscrew nut 1 Unscrew the nut holding the pin that joins the arm to the swivel Use tool 88062036 mo...

Page 236: ...d holes Check that the rack locating piece is not over tight in its seating on the housing and is free from undue wear particularly in cases where the housing has been working without oil Check the wo...

Page 237: ...The total will show the thickness of the shims to be added to the known shim so that this value is obtained The same result can be achieved as follows Add shims of known thickness to the pinion beari...

Page 238: ...e correct torque loading r Fig 124 7 Checking the difference in height between the housing surface and the support to set the backlash between the worm and the rack Set the rack about half way into th...

Page 239: ...ding values and minir lum 88063006 Torque meter extension for measurement of rolling torque 88065001 Tool used in checking rack housing clearances 88091134 Torque spanner 88095122 Dial gauge 88095851...

Page 240: ...moving and refitting the heater cock 13 2 1300 Replacing heater cock sheath and control lever 1322100 Removing and refitting the windscreen w pers assy 1322500 Renewal of wiper blades or levers 132290...

Page 241: ...c J C1 ro LL n o o N Y 0 0 E I 0 0 0 0 0 0 I o o 0 O N M 0 0 Q 0 Q c 0 0 Q c Q cr 0 ca Q ca Q ca u 0 ca CI ca CI c J ca 00 00 L 00 N MM Q ca Q c 0 0 0 C ca t 8 Q Q w ca Q O c 0 t ca 0 Q caca J Q ca o...

Page 242: ...c Q 02 c o 0 E 0 Q 0 E Q o a 0 0 E Q CI 0 0 0 J C1J u o 0 V N q w 0 ca 0 w 0 c 0 0 Q 0 0 Q 0 0 Q t E Q a o o Ll N N M c Q Q Q 0 Q 0 c 0 Q cn 0 c 0 cn Q 0 0 c Q 0 ro 0 0 Q 0 ro I L 0 0 0 0 0 0 0 0 0 c...

Page 243: ...c u Q Q c 0 0 c ca Q u 0 Q 0 Q Q c UI Q Q Q N UI N 0 ca C Q Q UI c J c Q Q ca Q E Q O 0 u O E c u 3 Q 0 c caca c C O Q u Q Q CQ c c c Q c E c u Q Q Q C C Q c O u Q c c O c D N N O c tJ 01 O 3 O c 0 0...

Page 244: ...l Cl E o 0 Cl Cl 0 c o to Cl to c s Cl t 0 Cl t a 1 1 E o 0 1 1 a tn j 0 U c Q E I c 0 LL o o I M N M c o E C c C ro Q Q C Q J Q C C c J J C ro c J c Q ro E c c roQ E2 EQ o J C C E C C ro Q C a s o b...

Page 245: ...ithdraw it Disconnect the compartment light snap fitting and remove the screw and nut securing the the compartment light earth cable Unscrew the screws holding the central cabinet to the tunnel and th...

Page 246: ...nd the blender flap are working perfectly Go down into the pit place a clean container under the drain plug and drain off the coolant remove the battery and the glove locker complete with light For re...

Page 247: ...nch Take off the mounting springs and remove the levers Check the effective operation of the link rod joints Renew the lever assembly in the case of wear between the bushings and pins Removal R e m ov...

Page 248: ...216 casings Fuse cover and steering column half 1323500 Partly withdraw the cluster and disconnect the terminals Remove the cluster 10 REMOVAL AND REFITTING OF THE INSTRUMENT CLUSTER speedometer rev c...

Page 249: ...ressure of 0 6 atm Dip the core in a tank full of water and locate the leaks Then clean the leaking part or parts with a wire brush and acid zinc chloride and a liquefied gas torch then soft solder If...

Page 250: ...142 1000 Removing and refitting a right or left front beam unit including renwal of the bulb Do for SCORPION cars 1422800 Removing and refitting the windscreen motor 1423100 Removing and refitting the...

Page 251: ...E Q 1 c 0 0 CJ Q Q c 0 c 0 0 J u 01 O u Q 0 u Q Q 01 i 0 o E Q ro I c Q 3 Q c o o o o 0 N Q 0 0 O N 0 0 o E 0 Q o 0 0 E b c E ro V Q Q J ro o c c E u c Q Q Q a X o 14 ELECTRIC SYSTEM J cg c u I 0 c 0...

Page 252: ...01 la a J la L1 Q 01 0 i Q 0 c Q 0 0 E 3 Q 01 a Q 0 Q 0 0 0 c Q ro u 0 i 5 Q 0 c Q c 0 i l l l c ro 5 c c l l l r s o c O co co O 0 E l l E co t o o o o 0 N 00 r 10 N v v v 0 c E E c ro II c 0 c Q II...

Page 253: ...o 0 0 u f ro c u J 0 ro s u E ro C c u ro C r u C c ro In C o o c E C C o CI 0 E to 0 to c 111 u c J 0 to LL C J 0 c u C 00 O 0 ro u a c c 0 c 0 u Q c 0 E c ro ro 0 Q ro Q o C E 0 Q c C O 0 N 14 ELECT...

Page 254: ...0 ro c Q 0 0 c c roC J c o 1 u u c u a o u J ca LL c Q Q 0 C c s o Q Q co c C c C co c Q co 0 E Q c a O 0 v N V Q 0 c o Q CJ 0 0 c c 0 0 SoP J ro 0 0 E 0 1 0 c Q Q u a c Q a o c ro O Q E 0 E Q a Q a o...

Page 255: ...E J c c QJ E J J CO o LL tI I c Q E J s Q C c c u ro Q 0 E Q C a c ro ro 0 c 0 0 c ro 0 0 E 0 0 0 F 0 o E c 0 J 0 LL tn Q O 0 c ro 0 Q ro Q 0 I c o 0 V N V 0 0 c 0 II c ca 0 c O 0 u I u J 0 ca U l cl...

Page 256: ...ing headlamp alignment with equipment 88075020 Fig 142 3 Headlamp aiming screws If this does not occur adjust screw 1 as necessary Set the front wheels in straight ahead position and place equipment 8...

Page 257: ...UNIT INCLUDING RENEWAL OF THE BULB Fit covers 88083051 and proceed as follows Check the electrolyte level and top up with distilled water if necessary Wait till this mixes in thoroughly with the acid...

Page 258: ...move the steering wheel as described at 12 2 1000 Unfasten the securing bolts and remove the steering column casings Detach the control cables and then loosen the screw securing the windscreen wiper t...

Page 259: ...as follows Remove the various electric connections from the alternator undo the bolt securing the alternator from the top Working above the car Detach the positive battery lead Take out the spare whee...

Page 260: ...8 Removing alternator Fit covers 88083051 and proceed as follows Remove nut 1 lower the coolant pipe in the direction of the arrow and remove the bolt 2 Remove the alternator after freeing it from the...

Page 261: ...en take off the armature complete with the fork 4 and the core 6 Separate the fork 4 and core 6 from the armature 5 Fig 144 1 Disassembly of starter motor 0416 Fig 144 3 Disassembly of pinion Clamp th...

Page 262: ...ure 1 on the testing pole shoes Turn the tester on by means of its switch Lamp 5 will come on Fig 14414 Checking armature insulation Place the armature on the insulated portion of test stand 88075016...

Page 263: ...h 1 to Mains Place the armature 4 on the testing pole shoes 2 Turn the tester on by means of button 5 Rest blade 3 on the armature segments and turn the armature slowly Short circuits will be shown by...

Page 264: ...h holder Connect the brush leads to the stator windings Lower the brushes onto the commutator and remount the dust excludingcollar 1440520 RENEWING THE STARTER MOTOR FIELD COIL Fig 144 9 Reassembly of...

Page 265: ...ree phases of the stator in turn If the warning light comes on this shows that the insulation between the winding and the segments is faulty Check of rotor continuity and insulation Rest the rotor on...

Page 266: ...nt should pass in one instance only If this is not so the part must be renewed Use thermometer 88075002 to check that the electrolyte temperature does not rise to more than 40 If this value is exceede...

Page 267: ...Removing headlight support Unfasten the bolts 1 and 2 working from inside the front bonnet remove the bo1t 3 and take off the support assembly Refitting Refit in the reverse order to removal then chec...

Page 268: ...ER 2 Disconnect the bushing 1 Withdraw the spring 2 remove the bolts 3 and then free the lever 4 and remove the bracket and motor 5 At the bench detach the motor from its fixing bracket Refitting Refi...

Page 269: ...Removing and refitting a door trim panel 1520500 Removing and refitting a door drop window 152 0560 Removing and refitting quarterlight glass 1520600 Removing and refitting a window regulator 152 080...

Page 270: ...usting the boot lid catch 1524410 Removing and refitting the boot lid release cable and sheath 152 17 152 17 152 17 15 2 1 15 2 1 152 17 152 2 15 2 2 152 18 Variant SCORPION Variant SCORPION Variant S...

Page 271: ...Q c C Joroc C Q Q Q C Q O r c Q 3 ro 0 3 0 c 0 0 3 Q 0 ro ro 0 Q ro r CIJ C CIJ c CIJ 0 0 C c C C J a C C C 0 c a CIJ c J a ro ro Q cn c c O C c L c o C 0 c M 00 o E OOro C 00 ro cn E c 1 J JOcn C c c...

Page 272: ...O a co U 0 c co co Q c Q Q a Q c aJ 0 a 0 O c V c aJ V c c J aJ aJ tJ aJ 0 c O j j ro V u o o 0 O CI c j Q 0 c 0 0 0 Q tII 0 E c Q 0 a o 0 N N N Ln O c In O a OoQ Q ro c Q In In ro Q o c Q c o t J c...

Page 273: ...ID CI on o U 0 3 C 0 0 0 0 0 0 u 0 U 0 Q t 0 U U 0 c o o o c Q 0 Q U 0 Q J Q c 0 00 co u 00 0 vv NN L L O c O u c u O tJ C c 0 0 c Q tJ 0 c ca c Q ro t E u o o E Q tJ C a t 0 c C Q 0 0 c Z c J u 0 0 o...

Page 274: ...no wire of diameter 0 5 0 7 mm between glass 1 and seating 2 apply two handles to the ends Two mechanics one inside and one outside the car should then cut the strip of sealant by sawing the wire back...

Page 275: ...and the edge of the glass no greater than 15 mm width Using a compres ed air gun part 88083062 form a bead of silicon sealant of diameter 8 10 mm along the whole seating to achieve a uniform cord of t...

Page 276: ...les on the pillars and the two wings as described at 15 2 7300 Using a suitable knife or tool scrape away the adhesive between the rear window and its seating then remove the rear window glass in the...

Page 277: ...15 219 Side window adhesion fixture Take out the glass as described at 1520200 Prepare the glass the seating centering and spacing as described at 15 2 0300 and make sure that there is a constant cle...

Page 278: ...g remove the glass run 9 Removing Unscrew the bolt 6 holding the locking knob and take this off remove the bolts securing the upper armrest and dashboard extension 3 and remove it Unscrew the two bolt...

Page 279: ...ITTING OUARTER llGHT GlASS After removing the door trim panel as described at 15 2 0450 proceed as follows Remove the plastic pro1ections unfasten the two bolts 9 holding the regulator handle and take...

Page 280: ...ositioned correctly by simply shifting the hinges adjust the rear door as described at 1520810 to ensure perfecr closing 1520810 ADJUSTING A DOOR MOUNTING setting the hinges bumper and striker plate P...

Page 281: ...n the striker plate or spacers slackening the mounting bolts or increasing or reducing the number of spacers To eliminate the faults noted at points 1 2 3 4 proceed as follows Remove the door trim pan...

Page 282: ...he pawl return spring and remove the lock cylinder Fig 152116 Removal hinges Remove the door as described at 15 2 0800 at the bench mark the position of the hinges on the door with a pencil remove the...

Page 283: ...r After removing the door trim panel as described at 152 0450 proceed as follows Loosen the nut 11 and hence the spring 6 and tighten nut 5 the cable 8 remains under tension and places lever 4 under t...

Page 284: ...AND REFITTING SEAT Proceed as follows Removing Unfasten the front and rear bolts securing the seat runners to the floor moving the seat forwards and backwards to make it easier Remove the seat from th...

Page 285: ...2123 Bonnet Slide off the number plate lights snap fitting 1 unscrew nut 2 and take off the bonnet complete with its hinge pins Refitting Reassemble in the reverse order If necessary adjust the distan...

Page 286: ...NET HINGES Removal Open the glove locker cover Unscrew the bolts holding the lock to the cover and remove the lock Fit covers 88083051 and proceed as follows Removal Refitting Reassemble in the revers...

Page 287: ...that might arise at point 2 adjust the lid brackets or increase or reduce the spacers of the two locks unti I the condition specified at point 2 is achieved Check that the gap C D and C D between the...

Page 288: ...ing Open the boot lid remove the two nuts 8 that secure the tie rod 9 to the two loeks remove the two bolts with nuts 6 securing the locks to the windscreen lower crosspiece then remove the locks 1524...

Page 289: ...t the bench Undo the nuts holding the moulding to the grille and remove the moulding Undo the nuts holding the badge to the grille and take off the badge At the bench Unscrew the bolts securing the fr...

Page 290: ...al Remove the spare wheel and jack Unscrew the bolts holding the radiator reservoir and shift it towards the engine Disconnect the headlamp leads Unscrew the nuts holding the grille and detach the gri...

Page 291: ...orking from within the engine compartment unfasten the three nuts securing the wing to the wheelhouse panel and remove the wing Fig 152 33 Refitting air outlet grille Refitting Refit the wing to the p...

Page 292: ...llows Fig 15 2136 Soft top opening catch Removal From the engine compartment unscrew the nuts holding the stale air escape grilles and remove the grilles Unscrew bolts 1 and remove the strikers 2 and...

Page 293: ...152 5710 Fig 15 211 Removing bumper Fig 152 2 Removing bumper shock absorber r Unfasten the bolt 4 fig 15 2 1 Remove the bolts 2 and withdraw the shock absorber from its seating Disconnect the electri...

Page 294: ...move the bumper as described at 15 2 5910 Fig 152 3 Removing bumper Unfasten the nuts 1 and 2 and detach the bumper from the shock absorbers Fig 152 4 Removing bumper shock absorber Unfasten the bolts...

Page 295: ...9 164 10 164 3 164 15 Introduction to carburet tor test Hydraulic checks Air leak checks 164 1150 Fuel level check on the Weber DATA 200 carburet tor 164 1700 Bench testing the Weber 34 DATA carburet...

Page 296: ...ly an approximate idea of a plug s performance since it does not reproduce the actual conditions under which it has to work on the engine TOOLS REQUIRED Turn the switch to Mains and check that lamp 5...

Page 297: ...robe lead to socket 3 Select 12 V on the socket holder plate Depress button 1 to i nsert the voltmeter and short circuit the socket 2r Lead insulation check Fit an efficient ignition coil to the bench...

Page 298: ...H T terminal to the spark gap H T socket The gap between the points should be 8 10 mm Set the switch to the coil test position Start the motor and check that the correct values are obtained when the...

Page 299: ...rface for the test tubes used to measure the delivery of the acceleration pumps A pressure gauge and an electric fuel pump similar to that usually employed on the Flavia injection model though modifie...

Page 300: ...in are poured into the reservoir Petrol is not used for safety reasons During the tests check the cleannes of the paraffin in the reservoir frequently to prevent dirt from entering the various parts o...

Page 301: ...pe of air is measured by comparing known leaks through a master jet and the leaks to be determined Equal levels in the columns correspond to an equal escape of air The equipment shown in the photo can...

Page 302: ...0 Two type D jets for the range to 110 100 Two type I jets for the range to 160 100 Two type K jets for the range 90 to 200 100 Two type N jets for the range 160 to 400 100 The jet most suited to the...

Page 303: ...rs 15 slow running jets with values from 35 100 to 70 100 33 main jets with values from 50 100 to 200 100 21 air corrector jets with values from 100 100 to 300 100 Warning the gasket must always be fi...

Page 304: ...gulate the pressure to the value required for the test Slacken knob 6 until a small trickle is obtained This represents the consumption of fuel that would take place if the engine was idling Check tha...

Page 305: ...ydraulic tests 88015350 Apparatus tor tuellevel test 1641700 BENCH TESTING THE WEBER 34 DATR CARBURETTOR Proceed as follows Clean the carburet tor thoroughly with paraffin or trichloroethylene and blo...

Page 306: ...e support to connector 88015372 complete with a master air corrector jet whose delivery corresponds to the correct escape value for the primary valve Feed air at the correct pressure to the flowmeter...

Page 307: ...arburet tor locating inlet with a gasket and mount the carburet tor with the primary choke well attached to this inlet Lock the carburet tor in position with the locking device Incorporated in the fix...

Page 308: ...of fluid Turn off the fixture feed pump Remove the hoses Take off the carburet tor and blow it dry with compressed air r TOOLS REQUIRED 88095770 Feeler gauge 88015363 Flowmeter 88015371 Support 880135...

Page 309: ...8015330 and then mount the slow running jet to be tested The level of the liquid in the column should Fig 164 19 Flowmeter II I Mount on one of the flowmeter 88015363 pipes a head jet with a range cor...

Page 310: ...1644200 CYLINDER HEAD TIGHTNESS TEST Disassemble as described at para 01 4 2700 and proceed as follows Remove the carburet tor from the inlet manifolq Fit a new gasket to the manifold and mount it on...

Page 311: ...and connect it to the compressed air hose Fit plug 3 on the water outlet to the heater Fit plug 88015470 on the water outlet to the automatic rich mixture control Supply air at 4 907 5 88 bar 5 6 Kg c...

Page 312: ...hole corresponding to a length of 200 mm Mount the front or rear shock absorber on the arms as shown in the photo To check the effective travel 100 mm of the shock absorber adjust the slide as follow...

Page 313: ...than that prescribed N B This test is influenced by shock absorber temperature and the speed of the machine If the shock absorber is unusually cold for example the load will be greater Alternatively t...

Page 314: ...ervoir and check that the gauge light goes out when the level exceeds the minimum mark top up to maximum Move lever 13 to the end of its stroke and open and close immediately cocks 7 10 before releasi...

Page 315: ...the dynamometer control pedal 7 until specified revs are reached Read voltage on the voltmeter 1 current input on the ammeter 2 and pressure on the gauge 3 Torque in kg m is gjven by the following fo...

Page 316: ...t circuit test With the starter motor 5 connected as shown in fig 16 4 31 turn on switch 6 and depress the dynamometer control pedal 7 to stop the motor for an instant 5 sec max rake the reading on th...

Page 317: ...about 8 litres reserve Radiator and engine incl vehicle heating unit Engine oil sump filter and pipes Gearbox and differential oil Steering rack housing Brake fluid reservoir Clutch control liquid re...

Page 318: ...vehicle windscreen washer front compartment and cooling and fuel circuits Washing Wash the outside of the vehicle using any commercially available neutral soap Rinse thoroughly Rear end of vehicle Re...

Page 319: ...running until the temperature required for setting the slow running mechanism is reached Lubricate the front and rear bonnet release controls the seat sliders and the door locks and hinges Check that...

Page 320: ...e operations marked by an X is given in the schedule of times in accordance with the paragraph numbers shown at the head of each column It will be obvious that the overall time needed to perform the t...

Page 321: ...D OUT AFTER THE SERVICING COUPON HAS EXPIRED Distance run in 000 Km and relevant paragraph in Maintenance section OPERATIONS 60 I 65 I 70 I 75 I 80 I 85 I 90 I 95 i 100 5 i 10 15 30 I 35 I 40 I 45 I 5...

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Lancia Beta montecarlo, Shop Manual

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