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Страница 1: ...DELOREAN WORKSHOP MANUAL PJ GRADY INC 631 589 6224 800 350 7429 FAX 631 589 6241 J ...

Страница 2: ...I r r r r r r r r P J GRADY INC 631 589 6224 800 350 7429 FAX 631 589 6241 ...

Страница 3: ... r I r r I DE LOREAN WORKSHOP MANUAL Pan No 113096 I Issued by Technical Publications Department De Lorean Motor Cars 1982 Ltd Dunmurry Industrial Estate DUNMURRY Co Antrim N Ireland BT17 9JJ Copyright Reserved ...

Страница 4: ...des are dealt with in sections designated by a letter This is further divided into subsections which are identified by a number and a page number within the subsections Pag A 01 12 Subsection r i Each section opens with a contents and inaex page so that any particular operation may be easily referred to F I I I I r General Data Comprehensive informaiion regarding dimensions tolerances and weights ...

Страница 5: ...RTS De Lorean genuine parts are identical to the high quality factory parts installed in new De Lorean cars In order to provide the best possible service for owners the dealer organisation throughout the world form a link between the owner and factory All problems related to the servicing and repair of cars are dealt with through that organisation Dealers have the backing of the National Distribut...

Страница 6: ...se of specially designed tools manufactured by Kent Moore Ltd These tools are essential to achieve the Flat Rate Man Hour Schedule Times approved by the factory The use of the tools is described under the appropriate sections and the relevant tools are listed at the beginning of each section r ...

Страница 7: ... a closed container LEGISLATION REQUIREMENTS Most countries have stringent regulations governing the design and manufacture of cars aimed mainly at maintaining standards of safety noise and pollution De Lorean cars conform to the homologation specifications required in the countries to which they are distributed Alterations to the car after purchase by changing settings or adjustments by addition ...

Страница 8: ...AL TRANSMISSION AUTOMATIC TRANSMISSION STEERING FRONT SUSPENSION REAR SUSPENSION BRAKES WHEELS AND TYRES ELECTRICAL SYSTEM AND INSTRUMENTS jjjHEATING AND AIR CONDITIONING BODY SUB DIVIDED INTO THE FOLLOWING GLASS REINFORCED PLASTIC G R P STAINLESS STEEL INTERIOR CHASSIS S SECTION A B C D E F G H J K L M N P R a f l ...

Страница 9: ...ICLE SPECIFICATION DATA ENGINE TUNING DATA TORQUE DIMENSIONS GENERAL RECOMMENDED LUBRICANTS FLUIDS AND CAPACITIES DMC MAINTENANCE PRE DELIVERY INSPECTION LABEL IDENTIFICATION A 01 01 A 02 01 A 03 01 A 04 01 A 05 01 A 06 01 A 07 01 A 08 01 ...

Страница 10: ...ing order Ignition Timing Spark Advance Vacuum FUEL I N J E C T I O N 130 B H P I S O at 5 550 R P M on 91 Octane Fuel unleaded 208 Nm 153 ft lbs at 2750 R P M Positive pressure closed system 85 89 C 185 192 F 100 C 212 F Impellor type pump thermostatically controlled Electrically operated twin thermostaticaliv controlled Bosch K Jetronic continuous injection Electric immersed in fuel tank Paper w...

Страница 11: ...orola 90 Amp output AUTOMATIC TRANSMISSION TYPE 4141 Ratios 1st 2 40 2nd 1 48 3rd 1 00 Reverse 1 92 MANUAL TRANSMISSION TYPE 369 Ratios 1st 3 36 2nd V 2 06 3rd 1 38 4th 1 06 5th 0 82 Reverse 3 18 WHEELS AND TYRES j Wheels type i l Cast r1 iloy Size Front 14 x 6W 35 7 mm x 152 mm Rear 15 x 8 381 p 203 mm Spare 15 x 4 381 mm x 102 mm Tyres type Goodyear NCT steel belted radial Size Front 195 60 HR 1...

Страница 12: ...AKES Type Disc Diameter Front Rear Power assisted Discs front and rear 254 mm 10 in 275 mm 10 in SUSPENSION Front Rear Unequal length upper and lower control arms coil springs telescopic shock absorbers and stabilizer bar Diagonal trailing radius arms with upper and lower links coil springs with telescopic shock absorbers I Ml f HEATING AND A C CHASSIS BODY Orifice tube type electrically operated ...

Страница 13: ...3 Valve clearance cold Inlet 0 10 0 15 mm 0 004 0 006 Exhaust 0 25 0 30 mm 0 010 0 012 Valve Timing LH RH Inlet opens B T D C 9 7 closes A B D C 45 43 Exhaust opens B B D C 45 43 closes A T D C 9 7 SPARK PLUGS Type Bosch HR 6 DS Gap 0 6 0 7 mm 0 024 0 028 Torque 17 20 Nm 13 15 ft lbs F i P 1 i l fi j ...

Страница 14: ... Shaft to Hub Travelling Arm to Pivot Bush Shaft to Inner and Outer Drive Shafts i Parking Brake Cable Bracket to Hub Carrier Caliper Hub Carrier Flex Brake Pipe Attachment Wheels TORQUE 16 lb ft 22 Nm 8 lb ft 11 Nm 8 lb ft 11 Nm 16 lb ft 22 Nm REMARKS 8 lb ft 11 Nm 3 lb ft 5 Nm 16 lb ft 22 Nm INNER OUTER INNER OUTER 60 lb f t 4 2 lb ft 8 0 N m 6 4 N m 60 lb f t 4 2 lb ft 8 0 N m 6 4 N m 75 lb ft ...

Страница 15: ...ower Stabilizer Bar Lower Control Arm Stabilizer Bar Pivot on Chassis I Flex Brake Pipe Attachment Upper Ball Joint to Steering Knuckle Lower Ball Joint to Steering Knuckle Body to Chassis Fixing Bolts TORQUE 15 lb ft 20 Nm 18 lb ft 25 Nm 26 36 16 lb ft 22 Nm 55 lb ft 75 Nm 20 lb ft 28 Nm 20 lb ft 28 Nm 165 lb ft 220 Nm 145 lb ft 190 Nm 60 lb ft 80 Nm 60 lb ft 80 Nm 20 lb ft 28 Nm 60 lb ft 80 Nm I...

Страница 16: ...ame Line Union through Frame RADIATOR Fan Cowl to Radiator STEERING UNITS Lower Column to Universal Joint to Rack Pinion and Upper Column Tie Rod to Steering Knuckle Tie Rod to Lock Nut Steering Rack Assembly to Frame TORQUE 18 lb ft 25 Nm 12 lb ft 16 Nm 8 lb ft 11 Nm 30 lb ft 40 Nm 11 lb ft 15 Nm 16 lb ft 22 Nm 22 lb ft 30 Nm 8 lb ft 11 Nm 8 lb ft 11 Nm 16 lb ft 22 Nm 12 lb ft 16 Nm 12 lb ft 16 N...

Страница 17: ...Fixing Bolts Converter Driving Plate Bolts Sump Fixing Bolts Crankshaft Pulley Fixing Oil Pump Sprocket Bolts Chain Tensioner Blade Bolts Timing Cover Fixing Bolts Camshaft Sprocket Fixing Bolts Camshaft Pulley Fixing Bolts Camshaft Sprocket Access Plug Inlet Manifold Fixing Bolts Taper Seat Spark Plug No Washer TORQUE REMARKS 34 lb ft 46 Nm I 42 lb ft 58 Nm With Loctite 601 I 49 lb ft 66 Nm 11V4 ...

Страница 18: ...m 26 lb ft 35 Nm 100 lb ft 130 Nm REMARKS 105 lb ft 135 Nm j 37 lb ft 50 Nm 105 lb ft 135 Nm I I AUTOMATIC TRANSMISSION j f f r DESCRIPTION Output Shaft Planet Wheel Carrier Nut Half Casing Assy Bolts 8 mm Dia Half Casing Assy Bolts 10mm Dia Final Drive Pinion Nut F2 Brake Bolts Stator Support Fixing Bolts Converter Casing to Final Drive Casing Fixing Bolts Hydraulic Distributor Fixing Bolts Crown...

Страница 19: ...Base C Height Door Open D Height Door Closed E Width F Track Front G Track Rear H Ground Clearance Front J Ground Clearance Rear M if mJhes is 166 oo 95 00 77 20 44 90 73 10 62 60 62 80 5 60 6 10 Millimetres 4213 2410 1962 1140 1856 1590 1594 142 155 n A p j r V F j ...

Страница 20: ...10C C H4 F1 SAE 80W ABOVE i0 C 14 F1 W H E R E SAE 5 W OIL IS N C T A V A I L A B L E SAE BOW OIL M A Y BE U S E FINAL DRIVE AUTOMATIC 0 42 2 6 1 5 SAE 80W MIL L 2105C API GL5 AUTOMATIC TRANSMISSION CONVERTER 1 57 10 5 5 0 ATF TYPE DEXTRON 11 ELF RENAULT MATIC D2 OR MOBIL ATE 220 BRAKE CIRCUIT 0 764 DOT 4 I COOLING SYSTEM 2 9 19 37 11 0 ETHYLEN GLYCOL BASED j CONTAINING NO BORAX MINIMUM 50 50 MIXT...

Страница 21: ...and interior Work carried on hy Vehicle approved lor delivery Service Manager DEALER CERTIFICATE PDI DATE MILES RO No We hereby c ortily that this motor vehicle conforms to all applicable emission standards ol the U S Environmental Protection Agency This certificate is being made upon the basis of 1 our knowledge that the vehicle is covered by an EPA certificate of conformity based on written noti...

Страница 22: ... N G IGNITION CHECKS Engine stopped ignition on rherk battery voltage ranking speed coil output coil input At idling si eed cherk initial Inning centrifugal timing vacuum advance At 1 500 R P M check coil polarity primary snip spark plug bring voltage spark plug firing voltage snap a n I Replace plugs if necessary maximum coil output plug lead removed secondary resistance condensei alternator diod...

Страница 23: ...r r General Data A A 08 01 J I r LABEL IDENTIFICATION ...

Страница 24: ...ONLY WARNING 4 I BATTERIES PRODUCE EXPLOSIVE GASSES KEEP SPARKS FLAME CIGARETTES AWAY WARNING Oeon filler cap before removing Use only DOT 4 fluid from a sealed container 12 5 M BATTERY ACCESS SEE OWNERS HAN08OOK FOR SAFETY INSTRUCTIONS 7 0 _ ACKING PQ NTS SLOCK WIN L 8 WARNING RADIATOR FANS MAY START AT ANY TIME J 0 A i C iQA STO l M l i o sr q ia ne 0 iO J a s Q A S 0 0 3 M 0A c B I I M 0 K ot i...

Страница 25: ...ery Gas Warning Label 5 California Assembly Line Decal USA 6 Glove Box Placard 7 Battery Access Label 8 Jacking Instruction Label DESCRIPTION COUNTRY 9 Radiator Fan Warning Label 10 Engine Start and Operation Label 11 Vehicle Identification Number 12 Unleaded Gasoline Label Canada USA 13 Brake Fluid Warning Label 14 Not Yet Applicable 15 1 Windshield Washer Reservoir Label jfi T ...

Страница 26: ... I VtNICLi WtlGMT KAHMO 1471 KG GAOSS A X L i WtlGMT H A T I M MOM T S U KG MAM O S KG TMII VEHICLE comumtm r o ALL Ar tKiCAScl ftDCKAL MOTOM VEHICLE SAMTV ITAMOAMQl IN Ef MCT OH rMf OATI Of MAMUrtACTUMC SHOWN AftOVl GMO0 VlHtCLC WVlCHT AATlMG 12 I I I GftOU AXLE Of IQMT 4 r i K MOUT 7W laU l Art U 111 rHri VEHICLE COWJP OMm TO ALL A L I C A B U FEOCHAL MOTOM VEHICLE lAftTf AMO l JM t l I TAMOAMM ...

Страница 27: ...liance Plate Canada 20 ACU Warning Label 21 Automatic Transmission Type Number Plate 22 Vehicle Exhaust Emission Label DESCRIPTION 23 Emission Control Update Label 24 i Negative Ground Label 25 Jump Start Label 26 Air Filter Element Label 27 Header Bottle Warning Label 28 Chassis Number 29 Engine Type Number Plate 30 Manual Transmission Type Number Plate COUNTRY ...

Страница 28: ...r r r r r r r r r r r r r r r Fuel Tank Contents FUEL TANK B 01 01 ...

Страница 29: ...1 REMOVING REFITTING IMPORTANT Be acutely aware of the fire and explosion hazard when working on fuel svstem Take every precaution to ensure that sparks cigarettes open flames etc are Kept well away from the work area ...

Страница 30: ... easing the tank between water pipes REFITTING Before refitting a fuel tank examine the tank for any signs of damage or chaffing Replace the tank if there is any doubt about its serviceability Ensure the foam rubber protection strips are in place and in good condition 2 Fig 3 Insert the tank from under the rear of the car guiding it between the water pipes Whiist supporting the tank slide in the s...

Страница 31: ...Fuel Tank B 01 03 ...

Страница 32: ... 03 01 ENGINE GEARBOX C 04 01 CYLINDER HEADS C 05 01 LINERS PISTONS C 06 01 CYLINDER BLOCK C 07 01 MAIN BEARING Oil Seal Flywheel End C 08 01 MAIN BEARING Oil Seal Timing End C 09 01 OIL PUMP C 10 01 OILPRESSURE C 11 01 WATER PUMP C 12 01 INLET AIR MANIFOLD C 13 01 RADIATOR C 14 01 r ...

Страница 33: ...Specifications Fig 7 Number of Cylinders Bore Stroke Engine Capacity Compression Ratio V6 91 mm 3 58 in 73 mm 2 87 in 2849 cc 173 86 cu in 8 8 1 imi ...

Страница 34: ...Fig 2 imi ...

Страница 35: ...sioner Blade Bolts Timing Cover Fixing Bolts Camshaft Sprocket Fixing Bolts Camshaft Stop Fixing Bolt Camshaft Sprocket Access Plug Inlet Manifold Fixing Bolts Spark Plug 35 Ib 45 lb 50 Ib 11 Ib 135 Ib 4 Ib 11 Ib 11 Ib 60 Ib 11 Ib 22 Ib 11 Ib 15 Ib ft 48 Nmi ft 60 Nm ft 68 Nm ft 16 Nm ft 183 Nm ft 6 Nmi ft 15 Nm ft 15 Nm ft 81 Nm ft 15 Nm ft 30 Nm ft 15 Nm ft 20 Nm With Loctite With Loctite With L...

Страница 36: ...I S fmm X C 3 rt Fig 3 ...

Страница 37: ...l Aluminium Tin Side Clearance mm 0 20 to 0 38 008 to 015 CRANKSHAFT Number of Bearings Main Bearing Shell Material Aluminium Tin End Play mm 0 07 to 0 27 003 to 010 Thrust Washer Thickness mm 2 3 0 2 4 0 2 4 5 2 5 0 i 0 9 0 5 0944 0964 0984 Roll Hardened Main Bearing Journals nominal diameter mm 70 062 2 7583 regrind diameter mm 69 762 2 7465 regnnding tolerance mm 0 0 019 0007 LINERS Bore mm Bas...

Страница 38: ...g the roll hardened zone should re main intact over the 140 sector The zones concerned are those marked A and B B Fig 5 OIL PUMP Minimum oil pressure at 80 C at 900 rpm ibar 2 2 32 psi at 4000 rpm bar 4 4 64 psi iffni ...

Страница 39: ...ith the clutch shaft spigot bearing The spigot bearing must be inserted if the engine is mated to a manual gearbox It is bonded in smear the outside of the bearing with loctite Fig 8 Components which must be cnanged at each dismantling Flywheel fixing bolts Convenor driving plate fixing bolts Big end cap nuts CYLINDER NUMBERING IN EACH BANK The bank comprising cylinders 1 2 and 3 is aesignated the...

Страница 40: ...ER BAR J 28856 CYLINDER LINER DEPTH GAUGE J 28857 ANGULAR TORQUE GAUGE J 28858 TIMING SPROCKET SUPPORT TOOL J 28859 FLYWHEEL LOCK J 28860 REAR CRANKSHAFT PULLEY SEAL INSTALLER J 28861 FRONT CRANKSHAFT SEAL INSTALLER J 28872 OIL GAUGE J 28873 PIPE AND ADAPTOR FOR OIL GAUGE Fig No Not Illustrated Not Illustrated Not Illustrated Fig 88 Fig 91 Fig 71 Fig 40 Fig 66 Fig 38 Fig 45 Not Illustrated Fig 115...

Страница 41: ... harness coil lead engine harnesses from their multi sockets Remove rear side markers and disconnect wiring harnesses Remove engine compartment lock and disconnect release caole Fig 10 Q Remove rear fascia attachment bolts and remove fascia Figs 10 7 J Remove exhaust muffler and heat shields See Section D Remove chassis cross brace Fig 12 Drain coolant from cylinder block Fig 131 engine oil and tr...

Страница 42: ...lve and cylinder neaa neater bleed pipe from header tank orake servo vacuum pipe uel feed to metering head fuel return at bundy metal pipe connection accelerator cable starter positive cables Fig 14 wiring harness at bulkhead auto transmission only ...

Страница 43: ... at cooler end Disconnect gear change control manual transmission For automatic transmission disconnect cable at relay lever Remove gear box side mounting bolts Fig 16 R H illustrated Fit lifting sling to rings provided Figs 17 18 L H S Figs 19 20 R H S Take weight off engine and remove both mounting bolts Pull engine forward and lift out Fig 27 L H S illustrated r ...

Страница 44: ...TTING Adjust the travel of the accelerator cable and gear change linkages CHECK Engine gearbox or automatic oils and fill as necessary Fill and bleed cooling system Adjust all controls For automatic transmission adjust the governor cable travel and the selector cable travel ...

Страница 45: ...as been fitted While engine is in its transit cradle and easily accessible The vehicle need not return to workshop for cylinder head retightening when the above procedure is observed PRETIGHTENING Fig 22 Loosen bolt No 1 and retorque tighten to 15 lb ft 20 Nm Repeat the above on each bolt in the tightening sequence shown 0 7 8 0 l 0 7 8 0 0 3 4 0 0 3 4 0 0 2 1 0 0 2 1 0 0 6 5 0 0 6 5 o Fig 22 ANGU...

Страница 46: ...and lock it as previously Adjust the mobile pointer to angular tightening value 115 Tighten bolt No 1 until the moving pointer reaches 0 Repeat the above operation on each bolt in the sequence shown Then commence retightening operations after running the engine ADJUSTING ROCKER A R M CLEARANCES Clearances with engine cold inlet 0 10 004 exhaust 0 25 010 FIRST METHOD Adjust the rocker arms on eacn ...

Страница 47: ...shaft pulley opposite pointer 0 on timing cover Fig 28 Cylinder No 1 on T D C Firing Stroke Adjust Inlet Exhaust 1 1 12 14 E1 E3 E6 2 Starting from pos 1 turn the crankshaft one complete turn 360 which corresponds to T D C End of Exhaust commencement of inlet on cylinder No 1 Cylinder No 1 rocker arms on the rock Timing mark 0 on the crankshaft pulley opposite pointer A on timing cover r Cylinder ...

Страница 48: ... be used if the crankshaft has to be turned for example when piston and liner assemblies are changed to prevent any alteration in the valve timing I_H Cylinder Disconnect battery Drain cooling system Remove intake manifold Remove water pump hose leading to neaa Disconnect any neater hoses leading to cyiinaer heads Remove rocker cover and access Diug for the camshaft sprocket bolt Turn the camshaft...

Страница 49: ... disengages the sprocket Fig 32 Press the locating roll pins down at A and B using an old pushrod Fig 33 C ji i B Fig 33 Remove the 4 bolts securing the cylinder head to the timing cover Remove cylinder head bolts and remove rocker arm assembly Unstick the cylinder head gasket and remove the cylinder head taking care not to unseat the liners Remove the cylinder head gasket Fig 34 a P D ...

Страница 50: ...ease the tensioner In this case use the dummy bearing to prevent the valve timing becoming out of phase Oil tightness between cylinder head and timing cover Cut the timing cover gasket off level with the cylinder head gasket face Cut sections from new gaskets to replace the above Use gasket cement to hold new gaskets in place and seal joint at cut area Insert a 3 mm 1 8 dia pin punch into each loc...

Страница 51: ...anifold using new gaskets 0 j 7 8 0 1 i 0 7 8 0 0 3 4 0 0 3 4 0 0 2 1 0 0 2 1 0 0 6 5 0 0 6 5 0 Fig 39 Refit hoses and pipes Refit exhaust clamp Adjust the rocker arm clearances Fit the rocker cover Fill and bleed cooling system Run engine for 30 minutes Let the engine cool down for at least 2 hours then retighten the cylinder head Fig 39 RH CYLINDER HEAD The removing and refitting operations for ...

Страница 52: ...ad Compress the valve springs using a valve spring compressor Remove the split cotters topcups springs and thrust washers lay them out in their correct order Fig 40 RE ASSEMBLING Grind in the valves and check them for gas tightness Clean the cylinder head carefully Re assemble the valves fitting components in the following order 1 Thrust washer 2 Oil seal 3 Valve spring closest coil facing cylinde...

Страница 53: ... lay them out in order RE ASSEMBLING The RH and LH side rocker shaft assemblies are identical They match their respective cylinder heads by turning the complete assembly round The position of the rocker shaft must not be reversed because the oil feed holes A will be ofocked the rocker shafts must be fitted with tneir oil holes facing downwards Fig 43 Fig 44 ...

Страница 54: ...flat on boss facing snap ring Fig 45 3 Spacer spring 4 Rocker arm with tappet adjusting screw on left 5 Spacer E equals 5 35 mm thick 6 Rocker arm with tappet adjusting screw on right 7 Spacer E equals 8 2 mm thick 8 Bearing with flat on boss facing snap ring i f prra ...

Страница 55: ...pack up with shims to prevent any slackening of the timing chain which may jam the tensioner in the forward position Moderately tighten both bolts Remove support IS Removal of all six assemblies is dealt with in this chapter As both cylinder heads have to be removed it is more practical to remove the timing gear Disconnect battery Drain the cooling system and sump oil pan Remove the air filter inl...

Страница 56: ...ngine They are available in the following thicknesses blue tag 0 087 mm 0034 white tag 0 102 mm 004 red tag 0 122 mm 0048 yellow tag 0 147 mm 0058 With liner base seals in position the amount of liner protrusion above the cylinder block face should be between 0 16 and 0 23 mm 0063 to 0091 work as close to 0 23 mm as possible The new liners need not oe inserted with an angular reference Difference ...

Страница 57: ...ositions 1 2 3 or 4 Check the protrusion of each liner in relation to the cylinder block If necessary change the thickness of the seals in order to position the liners so that the difference in protrusion between any two adjacent liners do not exceed 0 04 mm 0016 within the permitted tolerance Fig 53 and any differences are stepped from cylinder No 1 to No 3 or 4 to 6 and vice versa Once the corre...

Страница 58: ...on hole Press out the piston with the extracting mandrel IB Fig 56 Engine INSERTING GUDGEON PINS Preparing the connecting rods Check the rods for truth twist out of square Selecting the bottom end components by cylinder bank The connecting rod big ends are offset and have an extended flange E on one side counter balanced side in order that a pair of connecting rods can share a common crank pin Fig...

Страница 59: ...s Wipe off the solder droplet Insert locating guide D in the piston Fit the connecting rod to the piston with one hand extended flange E facing downwards Press in the piston pin quickly with other hand until the guide bottoms against the support base After a few seconds remove the connecting rod piston assembly from the support base unscrew the guide and remove the mandrel assembly Assemble the ot...

Страница 60: ...ssion Ring Spaced evenly at f 120 from the 3 Top Ring j expander gap Lubricate the pistons Fit the connecting rod piston assemblies into their respective liners using a piston ring ciamc Fit the snell bearings to the big enos insert No 1 assembly in the cylinder block arrow on tne Diston crown facing towards the timing gear end Fig 63 Fit No 1 big end cap together with its shell bearing Make sure ...

Страница 61: ...assemblies No 2 3 4 5 and 6 clamping the liners as assembly proceeds The cylinder heads Timing chains Timing cover Anti emulsion plate suction pipe and sump Refer to chapters Cylinder Block Changing and Cylinder Heads Changing r r ...

Страница 62: ...Engine C 07 01 f Cylinder Block Changing Fig 65 ...

Страница 63: ...IflTtl ...

Страница 64: ...g 67 fuel injection equipment and crankshaft pulley fixing nut Turn the crankshaft so that the keyway is vertical Fig 68 Remove the pulley the rocker covers timing cover and sprockets with oil pump driving chain retain the key and spacer Loosen the two camshaft fixing bolts Mark all the timing gear components according to side if they are to be re used Fig 69 cJ m mk m e Fig 69 Release both chain ...

Страница 65: ... mallet Remove the cylinder head gasket Clamp the liners with the clamps J 28852 Fig 72 Turn the cylinder block so that the LH bank of cylinders is uppermost and carry out the same operations to remove the LH cylinder head Fig 73 73 Turn the engine over Fig 74 Remove the sump suction pipe and gauge anti emulsion plate bottom casing and intermediate main bearing caps after marking their positions F...

Страница 66: ...ner piston conrod assembly Refer to chapter changing pistons and liner replacement Fig 78 Remove the connecting rod big end caps liner retaining clamps marked liner piston connecting rod assemblies front and rear main bearing retaining caps and caps themselves thrust half washers and crankshaft Clean all parts and inspect them for condition Use extractor to remove the clutch shaft spigot bearing F...

Страница 67: ... the timing gear end Read off the value of the end play It should lie between 0 07 and 0 027 mm 003 to 010 If it is incorrect change the thrust washers Fit the half shells to the connecting rods Fig 81 ASSEMBLING THE LINER PISTON CONNECTING ROD ASSEMBLIES Keep strictly to the markings made on dismantling to deno te the correct way round and position of the various components Insert the assemblies ...

Страница 68: ...d smear the assembly face with sealing compound FITTING THE BOTTOM CASING It is essential that the bottom casing and cylinder block are absolutely flush at the clutch end in order to avoid distortion of the clutch housing when the gear box is fitted Refit The bottom casing The flat washers boss under nut and main bearing cap nuts without tightening Another peripheral bolts also without tightening ...

Страница 69: ...sc clockwise until the locking stem rests against a solid object which will prevent the disc from turning Adjust the moving pointer to the angular tightening value 75 for main bearing cap nuts Tighten the nuts until the moving pointer reaches 0 Repeat the above operation on each nut Fig 85 REAR PLATE Offer up the rear plate with its paper gasket It is located laterally by dowel A Tighten bottom bo...

Страница 70: ... so that its slot E is positioned as shown Fig 90 This corresponds to the on the rock position of the rocker arms for No 1 cylinder Remove the pin punches Fit the rocker shaft assembly taking care to place it the correct way Fig 90 Z FITTING CYLINDER HEADS A LH cylinder head insert a pin punch into the side of each cylinder locating roll pin hole to prevent the latter being pushed down when the cy...

Страница 71: ...centre lies on the centre line of the LH bank of cylinders Fig 93 Engine Fit the timing chain to the LH sorocket with the dual marking on the chain astride the timing mark on the sprocket Now fit the timing chain over the rear set of teeth on the timing double sprocket with the single marking on the chain in line with the timing mark on the front of the double sprocket JFig 94 Fit the camshaft spr...

Страница 72: ...g the crankshaft from turning Set both timing chain tensioners by turning the ratchet mechanism clockwise with a screw driver Do not assist the tensioner to find their operational setting Fig 96 4 Fig 96 Position the crankshaft with the keyway uppermost Fig 97 Refit The distance piece for the oil pump drive pinion The key And oil pump drive pinion The oil pump drive chain and sprocket assemble the...

Страница 73: ...ibutor and leads Adjust rocker arm clearances Fit the rocker covers and spark plugs Remove the engine from the support Fit and tighten the cylinder block drain plugs and new oil filter after injecting some oil through hole A to prime oil pump Fig 101 Fit the main bearing oil seal using tool J28861 Fit the flywheel or convenor driving plate The final bolts are of the self locking type ana they must...

Страница 74: ...wo hours then re tighten the cylinder heads Loosen bolt No 1 and re tighten it to 15 lb ft 20mm Repeat the above on each bolt in the order shown Fig 102 Slip graduated disc over the socket before fitting the torque wrench and angular tighten to 115 Repeat for each bolt in the order shown Adjust valve clearances 0 7 8 0 r i 0 7 8 0 0 3 4 0 0 3 4 0 0 2 1 0 0 2 1 0 0 6 5 0 0 6 5 0 Fig 102 tv T flPSfr...

Страница 75: ...l seal and insert it in the tool J28861 Take extreme care when fitting as the oil seal lip is delicate Locate the seal by tapping on the end of the tool Fig 104 Remove the tool by pulling and turning at the same time Smear the new bolts for the flywheel or convenor driving plate with loctite Note Place one plate A on each side of the convertor driving plate Fig 705 Torque tighten bolts Convertor d...

Страница 76: ...oil seal location REFITTING Lubricate the new seal fit it to inserting tool J28860 offer up tool and seal push the tool in until it contacts the timing cover which locates the oil seal correctly Fig 107 Check the oil seal locating on the old pulley Fit a new pulley if the old pulley is marked or worn make sure it enters the key Smear the bolt with 1 or 2 drops of ioctite and torque tighten the nut...

Страница 77: ...lley and timing cover Remove the sprocket and chain Fig 108 oil pump cover never unstick the cover by tapping the release valve boss A Fig 109 and driven gear DISMANTLING Remove the split pin 1 and take out the concave spring seat 2 spring 3 and release valve plunger 4 O V E R H A U L I N G Check condition of components and location in cylinder block Fig 110 The complete oil pump assembly must be ...

Страница 78: ...ely Remove the oil filter and inject some engine oil through hole A with an oil can to prime the oil pumps Fig 111 Fit the oil pump sprocket bolts and the timing cover bottom bolts with loctite Torque tighten the pulley nut after smearing the crankshaft threads with loctite Refit alternator drive belt and tension rocker covers air conditioning compressor air conditioning drive belt and tension exh...

Страница 79: ...I l Oil Pressure Checking Fig 112 T T ryift 7 1 Fig 112 p ...

Страница 80: ...ng tools J28872and J28873 Fig 113 and 114 Remove oil pressure sender then connect oil pressure checking gauge The oil pressure should be 32 psi 2 0 bars min at 900 rpm 65 psi 4 4 bars min at 4000 rpm J28872 nv Fig 114 Refit the oil pressure sender using a new copper washer and top up engine oil if required ...

Страница 81: ...p mounting bolts Remove water pump Remove water pump body Fig 116 coolant temperature switch thermostat cover and thermostat FITTING Clean the joint faces before fitting new gaskets Fit the thermostat to its cover the right way round Fig 117 Check that 0 rings are in position in the inlet manifold Tighten all hose clamps Refit alternator and A C drive belts and tension Refit intake manifold Fill t...

Страница 82: ...he pipe to free the idle speed control hose and pull to release it from the lower air casing The pipe is assembled with an 0 ring 2 in the lower air casing for sealing purposes Remove idle speed control Unscrew the 2 capscrews 3 and bolt 4 holding the lower air casing to the inlet manifold Disconnect arm 5 Fig 119 from the throttle linkage ball as follows rotate clip half a turn to free it then sl...

Страница 83: ...wires to the distributor cap All fuel unions The idle speed air pipe after greasing the 0 ring in the lower casing The idle speed control The throttle arm ball joint locking it correctly with the clip 8 Fig 119 INLET AIR M A N I F O L D REMOVING Remove lower air casing see preceding page Unscrew the 4 manifold bolts 1 Fig 120 Fig 120 REFITTING Note the following Change all gaskets and seals Fit in...

Страница 84: ... thermostat is housed in the top of the water pump under the thermostat housing cover The thermostat sing cover is equipped with an air bleed screw used to purge the air from the coolant system when refir Coolant leaving the engine is directed through a series of pipes and hose couplings along the left side of the vehicle centre tunnel to the radiator Coolant leaving the radiator is directed throu...

Страница 85: ... s t 9 S O C o Fig 121 c ...

Страница 86: ...s securing condenser Ease condenser forwards and disengage mounting studs from radiator downwards between condenser and fan housing and remove Provide temporary support for condenser and fan housing REFITTING With the fan housing assembly and condenser supported in position insert the radiator between and engage the condenser mounting studs in the radiator top and bottom flanges Fit nuts to all fo...

Страница 87: ...PECIFICATIONS D 02 01 SPECIALTOOLS D 03 01 EMISSION CONTROLSYSTEM D 04 01 IDLE SPEED CONTROLSYSTEM D 05 01 EVAPORATIVE EMISSION CONTROLSYSTEM D 06 01 AIR INLET SYSTEM D 07 01 IGNITION VACUUM ADVANCE CONTROL D 08 01 DECELERATION CONTROL D 09 01 REMOVING REFITTING EXHAUST MUFFLER D 10 01 ...

Страница 88: ...n system which does not require any form of drive mechanism An electric fuel pump mounted inside the tank provides fuel at a constant pressure to the mixture control unit The control unit consists of an air flow sensor which measures the flow of air entering the engine and a fuel distributor which is mechanically operated by the air flow sensor The fuel distributor provides the injection valves wi...

Страница 89: ...r D 01 02 V Fuel Emission and Exhaust System J COMPONENT LOCATION Mixture Contro Unit Control Pressure Regulator Accumulator Thermo Time Switcn Cold Start Valve Fig J ft f r ...

Страница 90: ...m D 01 03 J 1 FUEL TANK 2 FUEL PUMP 3 FUEL ACCUMULATOR 4 FUEL FILTER 5 FUEL DISTRIBUTOR 6 PRIMARY PRESSURE REGULATOR 7 CONTROL PRESSURE REGULATOR 8 AIR FLOW SENSOR 3 COLD START VALVE 10 THERMO TIME SWITCH 11 INJECTORS 12 THROTTLE VALVES ...

Страница 91: ...main line fuel pressure in the system The regulator is located inside the fuel distributor 7 Control Pressure Regulator The control pressure regulator provides fuel enrichment during warm up and cold acceleration The regulator is mounted on the left valve cover 8 Air Flow Sensor The air flow sensor measures the amount of air entering the engine 9 Cold Start Valve An electrically operated cold star...

Страница 92: ... i 3 Si AIR MEASUREMENT The amount of air entering the engine is controlled by the throttle valves engine speed and engine load Air flowing through the air funnel 1 moves the sensor plate 2 downward in direct proportion to the air volume This movement is transferred by the balanced lever assembly 3 to the control plunger 5 located in the fuel distributor Fig 3 C t ...

Страница 93: ...ranking and when the engine is running It supplies uel to the lower chambers of the fuel distributor Any fuel that is not used returns to the fuel tank by passing through the primary pressure regulator 5 The primary pressure regulator controls main line fuel pressure If the main line pressure increases above a pre set value the pressure forces the regulator open This allows fuel to return to the t...

Страница 94: ...linder will receive the same volume of fuel as the control plunger rises or lowers Fig 6 If the primary pressure decreases the pressure regulator will close by opposing spring tension and restrict the amount of fuel returning to the tank The movement of this regulator valve will maintain constant main line pressure and distributor lower chamber pressure regardless of engine fuel requirements or vo...

Страница 95: ...ssure circuit is referred to as the control pressure The control pressure generates an opposing force to that originating from the air flow sensor plate When the control pressure gulator 3 decreases the control pressure the sensor plate will travel further downward per given air volume thus increasing the amount of fuel injected to the engine rich mixture Increasing the control pressure will reduc...

Страница 96: ...below 35 C 95 F and during the cranking process The cold start valve 1 is of the solenoid operated type The winding of an electro magnet is fitted inside the valve In the off position the move able armature of the electromagnet is forced against a seal by means of a spring When the magnet is energised the armature is pulled away from the seat and fuel is allowed to flow through the valve A special...

Страница 97: ...nd injecting additional fuel to the engine while it is being cranked During cranking voltage is also applied to the heating element in the thermo time switch The heating element will warm the bimetal arm and open the contact points to prevent excessive cold start injection flooding The length of time that it takes the heating element to open the contact points is dependent on the engine coolant te...

Страница 98: ...r ature rather than ambient air temperature The regulator contains both a bimetal arm a which reacts to the engine temperature and an electrical heating element b As the bimetal arm bends the circuit pressure changes by opening or closing a passage c which allows fuel to return to the tank On a cold engine the bimetal arm will open the passage allowing more fuel to return to the tank lowering the ...

Страница 99: ...m separating these two chambers then deflects downwards opening the pressure regulator momentarily This results in a very short Low Control To Fuel Pressure Tank Vent A Acceleration Fig 13 fy y enrichment spike in the air fuel mixture Fig 12 13 The vacuum delay valve 1 located in the hose connected to outlet b provides a 10 second delay during acceleration After 10 seconds the pressures above and ...

Страница 100: ...e Lorean since an electronic idle speed control system is used The air adjusting screw 1 should be fully seated to eliminate any air bypass at the throttle plates The idle speed regulator 5 allows the proper amount of air to bypass the closed throttle plates during an idle condition The CO adjusting screw 4 is used to control the amount of injected fuel in relation to the position of the air senso...

Страница 101: ...event vapour from forming in the lines and ensure instant re starting When the fuel pump stops a check valve 1 and two seals 2 Et 3 close sealing off the fuel return lines to the tank The accumulator will then maintain pressure in the system to prevent vaporisation In addition to the check valves and seals it is important that the control plunger b returns to the closed position all injectors a cl...

Страница 102: ... Current from No 7 fuse is then supplied to the fuel pump and control pressure regulator The RPM relay remains closed as long as the ignition switch is on and the engine is running If the pulses from terminal No 1 of the ignition coil stop because the engine has stopped turning the RPM relay opens about one second after the last pulse is received This safety circuit prevents the fuel pump from pum...

Страница 103: ...The largest problem affecting the operation of fuel injection components is dirt and moisture contamination Therefore precautions should be taken when working on the system to avoid contamination 3 When replacing fuel lines or components use only approved replacement parts that were designed for this system Due to the high fuel pressures used in this system do not attempt to splice fuel hoses 4 Af...

Страница 104: ... enrichment thermal vacuum control valve a Fully closed at temperatures above 53 C 127 F b Must start to open at 48 C 118 F when temperature is decreasing fS NOTE 1 Bar 14 5 PSI Fig 17 Control Pressure WARM Regulator temp above 40 C a Test with intake manifold vacuum hoses disconnected from control pressure regulator 3 4 3 8 Bar b Connect vacuum pump to vacuum port on control pressure regulator wh...

Страница 105: ...unning To by pass the RPM relay remove relay and connect a jumper wire between terminals No 87 and No 30 in the connector The RPM relay is located in the relay compartment behind the passenger seat See Electrical System and Instruments Section M Caution When connecting or disconnecting the test gauge rest pressure will be present in the fuel system Fuel fittings should be loosened slowly to avoid ...

Страница 106: ...Fuel Emission and Exhaust System D 03 01 SPECIAL TOOLS J 28876 INJECTOR VALVE TESTER J 28872 PRESSURE GAUGE J 28873 HOSE CONNECTOR rr J 28875 FUEL METERING TUBES J 28874 ADAPTOR NIPPLE ...

Страница 107: ... electrical connection to the oxygen lambda sensor 4 Ensure that the idle speed screw 1 common to both banks is fully closed Note DO NOT adjust the two individual bank by pass screws as they are set at the engine manufacture plant 5 Ensure that the air conditioning system is switched off 6 Fit a link wire to the cooling fan switch to ensure the cooling fans are on continuously 7 Stan the engine an...

Страница 108: ...nection to the oxygen sensor 19 Using the idle speed screw common to both banks adjust the idle speed to 775 50 RPM This will normally require the screw to be fully closed 20 Switch off the engine 21 Insert the tamper proof plug in the mixture hole in the metering unit and drive home 22 Remove exhaust sampling probes from the down pipe and insert the blanking plugs Note Section 203 of the Clean Ai...

Страница 109: ...no longer provide a press fit EMISSION SETTINGS AT HIGH ALTITUDE To ensure compliance with the Emission Regulations at high altitude and maintain optimum fuel economy and driveability requires adjustment to engine settings Full technical details on emission settings and tamperproofing are contained in Service Bulletins 30 and 40 It is the responsibility of the DMC dealer to ensure that each new ve...

Страница 110: ...talytic converter is capable of reducing the noxious emissions of carbon monoxide CO hydrocarbons CH and nitrogen oxides NOx A requirement for this action however is that the air fuel ratio must be controlled to a high degree of accuracy so that the engine will operate within an ideal air fuel mixture range LAMBDA CONTROL PRINCIPLE The control principle employed is based on the fact that the Lambd...

Страница 111: ...ures the exhaust gas it produces an electrical signal which informs the Lambda ECU module if the engine is running richer or leaner than the ideal air fuel mixture ratio The sensor is mounted in the exhaust pipe in a position where it will monitor the exhaust gas from both cylinder banks before it enters the catalytic converter Fig 22 OXYGEN SENSOR Fig 22 imi ...

Страница 112: ...OT USED _ V y R From Starter Circuit i HOT during cranking only W From Main Relay HOT when ignition fsj0 i switch is in Run or Start position F U S E From Main Feed Wire N Hot at all times i s No 7 FUSE G 15i oo N RPM 30 RELAY 87 o WP 87b YRI r X i To Lambda 31bl 131 R e l a v A From Coil I Terminal No 1 WP FUEL PUMP M BP lYR THERMO TIME SWITCH L4i Hot INERTIA SWITCH CONTROL I PRESSURE o REGULATOR...

Страница 113: ...el Mixture IFig 24 FREQUENCY V A L V E The frequency valve regulates the pressure in tne lower chambers of the fuel distributor This regulation will affect the normal operation of the fuel distributor The frequency valve is an electrically operated valve Fig 25 It is mounted on the right valve cover and is connected to the lower chambers primary pressure of the fuel distributor and the return line...

Страница 114: ...ed to the engine enrichening the mixture When the frequency valve closes the pressure in the lower chambers will return to normal and the diaphragm will return to its original position Fig 26 27 The frequency valve operates at 70 cycles per second The length of time the valve is held open during each cycle depends on the pulse ratio supplied by the Lambda ECU module The pulse ratio is the frequenc...

Страница 115: ...the exhaust gases reflect a lean condition the oxygen sensor will signal the ECU module to change to a pulse ratio that will allow the frequency valve to remain open for a longer period Therefore an increased amount of fuel is fed from the lower chambers This reduction of pressure in the lower chambers causes the diaphragm in the fuel distributor to deflect injecting more fue v o the engine the fu...

Страница 116: ...eds a minimum operating temperature to deliver a signal approximately 300 C In order to achieve driveability from start the ECU module sets the frequency valve on a fixed pulse ratio until the sensor warms up This is also the case if the sensor fails at any time during operation The fixed ratio will provide a richer fuel mixture than normal The pulse ratio is controlled at another fixed value when...

Страница 117: ...r Fuel Emission and Exhaust System D 04 11 f r Coolant Distribution I Pipe LAMBDATHERMALSWITCH Fig 31 ifold FULL THROTTLE MICRO SWITCH Fig 32 P 1 Jr ...

Страница 118: ...rom RPM Relay Terminal No 87b VJ HOT only when engine is rotating From Main Feed Wire HOT at all times No 7 Fuse N Diagnostic Plug o 17 NI30 Fig 33 i 87 GY rn i 87b i IRP 186 85i Y R f RN 1 ECU Module 2 Lambda Relay LG O 1 6 RN 15 3 12 GY O LG 0 H 3 Frequency Valve 4 Oxygen Sensor U rr r FT a 7 a 5 4 2 e Shielded Cable 0 5 Full Throttle Enrichment Switch 6 Thermal Switch ...

Страница 119: ...aust System D 04 13 rf H I rm Pvf9 Electronic Control Module Oxygen Sensor Air Metering Unit Fuel Fuel Distributor Return i A From Fuel Pump Frequency Valve Three Way Catalyst Clean Exhaust Gas F 0 34 LAMBDA CONTROL SYSTEM ...

Страница 120: ...when the coolant temperature is below 15 C 59 F These two switches override the oxygen sensor input to the ECU module allowing a fixed pulse cycle to be sent to the frequency valve Fig 33 SYSTEM REPAIR NOTES All of the Lambda system parts with the exception of the throttle microswitch are sealed units and cannot be adjusted or repaired Tampering with a sealed unit will automatically void the warra...

Страница 121: ...10 12 Nm 7 9 FT LB MIOBolt M12Bolt M14Bolt M12CapNut M14CapNut 13 15 Nm 9 11 FT LB 20 24 Nm 14 17 FT LB 15 20 Nm 11 14 FT LB 15 20 Nm 11 14 FT LB 25 30 Nm 18 22 FT LB 5 Pulse Ratios A Normal Operation Sensor connected and CO properly adjusted 35 45 reading pulsates B Oxygen sensor disconnected 40 50 steady reading C Oxygen sensor lead disconnected Ground lead 87 minimum steady reading D Oxygen sen...

Страница 122: ...tor contains a rotary valve which controls the air flow through a duct that by passes the throttle plates During engine warm up for example the engine speed is reduced due to friction The idle speed regulator will open allowing additional air flow to the engine increasing the RPM to specification Fig 35 SYSTEM OPERATION The idle speed regulator is constructed in a similar fashion to that of an ele...

Страница 123: ... 3 located in the coolant system distribution pipe will activate another circuit within the ECU module when the coolant temperature is below 15 C i59 R This circuit will provide a fast idle condition The ECU module receives an RPM signal from coil terminal No 1 When the engine idle speed is above or below specifications the ECU module activates the electric motor in the idle speed regulator 2 The ...

Страница 124: ...ACK LIGHT GREEN B S BLACK SLATE BR BLACK RED BK BLACK PINK Fig 39 From Main Relay Cj HOT when ignition switch in run or start position _ From coil terminal No 1 RPM pulse signal BS G fc BY BLG IDLE SPEED CONTROL CIRCUIT 1 ECU module 2 Idle Speed Regulator 3 Thermistor 4 Idle Speed Diode 5 Idle Speed Micro Switch ...

Страница 125: ...D 05 04 Fuel Emission and Exhaust System COMPONENT LOCATION IDLE SPEED CONTROL SYSTEM IDLE SPEED REGULATOR fJr T i ELECTRONIC CONTROL MODULE Fig 40 ...

Страница 126: ...pours are purged from the system and burned in the engine Fig 41 SYSTEM OPERATION The entire fuel system is sealed to prevent fuel vapour from escaping Gasoline vapour in the fuel tank is routed through the vapour separating hose 2 and the roll over valve 3 to a storage cannister in the rear of the car When the engine is not running fuel vapours will remain in the storage cannister In the event of...

Страница 127: ...so connected to the cold start valve air tube This allows any engine vapours to be drawn from the crankcase through the left valve cover to the cold start valve air tube An orifice in the air tube meters the amount of vacuum applied to the closed crankcase of the engine SYSTEM REPAIR NOTES 1 All connections must be tight and leak free for the evaporative control system to operate properly 2 Due to...

Страница 128: ...mage b An air leak in the engine crankcase will cause a lean running condition since the crankcase is connected to the intake manifold Possible air leaks could be the oil dip stick not installed completely oil filler cap not sealing properly or leaking engine gaskets The vapour cannister is not serviceable and must be replaced as a complete assembly The cannister is located inside the left rear bo...

Страница 129: ...x thermostat inside the air valve housing determines the position of a flap controlling the incoming air The flap is fully open to exhaust manifold heated air at temperatures below 15 C 59 F As ambient temperature increases the flap allows a mixture of hot and cold air to enter the engine until 25 C 77 F is reached At this time the flap is fully closed to hot air and fully open to the outside cold...

Страница 130: ...d vacuum from reaching the distributor advance Above 40 C the control valve is open allowing vacuum to pass to the solenoid valve B The electrically operated solenoid valve B is energised whenever the throttle plates are closed Energising the solenoid closes the vacuum passage to the distributor advance thus eliminating an over advanced condition during idle or deceleration Solenoid operation is c...

Страница 131: ...to the loss of air flow through the air flow sensor To eliminate this lean condition which causes high hydrocarbon emissions a by pass valve is located in each throttle plate The by pass valves open when the manifold vacuum is above the normal idling vacuum This allows enough air flow to by pass the throttle plates and permit continued fuel injection Fig 45 ENGINE Fig 45 AIR Bypass valve Throttle ...

Страница 132: ...g RH muffler support bracket to engine Withdraw rubber mounting off muffler pin and remove bracket Slide muffler pipe off catalyst pipe and remove muffler Raise rear of car and release four nuts and bolts securing heatshieid to muffler brackets and remove shield Loosen off catalyst muffler joint U clamp Before removing the two lower muffler mountings provide alternative support for the muffler to ...

Страница 133: ...e off catalyst pipe and remove muffler Remove bolts securing top muffler mounting bracket to engine Withdraw rubber mounting off mounting pin and remove bracket Raise rear of car and release four nuts and bolts securing heatshield to muffler brackets and remove shield Loosen off catalyst muffler joint U clamp Before removing the two lower muffler mountings provide alternative support for the muffl...

Страница 134: ... DESCRIPTION E 01 01 SPECIFICATIONS E 02 01 CLUTCH ASSEMBLY E 03 01 FLYWHEEL PILOT BEARING E 04 01 CLUTCH PEDAL E 05 01 BLEEDING FLUSHING E 06 01 MASTER CYLINDER E 07 01 SLAVE CYLINDER E 08 01 PIPING RESERVOIR E 09 01 ...

Страница 135: ...pressure causes the clutch fork to move the throw out bearing against the pressure plate As a diaphram spring is depressed pressure on the disc is released and the clutch disengages When the clutch pedal is released the procedure is reversed and the clutch engages The clutch controls consist of a mechanical pedal assembly and a hydraulic control system A clutch master cylinder connected to the ped...

Страница 136: ...utch Fluid Dot 4 Hydraulic Fluid to SAE J 1703 Torque Specifications Pressure Plate to Flywheel Bolts 20 NM 15 ft lb Flywheel to Crankshaft Bolts 55 60 NM 41 4 5 ft lb Note Flywheel Bolts must be renewed after each dismantling Apply Loctite 601 or equivalent on bolt threads Special Tools J28863 J23907 Clutch Alignment Arbor Pilot Bearing Puller ...

Страница 137: ...1 1 Dust Seal 2 Fork Clutch Release 3 Bearing Release 4 Bolt Pressure Plate 5 Lock Washer 6 Pressure Plate 7 Clutch Disc 8 Screw M9 x 100 9 Flywheel Wiring Gear 10 Ring Gear Flywheel 11 Pilot Bearing Crankshaft 12 Pin Dowel iwSS ...

Страница 138: ...cking runout or other defects Replace or repair as required 6 Slide clutch release fork from ball stud Remove fork and release bearing Fig 2 and Fig 3 7 Inspect condition of clutch shaft pilot bearing See pilot bearing section for replacement Fig 34 INSTALLATION 1 Clean pressure plate and flywheel They should be free of oil grease metal deposits or burned spots 2 Position clutch disc and pressure ...

Страница 139: ...ase Lubricate clutch fork pivot and clutch shaft splines with graphite grease 6 Install clutch fork and release bearing in the clutch housing 7 Install transmission as outlined in transmission section 8 Adjust shift linkage as outlined in transmission controls section f i r itin C 1 pfi l n s j ...

Страница 140: ... bolts and flywheel Installation 1 Reverse removal procedure Note Flywheel bolts must be replaced after each dismantling Apply Loctite 601 or equivalent on bolt threads 1 Disconnect negative battery cable and raise vehicle on hoist 2 Remove transmission as outlined in transmission section 3 Remove clutch as outlined in clutch section 4 Remove pilot bearing using tool J 23907 5 Apply Loctite 601 or...

Страница 141: ...essing in new INSTALLATION 1 Lubricate clutch pedal pivot bushes with grease 2 Smear clutch release shaft pivot pin with molybdenum based grease and lightly oil shaft retaining clips and felt washer 3 Position clutch pedal in pedal box with spacer washer if fitted between left hand stde of clutch pedal and pedal box 4 Push pedal shaft through spacer washer if fitted clutch pedal brake pedal accele...

Страница 142: ... 3 4 5 6 7 Felt Washer Retaining Clip Bush Shift Brkt Washer Spring Clu Ped Screw M6 x 20 Pedal Clutch Ret 8 9 10 11 12 13 14 Pad Brkt Clu Pedal Pivot Pin Pin Washer M8 Clevis Pin Clu M Cyl Clutch Rel Shaft Link Mech Clu and Brkt ...

Страница 143: ...stroke Release the pedal and allow it to return rapidly 6 Open bleedscrew and repeat operation 4 and 5 until all the air is evacuated 7 Remove bleed hose and top up reservoir to bring the level to within 10 mm 0 394 in of the bottom of the filler neck It is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic sy...

Страница 144: ...lly release crimps on metal retaining band securing dust cover Do not damage metal band as it must be reused 3 Pull back dust cover and remove circlip 4 Remove plunger assembly by shaking cylinder or by compressed air pressure 5 Lift leaf on spring retainer and separate spring assembly from plunger Fig 5 6 Compress spring to free valve stem from keyhole in spring retainer Remove spring and valve a...

Страница 145: ...d depress leaf of spring retainer to secure assembly 8 Lubricate plunger assembly and cylinder bore with clean brake fluid Insert plunger assembly into cylinder bore 9 Fit new dust cover on push rod Place push rod and retaining washer in master cylinder and install new circlip 10 Smear dust cover and plunger bore entrance with rubber grease supplied in service kit 11 Position dust cover over bore ...

Страница 146: ...tion occurs REMOVAL 1 Raiss vehicle on hoist 2 After engine exhaust has cooled disconnect clutch line from slave cylinder 3 Remove two 2 bolts securing slave cylinder to clutch housing 4 Remove slave cylinder Note Slave cylinder push rod does not have to be disconnected from clutch fork INSTALLATION 1 Reverse removal procedure 2 Bleed clutch See clutch bleeding section for procedure ...

Страница 147: ...s necessary to remove the vehicle body from the chassis See the Body section for removal and installation procedures CLUTCH RESERVOIR Removal 1 Remove left hand vertical access cover inside luggage compartment 2 Clamp reservoir hose and remove hose from master cylinder 3 From inside vehicle remove two 2 nuts securing reservoir 4 Remove reservoir from vehicle Installation 1 Reverse removal procedur...

Страница 148: ... f GENERAL DESCRIPTION F 01 01 SPECIFICATIONS SPECIAL TOOLS F 02 01 I ON CAR SERVICE F 03 01 r DIFFERENTIALOILSEAL F 04 01 REMOVAUINSTALLATION F 05 01 OVERHAULING F 06 01 CONTROLS DESCRIPTION AND OPERATION F 07 01 f ...

Страница 149: ...ube Fig 1 The power train consists of A Primary input shaft B Secondary output shaft C Six driving gears 0 Six driven gears E One reverse slider gear The selector control consists of A Four shift rods and shift forks B One pivoting interlock C One selector lever and shaft D One selector shaft arm All forward gear power flow is transferred via A Primary shaft input B The selected driving gear prima...

Страница 150: ...ctor shaft arm moves the interlock to the desired position and moves the appropriate shift rod in or out depending on the gear selected The shift fork attached to the shift rod moves the desired gear into the proper position while the synchroniser ring matches the speed of the two gears being coupled This shift sequence is repeated for all forward gears Reverse operation is the same with the excep...

Страница 151: ... 19 FT LB Flywheel protection shields to clutch housing 20 Newton Metres 14 FT LB Inner driveshaft to flange Shift cable mount brackets to rear cover 25 Newton Metres 18 FT LB Transmission drain and fill plugs 19 Newton Metres 13 FT LB Rear cover to case 20 Newton Metres 14 6 FT LB Half casing attaching bolts 8 mm diameter 30 NM 22 5 FT LB 10 mm diameter 45 55 NM 34 41 FT LB Clutch housing to case...

Страница 152: ...ug and allow oil to drain completely Fig 3 3 Install drain plug and tighten 4 Remove the fill plug located on the side of the transmission case Fig 3 5 Fill the transmission with lubricant until the level of the oil is at the bottom edge of the fill plug hole See specifications for proper specified lubricant 6 Install the fill plug and tighten Fig 4 I I I I _ _ i Fig 4 f 09 ...

Страница 153: ...ied sealer CAF 33 to the outer edge of the new lip seal and install the seal in the transmission using a suitable drift 5 Remove the driveshaft flange 6 a Right Seal Pry seal out of the transmission case using a suitable tool taking care not to damage case b Left Seal 1 Index mark the adjusting nut and transmission case for reinstallation Remove the differential adjusting nut lock plate Fig 6 2 Un...

Страница 154: ...usting nut into the case the exact number of turns noted on removal Align the index marks and install the adjusting nut lock plate and bolt 5 Align the retaining pin hole in the driveshaft flange with the retaining pin hole in the differential side gear shaft and position the flange accordingly Insert the retaining pin Connect the inner driveshaft to the driveshaft flange and torque bolts to speci...

Страница 155: ... the end cover 8 Disconnect the wires from the back up light switch 9 Disconnect the clutch hydraulic line plastic from the union leaving the steel line connected to the union and the clutch slave cylinder 10 Remove the flywheel protection shield from the clutch housing 11 Disconnect the plate securing the magnetic timing pick up on left side of the clutch housing 12 Remove the bolts securing the ...

Страница 156: ...fl jra I 1 i 5th PS I Fig 8 pp ...

Страница 157: ...ing attaching bolts and remove housing from the transmission case 3 Remove the 5th speed detent from end cover by removing the screw spring and detent ball 4 Remove the end cover attaching bolts 11 and remove end cover Fig 10 5 Select two 2 gears at the same time by moving any two 2 shift rods to lock transmission Fig 7 7 J Remove both shaft nuts and discard Remove both conical washers ...

Страница 158: ... the secondary shaft 10 Remove the pivoting interlock assembly 11 Remove three 3 bolts securing the roller bearing retaining plate and remove plate Fig 12 12 Remove the twenty 20 bolts securing the half casings and separate the cases by lifting up on the case half containing differential adjusting nut left hand case Fig 13 NOTE Do not use sharp metal tools to pry apart case halves 13 T I 9 7 5 4 1...

Страница 159: ... facing the rear cover end of the transmission and the 3mm washer placed between the flange and the case 12 Insert the secondary shaft assembly into the right hand half case NOTE When installing the secondary shaft align the notch in the double roller bearing with the pin in the case 13 Insert the primary shaft assembly into right hand half case taking care that the flange of the clutch shaft tube...

Страница 160: ...gned and install the pivoting interlock Fig 21 26 Clean the joint faces on the rear cover and transmission case Install the new gasket Fit the rear cover making sure that the selector finger enters the pivoting interlock Torque the rear cover bolts to specification 27 Insert the 5th speed detent ball and spring into the rear cover Coat the plug with specified sealer Perfect Seal in accordance with...

Страница 161: ...e primary shaft Remove the bearing from the primary shaft NOTE Do not drop the needle roller half bearings when performing the next operation 4 Remove the thrust washer and 4th speed driven gear Remove the 4th speed synchro ring Fig 22 NOTE Do not drop the three 3 balls and spring clips when performing the next operation 5 Mark the position of the 3rd 4th speed sliding gear with marking paint Fig ...

Страница 162: ... bearing lock ring 7 Install the bearing on the differential end of the primary shaft Fig 27 8 Install the oil seal on the clutch shaft end of the primary shaft 9 Fit the clutch shaft on the primary shaft and install the rollpin 10 Fit the clutch shaft tube onto the clutch shaft seat the tube on the shaft seal by tapping gently SECONDARY SHAFT DISASSEMBLY 1 Remove the double taper roller bearing f...

Страница 163: ...g and needle roller half bearings on secondary shaft NOTE The 2nd speed synchro ring is smaller than the 1st speed synchro ring 3 Heat the 1st 2nd speed synchro hub to 250 C 428 F on a hot plate 4 Install the synchro hub on the secondary shaft with the offset towards 2nd gear Press the synchro hub on until it touches the shoulder keeping the synchro ring aligned and the lugs below the level of the...

Страница 164: ... gear so that it covers the three 3 notches Install the 1st speed gear synchro ring and needle roller half bearings on the secondary shaft Fig 30 Fig 32 NOTE The 1st speed synchro ring is larger than the 2nd speed synchro 8 Install the double taper roller bearing on the secondary shaft with the shoulder on the bearing race facing the threaded end of the shaft Fig 32 l IN C 7 1 0 m Fig34 ...

Страница 165: ... shaft Fig 34 6 Remove the spider gears and concave washers 7 Remove the side gear and thrust washer 8 Remove the remaining carrier bearing Retain any shims that may be located between the bearing and the carrier Fig 35 9 Remove the bearing outer race from the right hand half case using Tool J23907 Fig 36 10 Remove the driveshaft flange seal from the right hand half casing 11 Remove the lockplate ...

Страница 166: ...e spider gear shaft and retaining pin 9 Press the carrier bearing onto the ring gear Fig 38 10 Lubricate the side gear and fit the gear into the ring gear 11 Install the ring gear on the case and torque tighten the bolts NOTE Use new self locking bolts on the ring gear 12 Install new O ring seals on the side gear shafts GEARSHIFT CONTROLS DISASSEMBLY NOTE Place the gearshift controls in the neutra...

Страница 167: ... 6 Depress the detent ball with a drift and insert the 3rd 4th shift rod into the case NOTE When installing the rollpins the gap in the pin must face towards the rear cover 7 Fit the 3rd 4th shift fork on the shift rod and insert the rollpin 8 Insert the 1st 2nd detent spring and ball into the half case NOTE When installing the rollpins the gap in the pin must face towards the rear cover 9 Fit the...

Страница 168: ...e selector shaft and insert the shaft into the rear cover spring and selector finger 4 Install the rollpins securing the selector finger to the shaft 5 Compress the spring using Tool J28869 and insert the two 2 half bushes in each end of the spring 6 Install the rear cover plug using specified sealer in accordance with its labelled precautions on the threads PFej IS31 ...

Страница 169: ...access to shift lever assembly Do not remove completely 2 With transmission in neutral and shift lever in 3rd 4th gate shift lever stop pin should be centred in cross gate guide plate notch NOTE Shift mechanism in transmission is spring loaded to return to 3rd 4th gate when shift lever is released Fig 41 ADJUSTING CABLE 1 Raise vehicle on hoist 2 Adjust shift cable to centre shrft lever stop pin l...

Страница 170: ...hift cable to shift lever clevis 4 Remove bolts securing shift lever assembly to chassis 5 Disconnect front gear change tube by lifting assembly out of chassis to gain access to securing pivot bolt 6 Remove shift lever assembly 7 Reverse above procedure for installation SHIFT CABLE REMOVAL AND INSTALLATION 1 Remove the gear shift knob 2 Remove two screws secuiing gear shift trim plate to console D...

Страница 171: ...NTS GENERAL DESCRIPTION G 01 01 SPECIFICATION G 02 01 SPECIAL TOOLS G 03 01 DIAGNOSIS G 04 01 MAINTENANCE ADJUSTMENT G 05 01 ON CAR SERVICE G 06 01 REMOVAL AND REFITTING G 07 01 COMPONENT REPAIR G 08 01 FINAL DRIVE G 09 01 r r r r ...

Страница 172: ...nverter is of welded construction and is serviced as an assembly The unit is made up of two vaned sections turbine and pump and a single stator mounted on a one way roller clutch Automatic clutch action and smooth coupling takes place when circulating fluid within the converter couples the two vaned sections together Increased torque is brought about by the stator redirecting the fluid flow and pr...

Страница 173: ...gear driven governor is a low output alternator that produces current which varies with output shaft speed and throttle position Current from the governor supplies information to the computer Depending on governor current and gear selector position the computer will activate or de activate one or both of the solenoid valves thus providing a gear ratio change at the proper speed The governor comput...

Страница 174: ...85 mm non adjustable Thrust Plate Thickness 8 5 mm BRAKE B 2 Steel Discs 4 Lined Discs 3 Clutch Pack Clearance 1 0 1 5 mm adjustable CLUTCH C 1 Steel Discs 5 Lined Discs 4 Clutch Pack Clearance 1 05 3 75 mm non adjustable CLUTCH C 2 Steel Discs 5 Lined Discs 4 Clutch Pack Clearance 1 0 2 0 mm adjustable Spacer Sleeve Dimension 43 3 mm FINAL DRIVE UNIT Ratio 3 44 1 Lubrication Capacity 3 6 pts 1 6 ...

Страница 175: ... 7 50 52 22 26 8 11 135 150 90 105 22 30 34 165 180 30 34 22 26 18 26 18 18 22 32 Notice The De Lorean contains many parts dimensioned in the metric system During any service procedure replacement fasteners must have the same measurements and strength as those fasteners removed either metric or customary The numbers on the heads of metric bolts and on the surface of metric nuts indicate their stre...

Страница 176: ... J 28864 Convenor Seal Installer J 28868 Final Drive Pinion Lock J 29351 C 1 Clutch Compressor J 28867 Automatic Transmission Tool Set includes J 28867 1 Dismantling Tool for C 2 B 1 Assemblies J 28867 2 C 1 and B 2 Piston Spring Compressing Tool J 28867 3 Transmission Operating Clearance Adjusting Tool J 28867 4 Output Shaft Planetary Carrier Oil Seal Inserting Tool J 28867 5 Bearing Pre load Che...

Страница 177: ... and perform fluid pressure check and adjustment see MAINTENANCE AND ADJUSTMENT section 7 Inspect the transmission fluid for evidence of gear fluid contamination burning or metallic particles 8 Check the microswitch for proper operation including inspection of the wiring for grounds and electrical continuity with a test light 9 Evaluate the results of the previous checks and adjustments Refer to t...

Страница 178: ...ne and run long enough to achieve operating temperature coolant fans begin to cycle A C off 3 Check the fluid level with the transmission selector in the PARK position and the engine running at idle The fluid level on the dipstick should be at the HOT 4 If additional fluid is required add sufficient fluid through the filler tube to bring the level to the proper mark on the dipstick Do not overfill...

Страница 179: ... AUTOMATIC NO DRIVE IN 2ND OR 3RD NO DRIVE IN 3RD NO ENG BRAKING IN FT NO DRIVE IN REVERSE NO DRIVE IN 1ST AUTO BUT DRIVE IN 1ST GEAR HOLD NO 1 ST AUTOMATIC NO 2ND AUTOMATIC NO 3RD AUTOMATIC NO 1ST GEAR HOLD NO 2ND GEAR HOLD REMAINS IN 1ST AUTO REMAINS IN 3RD SOME RATIOS UNOBTAIN ABLE AND SELECTOR LEVEL ABNORMAL PARK FACILITY NOT WORKING STARTER NOT WORKING SMOKE FROM EXHAUST CAUSES DUE TO TRANSMI...

Страница 180: ...ETTING VACUUM LEAKS GOVERNOR COMPUTER MICROSWITCH SOLENOID SHIFT VALVES VALVE BODY PRESSURE REGULATOR STARTER SWITCH FLUID PUMP FLUID PUMP SHAFT TURBINE SHAFT FINAL DRIVE CONVERTER DRIVING PLATE CONVERTER CLUTCH C1 CLUTCH C2 BRAKE 81 BRAKE B2 ROLLER CLUTCH MANUAL CONTROL VALVE CHARGING SYSTEM VOLTAGE VACUUM MODULATOR PICK UP SCREEN MULTIFUNCTION SWITCH 1 m m Adjustment on installed transmission Ov...

Страница 181: ... hoist CHANGING THE TRANSMISSION FLUID CAUTION The fluid should be drained while hot SPECIAL CARE should be exercised to prevent physical contact with transmission fluid when changing or checking as transmission fluid is scalding hot 80 C 176 F 1 Raise the vehicle on a hoist 2 Remove the drain plug from the transmission fluid pan and allow the fluid to drain thoroughly Fig 9 3 Install the drain pl...

Страница 182: ...With the engine turned off use a suitable weight to depress the accelerator pedal to the floor full throttle position Check to ensure full throttle at engine is achieved 3 Perform throttle cable adjustments if the throttle is not opening to the maximum before proceeding 4 Loosen the cable lock nut and adjust the cable sleeve stop G at the governor end to obtain clearance J between the quadrant arm...

Страница 183: ... the transmission sector lever in DRIVE and run the rear wheels until 2 500 RPM is reached with the transmission shifted into third gear 6 Read transmission fluid pressure the pressure should be 8 Bar 2 113 PSI 3 when the transmission fluid temperature is 80 C 176 F 7 Adjust the fluid pressure by unlocking the retaining clip and rotating the vacuum modulator in its housing Fig 14 VACUUM MODULATOR ...

Страница 184: ...rger pump gear must be fitted with the chamfered edge facing the pump housing 3 Fit the fluid pump drive in the center gear 4 Position and secure the fluid pump to the transmission case and torque the belts see torque specifications FLUID PAN AND OR GASKET Removal 1 Raise car on hoist 2 Remove the transmission fluid pan drain plug and drain the fluid CAUTION Special care should be exercised to pre...

Страница 185: ...ig 17 Fig 17 MANUAL CONTROL VALVE AND PARKING PAWL LINKAGE Notice On the solenoid with the dear insulation wires must be fitted on the side next to the manual control valves 2 Install the mounting plate and bolt 3 Fit a new 0 ring seal on the seal socket and install the socket in the transmission case 4 Connect the transmission wiring harness to the sealed socket 5 Clean the fluid pan and transmis...

Страница 186: ... gasket as previously described VACUUM MODULATOR Replacement 1 Raise the vehicle on a hoist 2 Disconnect the vacuum hose at the vacuum modulator 3 Remove the vacuum modulator hold down clamp and remove the modulator assembly 4 Remove the modulator retaining clip and unscrew the modulator from the Raptor housing 5 Reverse the above procedure for installation 6 Adjust the transmission fluid pressure...

Страница 187: ...ansmission fluid pan 12 Reverse the above procedures for installion Use new 0 ring seals and gaskets Torque tighten fastening bolts to the proper specifications see torque specifications 13 Fasten the wiring harness clear of the exhaust system using tie straps 14 Adjust the governor control cable see MAINTENANCE AND ADJUSTMENT section for procedure PARKING PAWL Replace 1 Raise vehicle on a hoist 2...

Страница 188: ...d the adjusting nut into the case THE EXACT NUMBER OF TURNS NOTED ON REMOVAL Align the index marks and install the adjusting nut lock plate Fig 23 4 Align the role pin hole in the driveshaft flange with the pin hole in differential side gear shaft and install the flange 5 Align the roll pin hole and insert the roll pin 6 Connect the inner driveshaft to t e driveshaft flange and torque bolts see to...

Страница 189: ...12 Disconnect the magnetic timing pick up and plate on the side of the converter housing 13 Disconnect the inner driveshaft from the drive shaft flanges 14 Remove the bolts securing the starter motor to the converter housing 15 Disconnect the transmission fluid cooler lines from the transmission 16 Loosen the engine mount bolts and jack the front of the engine up to gain access to the converter in...

Страница 190: ...eal in the housing with the lip on the seal facing the transmission Install the seal using Tool J28864 and a mallet Fig 27 5 Lubricate the seal with transmission fluid and install the torque converter Rotate the converter until it engages with the pump drive the turbine shaft and the stator support Notice Ensure that the converter is fully seated 6 Install the transmission as outlined in the TRANS...

Страница 191: ...SHAFT 4 Place the transmission in a vertical position resting on the converter housing 5 Remove the transmission fluid pan and gasket 6 Remove the bolts securing the multiple switch and remove the switch Fig 30 Fig 30 MULTIPLE SWITCH REMOVAL 7 Release the retaining lugs on the wire connector and disconnect the solenoid wiring harness from the socket Fig 31 Fig 31 SHIFT SOLENOIDS CONNECTOR 8 Remove...

Страница 192: ...ransmission 11 Remove the clutch C2 assembly by lifting off vertically Fig 34 Remove the needle roller bearing and washer from the top of clutch C1 Fig 35 Remove the clutch C1 assembly by lifting off vertically Remove turbine shaft from clutch C1 using a soft metal drift Fig 36 Fig 35 CLUTCH C 1 NEEDLE BEARING d1 3 Fig 36 CLUTCH C 1 AND TURBINE SHAFT REMOVAL Fig 37 BRAKE B 2 DISC PACK 13 Remove th...

Страница 193: ...ed in the final drive case therefore it is necessary to perform the following measurements on each unit to determine the amount of clearance that will exist when the two units are bolted together a Install the B2 disc pack on the planet wheel carrier as follows Fit the shim s that were removed a steel disc a lined disc a steel disc and so on Substitute the wave disc with a flat disc and fit on the...

Страница 194: ...tary gear carrier 2 Check and adjust the transmission end play When the transmission and final drive units are assembled together there must be a proper amount of end play clearance between the mechanical components within the transmission Incorrect clearance will result in premature failure It is necessary to perform the following measurements to determine the amount of clearance that will exist ...

Страница 195: ...Dimension B Calculate the end play clearance by subtracting dimension A Fig 41 from dimension B Fig 42 Example 74 10 mm 73 54 mm 0 56 mm Dimension B Dimension A End Play Clearance End play clearance should be between 0 37 0 74 mm 90 015 0 029 in If the clearance is not within specifications it will be necessary to increase or decrease the thickness of the shim s located between the transmission ca...

Страница 196: ...le maintaining alignment between the clutch C2 drum and brake B1 discs After the transmission case is fully seated install the case attaching bolts and torque tighten See specifications 11 Install the parking pawl link and fit the retaining clip 12 Fit a new 0 ring seal on the solenoid wiring socket and install the socket in the case until it is fully seated Connect the solenoid wiring harness to ...

Страница 197: ...scs 3 12 B2 Operating Clearance Adjusting Shims M pT I Manual control valve Pick up screen and gasket Valve body and gaskets Vacuum modulator Electric shift solenoids Fluid pump TRANSMISSION COMPONENT REPAIR BRAKE B2 Fig 43 1 Piston Support Outer Seal 2 Piston Support Disassembly 1 Remove the tension on the B 2 piston return springs using the special tool part of the A T Tool Kit Tighten the tool ...

Страница 198: ... that it is fully seated the 4 Lubricate the piston assembly with transmission fluid and install in the transmission case Notice Ensure that the three 3 lugs on the piston support mate with the large groove in the transmission case 5 Fit the piston return springs and spring retaining plate on the piston Tighten the spring compressor J 28867 2 until the tool contacts the face of the piston and inst...

Страница 199: ...ing with snap ring pliers and remove Fig 47 Fig 46 BRAKE B 1 DISC PACK 4 Remove the washer roller thrust bearing and adjustment shims from the hub in the bottom of the case Fig 47 TRANSMISSION CASE HUB SEAL 5 Compress the B1 piston return springs with the special tool J 28867 1 part of the A T Tool Kit and remove the lock ring securing the spring retaining plate Fig 48 6 Remove the special tool an...

Страница 200: ...ssion end play has been adjusted Part of the transmission reassembly procedure 8 Lubricate the needle thrust bearing with transmission fluid and fit the bearing on the hub with the needles facing upwards 9 Fit the washer on top of the needle bearing 10 Fit the wave disc on the B 1 piston Fig 45 11 Lubricate the new discs with transmission fluid and alternately install a steel disc a lined disc a s...

Страница 201: ...LER CLUTCH ASSEMBLY 4 Remove the upper thrust sleeve roller clutch and lower thrust sleeve from the outer hub Fig 53 Reassembly Clean and inspect roller clutch parts for any damage or scoring 1 Fit the lower thrust sleeve in the outer hub Fig 53 2 Lubricate the roller clutch with transmission fluid and install in the hub with the shoulder on the clutch to the outside of the outer hub Fig 53 3 Fit ...

Страница 202: ...STON REMOVAL CLUTCH C 1 Fig 55 1 Piston Seal Lip Type Outer 2 Piston Seal Square Section Inner 3 Piston 4 Return Springs 5 Spring Retainmg Plate 6 Lock Ring 7 Wave Disc 8 Steel Discs 5 9 Lined Discs 10 Input Gear Hub 11 Outer Hub 12 Inner Thrust Sleeve 13 Roller Clutch 14 Outer Thrust Sleeve 15 Needle Thrust Bearing 16 Clutch Housing 6 Remove the piston from the clutch housing Remove the inner and...

Страница 203: ...e piston return springs retaining plate and lock ring on the piston 5 Compress the retaining plate using the special tool and install the lock ring Make sure that the three 3 lugs on the retaining plate are holding the lock ring in position when the tool is removed Fig 56 6 Fit the wave disc on the piston 7 Lubricate the clutch discs with transmission fluid and alternately install a steel disc a l...

Страница 204: ...ings 5 Spring Retaining Plate 6 Lock Ring 7 Wave Disc 8 Steel Discs 5 9 Lined Discs 4 10 Distance Sleeve 11 Lock Ring 12 Ring Gear 13 Lock Ring Disassembly 1 Remove the lock ring and the ring gear from the clutch housing Fig 61 2 Remove the lock ring and distance sleeve Fig 62 A M t l LOCK J f RING Hg s t H SING GEAR 0 s x r 1 TvA 1 TV rl S xfe 3te S5 wy tfS 5s l y 7 Ts S S fc W j T j Fig 61 C 2 R...

Страница 205: ...for damage or scoring 1 Lubricate the new piston with transmission fluid and fit on the piston with the lip on the seal facing the bottom of the piston Fig 64 2 Check and ensure that the clutch depres surizing ball in the piston is clean and free to move in its seat 3 Lubricate the new clutch housing hub seal with transmission fluid and install on the hub with the lip facing the bottom of the hous...

Страница 206: ...nd lock ring on the piston 6 Compress the retaining plate using the special tool and install the lock ring Ensure that the lock ring is fully seated before removing the tool Fig 63 7 Fit the wave plate on the piston Fig 60 8 Lubricate the clutch discs with transmission fluid and alternately install a steel disc a lined disc a steel disc and so on 5 steel 4 lined 9 Fit the distance sleeve with the ...

Страница 207: ...in place Loosen the pinion gear nut Fig 68 2 BOLTS OUTSIDE HOUSING Fig 66 CONVERTER HOUSING ATTACHING BOLTS 8 f l i Fig 67 PLANETARY GEAR HOUSING 28868 PINION GEAR NUT Fig 68 PINION GEAR NUT REMOVAL 5 Remove the half casing assembly bolts With the final drive positioned as shown remove the upper half case Fig 69 Fig 69 HALF CASING BOLTS Notice gagf Do not use metal tools to pry apaf Jie case 6 Rem...

Страница 208: ...er Disassembly 1 Remove the carrier shaft locknut 2 Remove the roller bearing and output gear using a suitable puller Fig 71 3 Remove the spacer sleeve No 6 from the carrier shaft and separate the planetary carrier from the housing Fig 71 4 Remove the spacer No 10 and park sprocket No 11 from the carrier shaft Fig 71 5 Remove the needle bearing No 12 and washer No 13 from the carrier shaft Fig 71 ...

Страница 209: ...rger diameter facing the park sprocket Fig 71 6 Fit the parking pawl in the housing and install the pivot pin Attach the retracting spring to the pawl 7 Fit the bearing race planetary carrier clearance shims removed during disassembly and the bearing outer race in the housing Ensure that the race is fully seated Fig 72 8 Install the planetary gear carrier in the housing Notice Do not install the l...

Страница 210: ...ier shaft with thrust washer removed Fig 73 f Subtract the measurement from 120 mm 4 724 in to obtain dimension A Fig 73 13 Perform the planetary gear carrier bearing pre load adjustment as follows a Install the planetary carrier and gasket in the final drive case Torque tighten the bolts see torque specifications b Wrap a piece of string around the planetary gear carrier and pull with a spring sc...

Страница 211: ...n the lock nut Lock peen the nut to the shaft see torque specific ations Reassembly Notice The ring and pinion gears are not serviced separately If one part is damaged they must be replaced as a set 1 Press the inner pinion bearing onto the pinion gear shaft 2 Install the governor drive gear 3 Install the secondary gear with the flat face of the gear towards the head of the pinion gear 4 Install t...

Страница 212: ...er 3 Remove the ring gear and side gear from the carrier 4 Remove the lock pin from the spider gear shaft 5 Remove the spider gear shaft both spider gears and both concave washers 6 Remove the side gear and thrust washer from the carrier 7 Remove the carrier bearing using a press 8 Remove the lock plates securing the differential adjusting nuts to the final drive half cases Remove the adjusting nu...

Страница 213: ...MPONENT REPAIR section for adjustment procedures 14 f S9 13 Fig 79 HALF CASING BOLTS 5 Insert the spider gear shaft lock pin in the carrier hole to secure the shaft 6 Lubricate the side gear and position the gear in the carrier 7 Install the ring gear using new bolts and torque tighten the bolts see torque specifications 8 Install both carrier bearings using a press 9 Fit the 0 ring seals on both ...

Страница 214: ... with gear oil and fit the differential carrier assembly in the half cases d Assemble the half casings and torque tighten the case bolts in the proper sequence Fig 79 see torque specific ations e Tighten the differential carrier adjusting nut on the opposite side of the ring gear until all play is removed from the carrier bearings Use Tool J28866 to turn the adjusting nut Fig 78 Notice This proced...

Страница 215: ...new gasket and install the planetary gear carrier assembly in the case Torque tighten the mounting bolts see torque specifications 8 Perform the ring pinion gear backlash adjust ment as follows Notice When performing the following adjustment the differential adjusting nuts must be adjusted equally to maintain the proper carrier bearing pre load a Remove excessive backlash between the ring and pini...

Страница 216: ...Remove the stator shaft and gasket Fig 84 3 Remove the converter return safety valve ball spring and washer Fig 84 Notice If the check ball rolls into the fluid passage it can be recovered by removing the fluid cooler line fitting Reassembly 1 Fit a new seal on the return saferv val e 2 Fit the washer and spring into the converter housing 3 Position the check ball on the spring and install the val...

Страница 217: ...S H 02 01 1 STEERING WHEELPAD H 02 01 COLUMN TRIM CANOPY H 02 01 p STEERING COLUMN H 03 01 STEERING COLUMN IGNITION LOCK ASSEMBLY H 04 01 STEERING COLUMN UNIVERSAL JOINT H 05 01 RACK AND PINION ASSEMBLY H 06 01 RACK AND PINION TIE ROD BOOTS H 07 01 TIE ROD ENDS H 08 01 ...

Страница 218: ...aft fits through an opening in the driver s fctoAweU and is sealed with a gasket and plate The lower end of the steering column shaft is secured to the upper universal joint of the intermediate shaft The lower universal joint of the intermediate shaft is secured to the splined stub shaft of the steering gear The steering gear unit consists of a rack and pinion assembly tie rod assemblies and the r...

Страница 219: ...wheel puller tool remove steering wheel from column INSTALLATION 1 Position the front wheels in the straight ahead position 2 Position steering wheel in a centre position onto the steering column making sure that the steering wheel tabs on the hub of steering wheel mounting face engage the turn signal switch rotor Install steering wheel retaining nut and torque to specification 3 Reinstall steerin...

Страница 220: ...instrument cluster support bracket from cluster 7 Remove two 2 bolts securing steering column assembly to pedal box 8 Remove steering column assembly 9 Working on bench remove steering wheel trim pad and steering wheel assembly 10 Loosen multifunction switch assembly retaining band screw located on the underside of column and slide switch assembly off column 11 Remove both shear bolts securing ign...

Страница 221: ...driver s instrument column knee pads 9 Position and secure steering wheel to steering column and torque to specification Install steering wheel trim pad 10 With the steering column in the straight ahead position and front wheels pointing straight a d slide the upper universal joint onto the steering column assembly and secure the pinch bolt Torque to specification Fig 5 11 Tighten pinch bolt secur...

Страница 222: ...lumn s trim collar to upper trim collar Separate upper and lower trim collars and remove from car 5 Remove set screw securing ignition switch to ignition lock assembly and remove ignition switch from lock assembly 6 Using a pin punch remove both shear bolts securing ignition lock assembly and remove ignition lock assembly I N S T A L L A T I O N To complete installation reverse removal procedures ...

Страница 223: ...e both universal joint pinch bolts Torque to specification 3 Position and secure access cover and luggage compartment carpeting 4 Close luggage compartment hood COLUMN INTERMEDIATE SHAFT Removal 1 Raise luggage compartment hoods 2 Remove luggage compartment ca petincj Remove brake master cylinder reservoir access cover from luggage compartment floor and remove fuel filter neck access cover 3 Remov...

Страница 224: ...he rubber mount onto its proper position 3 Position the RH rubbef mourft onto the rack assembly and rotate the rubber mpunc into the proper position 4 Position lateral restraint bracket underneath the RH mounting making sure that the rack assembly collar is engaged between the two 2 tabs of the restraint bracket 5 Make sure both rubber mounts are positioned so that the rack assembly collar fits se...

Страница 225: ...icant to steering rack assembly via the left end before proceeding b If replacing both boots position and secure with new clamps one 1 boot invert the steering rack assembly and add Vi pint of specified lubricant via the left end Notice In order to properly add lubricant to rack and pinion assembly the rack and pinion assembly MUST BE removed and filled from LEFT side pinion end only 2 Position an...

Страница 226: ...mber it may be necessary to lift the front of the vehicle or load the luggage compartment to ensure that the chassis cross member rests on the block Ic Check toe in and adjust track d Ensure the steering wheel is in the dead ahead position Ensure all road dirt is removed from the threads of the track rod arms With the aid of suitable tracking equipment check wheel alignment ANGULAR WHEEL ALIGNMENT...

Страница 227: ...tower at the absorber s upper end and to the lower control arm at the absorber s lower end are positioned through the coil springs The single front spindle bearing supports the hub assembly on the spindle which is fastened to the steering knuckle The steering knuckle is secured to the upper and lower control arms with upper and lower ball joints and to the steering system with an adjustable tie ro...

Страница 228: ...iff Fig 2 0 ...

Страница 229: ...ssembly out of the way Caliper must not be suspended by brake hose Fig 3 6 Remove hub nut and D washer Fig 5 5 When working on left side remove speedometer drive cap from centre of hub Fig 4 7 Remove hub and brake disc assembly 8 Working on bench remove four 4 bolts securing brake disc to hub Fig 6 9 Remove snap ring retaining hub bearing to hub assembly INSTALLATION Reverse removal procedures sta...

Страница 230: ...ng bolts and position caliper assembly out of the way Caliper must not be suspended by brake hose Fig 7 5 When working on left side remove speedometer drive cap fronivcentre of hub Fig 8 8 Remove snap ring retaining hub bearing to hub assembly Remove hub bearing by pressing 9 Press new hub bearing into hub assembly Fig 9 10 Position and secure hub bearing snap ring INSTALLATION Reverse removal pro...

Страница 231: ...e 9 Remove brake disc spacer 10 With front suspension at full travel remove nut securing lower ball joint to steering knuckle and separate ball joint from steering knuckle 11 Remove nut securing upper ball joint to steering knuckle and separate ball joint from steering knuckle Remove steering knuckle assembly 12 Remove spindle retaining nut On left side nut is removed with speedometer 90 angle dri...

Страница 232: ...to steering knuckle and separate ball joint from steering knuckle 7 Remove hub and brake disc assembly 11 Remove nut securing upper ball joint to steering knuckle and se arate ball joint from steering knuckle Ren e steering knuckle assembly 12 Remove spindle retaining nut On left side nut is removed with speedometer 90 angle drive 13 Press spindle from steering knuckle 14 Remove four 4 bolts secur...

Страница 233: ...ed not to allow the steering knuckle assembly to pivot outward 4 Using nut cracker or splitter remove four 4 fasteners securing the upper ball joint to the upper control arm and remove ball joint Note Previously serviced ball joints will be secured with nuts and bolts INSTALLATION 1 Position and secure ball joint Install ball joint boot grease ball joint via its fitting and torque fasteners suppli...

Страница 234: ...er upper mounting nut and remove shock absorber 6 Place jack stands under lower control arm and lower car sufficient enough to compress coil spring using a suitable spring compressing tool Raise car and remove spring 7 Remove lower control arm pivot bolt and remove control arm from car 8 Working on bench remove the lower ball joint protective boot and remove lower ball joint retaining snap ring 9 ...

Страница 235: ...ontrol arm assembly from car 4 With upper control arm assembly removed from car and using an arbor press press the control arm bushings from control arm Fig 14 5 Press new control arm bushings into control arm 6 If control arm is being replaced a new upper service ball joint must be installed into the upper control arm By positioning and securing service replacement ball joint install ball joint b...

Страница 236: ...ar on hoist Note Step 3 is required if bar is being replaced 3 Remove nut securing stabilizer bar to lower control arm assembly Repeat on other side and remove stabilizer bar 4 Using a brass drift drive out stabilizer bushings in the lower control arm INSTALLATION To complete installation reverse removal procedure and torque fasteners to specifications ...

Страница 237: ...d remove shock absorber from car 8 Place jack stand under lower control arm and lower car sufficient enough to compress coil spring Compress spring using the service tool raise car and remove spring from car CAUTION Compressed coil springs are considered very dangerous Extreme care should be exercised to prevent personal injury 9 Remove lower control arm pivot bolt nut and remove bolt Remove lower...

Страница 238: ...y side load which may be on the through bolt 3 Remove shock absorber upper mounting nut and remove shock absorber through the bottom of lower control arm Fig 17 Note The location and placement of the upper shock absorber mounting bushes and caps should be noted prior to removal to ensure proper placement upon reassembly INSTALLATION To complete installation reverse removal procedure Torque fastene...

Страница 239: ...ock absorber upper mounting nut and remove shock absorber through the bottom of the control arm Note The location and the placement of the upper shock absorber mounting bushes and cups should be noted prior to removal to assure proper placement upon reassembly Note Compressing the coil spring by lowering the car on the hoist may assist in removing the shock absorber by gaining additional coil spri...

Страница 240: ...Upper control arm pivot bolt nut Lower control arm pivot bolt nut Shock absorber upper Shock absorber lower Stabilizer bar at lower control arm Stabilizer bar pivot on chassis Brake hose attaching screw Upper ball joint to steering knuckle Lower ball joint to steering knuckle Nm Torque 75 28 28 220 190 80 80 28 80 75 36 16 60 60 Ft lb Torque 55 20 20 165 145 60 60 20 60 55 26 12 45 45 T ...

Страница 241: ...01 01 UPPER LINK BUSHINGS K 02 01 LOWER L NK BUSHINGS K 03 01 HUB CARRIER K 04 01 TRAILING ARM K 05 01 TRAILING ARM BUSHINGS K 06 01 SHOCK ABSORBER COIL SPRING K 07 01 TOE IN ALIGNMENT ADJUSTMENT K 08 01 TORQUE SPECIFICATIONS K 09 01 ...

Страница 242: ...elescopic shock absorbers secured to the chassis frame at the absorbers upper end and to the rear hub carrier and the absorbers lower end are positioned through the coil springs The rear hub carrier is attached to the chassis frame with upper and lower links as well as the radius arm Rear suspension toe in is achieved by shimming the radius arm at its frame attaching location ...

Страница 243: ...K 01 02 Rear Suspension r r r ...

Страница 244: ... Remove upper link to hub carrier pivot bolt 4 Remove upper link inner pivot bolt at chassis frame Fig 3 5 Check the condition of the rubber bushings and replace if necessary by pressing them out Note Service replacement upper links are supplied with new bushings installed INSTALLATION 1 To install reverse the removal procedures and torque fasteners to specifications Notice Fasteners must be torqu...

Страница 245: ...nk pivot bolt 4 Remove the lower link to chassis frame pivot bolt and nut and remove lower link Fig 4 5 Check the condition of the rubber bushings and replace if necessary by pressing them out Note Service replacement lower links are supplied with new bushings installed INSTALLATION 1 To install reverse the removal procedures and torque fasteners to proper specifications Notice Fasteners must be t...

Страница 246: ...g 5 11 Remove two 2 nuts and bolts securing trailing arm to hub carrier and disconnect trailing arm from hub carrier Fig 6 10 Remove hub nut and pull off brake disc and hub assembly 12 Support the trailing arm to avoid straining the brake hose or pivot bushing 13 Remove nuts from both upper and lower hub carrier pivot bolts Remove bolt securing park brake cable to hub carrier 14 Support the hub ca...

Страница 247: ...sembly to hub carrier Remove caliper assembly Fig 7 7 Remove brake disc 8 Remove two 2 nuts and bolts securing trailing arm to hub carrier and disconnect trailing arm from hub carrier INSTALLATION 1 To complete installation reverse the removal procedure torque fasteners to specification Notice Fasteners must be torqued with car resting on its suspension 2 Bleed brake system 9 Remove trailing arm p...

Страница 248: ...K 05 02 Rear Suspension Fig 8 ...

Страница 249: ...emove trailing arm pivot bolt and nut Position trailing arm out of the way to gain access to bushing retaining plate 4 Fit new bushing Reverse removal procedures and torque fasteners Note Quantity of removed shim washers should be noted and replaced upon installation 5 Check rear suspension for specified tow in alignment and adjust if necessary ...

Страница 250: ...e car 8 Remove shock absorber from rear spring 9 Carefully remove spring compression tool from rear spring 3 Place jack under rear hub carrier to remove pressure from rear spring 4 Compress rear spring using a suitable compression tool 5 Remove lower mounting nylon nut and washers 6 Remove upper mounting nut and washers Note Coil spring can be dangerous A spring compression tool must be used at al...

Страница 251: ...y to lift the rear of the vehicle or load the vehicle to obtain the specified setting height 6 Proceed with wheel alignment per the directions of the manufacturer of the alignment equipment used Note Where equipment directions indicate to jounce the suspension substitute with check and ensure specified setting height is maintained ALIGNMENT SPECIFICATIONS REAR Toe In 3 mm 0 12 inch per whee CAMBER...

Страница 252: ...ufacturers of alignment equipment used 11 Torque trailing arm pivot bolt A Fig 10 to 75 Nm 55 ft lbs FIGURE CONVERSION TABLE FRACTIONAL INCHES DECIMAL DEGREES 12 Check adjustment h 06 V 13 A 19 i 26 h 32 38 A 45 i 51 58 A 64 H 70 i 77 H 83 90 H 96 i 1 02 ...

Страница 253: ...th ends Upper link both ends Trailing arm hub to carrier Outer drive shaft to hub Trailing arm to pivot bush Shaft to inner and outer drive shafts Parking brake cable bracket to hub carrier Caliper hub carrier Flex brake pipe attachment Wheels M8 x Vi x y2 x M12 x M22 x M12 x M10 x M6 x TV r M12 x 13 19 19 19 32 19 17 10 16 15 19 22 80 80 75 370 75 40 7 55 16 80 16 60 60 55 270 55 30 5 5 40 12 60 ...

Страница 254: ... BRAKE PADS L03 01 FRONT BRAKE CALIPER L 04 01 REAR BRAKE PADS L 05 01 REAR BRAKE CALIPER L 06 01 BRAKESERVO L 07 01 AIR NOISE FILTERS L 08 01 BRAKE MASTER CYLINDER FLUID RESERVOIR L 09 01 BRAKE PEDAL L 10 01 BRAKE BLEEDING PROCEDURE L 11 01 WHEELS AND TYRES L 12 01 ...

Страница 255: ...linder consists of two 2 independent cylinders in a single casting Should one cylinder or system fail the other system will remain operational Each hydraulic system front and rear has a separate brake fluid supply well in the brake fluid reservoir which is mounted to the top of the master cylinder The brake fluid reservoir is equipped with a float actuated low fluid warning indicator However this ...

Страница 256: ... Fig 1 ...

Страница 257: ... Braking Area Rear Disc Diameter Front Disc Diameter Rear Hand Brake Brake Fluid Specification Power Assistance Discs Front and Rear 2 2 to 1 190 mm 7Vi 1800 Sq Cms 279 Sq Ins 1690 Sq Cms 262 Sq Ins 254 mm 10 276 mm 10ft Mechanical Self Adjusting Acting on Both Rear Discs D O T 4 SAE J1703 Hydraulic Fluid J1 t i ...

Страница 258: ...ips If worn or corroded install new clips on re assembly Fig 3 5 Remove the disc pads from the caliper assembly Inspect piston dust covers for damage deterioration or leakage Replace as required INSTALLATION 1 2 3 4 6 Remove protective cap on brake fluid reservoir and place a clean shop towel over the opening to catch any displaced brake fluid Evenly press each piston back into its bore Clean pad ...

Страница 259: ...ding is generally unnecessary but check the brake fluid reservoir for the proper fluid level MAX mark on reservoir and top up with fresh brake fluid as required Install tyre and wheel assemblies and torque to specification Lower car on hoist ...

Страница 260: ...ing and remove piston dust covers Fig 6 3 Pack a clean piece of shop towel between the pistons and then drive them from the cylinder bores by applying clean compressed shop air to the inlet connection CAUTION Care should be exercised that fingers are kept well clear from the gap area and eye protection should also be worn as there may be fluid spray 4 Remove piston sealing ring from bore NOTICE Ca...

Страница 261: ...3 Insert the piston into cylinder bore and install the dust covers and retaining rings Make certain dust covers are correctly installed INSTALLATION 1 Position the caliper to the hub assembly ensuring shims originally removed between the mounting faces are correctly positioned Torque to specification 2 Replace pads retaining pins and retaining pin clips 3 Reconnect brake pipe and bleed system 4 In...

Страница 262: ...clips on reassembly 4 Remove disc pads and damping shims from caliper assemblies 5 Inspect piston dust covers for damage or deterioration Replace as required INSTALLATION 1 2 3 4 5 6 7 8 10 11 Remove brake fluid reservoir cap and place a clean shop towel in opening to catch any displaced fluid Remove protective cap on bleed screw and open bleed screw one full turn to prevent fluid pressure from bu...

Страница 263: ...d brake system UNIT DISASSEMBLY 1 Remove brake caliper assembly as previously described 2 Remove caliper piston dust covers retaining ring and remove piston dust covers 3 Pack a clean piece of shop towel between the pistons and then drive them from cylinder bores by applying clean compressed shop air to brake line inlet connection CAUTION Care should be exercised that fingers are kept well clear f...

Страница 264: ...d pistons carefully for signs of damage abrasion scuffing or corrosion 3 New pistons may be installed However if cylinder bore is damaged replace caliper UNIT REASSEMBLY 1 Lubricate cylinder bore and new sealing ring with fresh clean brake fluid and install sealing ring into groove in bore NOTE For ease of assembly keep dust cover dry and do not lubricate 2 Insert piston into cylinder bore and pos...

Страница 265: ...reather groove in servo flange is clear 4 Position the master cylinder to brake servo and secure with two 2 nuts and washers Torque to specification 5 Check vacuum pipe to valve on brake servo Secure with clamp 6 Position and secure the fuel filler neck and master cylinder access covers 7 Working inside car connect fork on input rod to pedal relay lever by inserting the grease smeared clevis pin a...

Страница 266: ...r retainer and dust cover NOTE If the dust cover is damaged replace as necessary SEAL AND PLATE ASSEMBLY REMOVAL 1 2 Remove the power brake unit as previously described Remove the seal and plate assembly from the front shell recess by gripping the centre rib and pulling off INSTALLATION 1 Wipe clean the output rod and recess wall Lubricate the new seal and plate assembly 2 Wipe clean the front mat...

Страница 267: ...w the cap onto the reservoir 3 Locate the master cylinder on the studs of the brake servo unit 4 Install the two 2 locking washers and nuts and torque to specification 5 Remove covers plugs and connect brake lines to master cylinder 6 Torque the brake line nuts to specification 7 Connect electrical connection to the cap on the master cylinder 8 Position and secure the access cover from inside the ...

Страница 268: ...e the brake pedal 4 The pedal pivot bushes may be replaced by knocking out the old bushes and pressing in the new INSTALLATION 1 Lubricate the brake pedal pivot bushes with SMP white lithium based grease 2 Smear the relay link clevis pin with a molybdenum based grease and lightly oil the shaft retaining clip and felt washer 3 Position the brake pedal in the pedal box and push the pedal shaft throu...

Страница 269: ...er 3 Position the relay levers in the pedal box with the spacer washer if fitted between the left 7 side of the clutch relay lever and the pedal box and the springs in their locations Push the relay shaft through the spacer washer clutch relay lever brake relay lever felt washer plain washer and into the D shaped hole in the pedal box Retain with spring clip Connect the relay links to the relay le...

Страница 270: ...lt washer 3 Position the relay lever in the pedal box with its return spring in position and the felt and plain washer between the relay lever and right side of the pedal box 4 Push the relay shaft through the relay lever felt washer plain washer and into the D shaped hole in the pedal box Retain with spring clip 5 Connect the relay link to the relay lever with the clevis pin and retain with its s...

Страница 271: ...he brakes several times 3 Raise car on hoist When bleeding all four wheels the following sequence MUST be followed A RIGHT REAR B LEFT REAR C RIGHT FRONT D LEFT FRONT 4 Install a box end wrench over the caliper bleeder screw and install a transparent drain hose over the bleeder screw The drain hose should then be placed into the receiving container with the other end immersed in brake fluid 5 Repe...

Страница 272: ...Brakes Wheels and Tyres kMM m Fig 13 ...

Страница 273: ...ly the wheel should be washed with warm water and detergent TYRES The tyres are TYRE SIZES Front Rear Spare steel belted tubeless radials TYRE PRESSURES for normal driving Front Rear Spare Normal 23LBF IN2 30LBF IN2 60LBF IN2 195 60HR14 235 60 HR 15 T125 70 D15 and high speed High Speed 29LBF IN2 34LBFIN2 GENERAL INFORMATION 1 Wheel nuts should be torqued to 100Nm 70 LB FT The wheel nuts should be...

Страница 274: ...LTERNATOR M 05 01 I BATTERY M 06 01 IP FUSES AND FUSE BOX M 07 01 P HORNS M 08 01 m WINDSHIELD WASHERS M 09 01 INSTRUMENT CLUSTER WARNING LIGHT r IDENTIFICATION M 10 01 LIGHTING SYSTEM M 11 01 IGNITION SWITCH M 12 01 HAZARD WARNING LIGHT SWITCH M 13 01 DOOR LIGHT SWITCH M 14 01 ENGINE COOLING M 15 01 RADIO M 16 01 DOOR ELECTRICS M 17 01 ELECTRIC WIRING DIAGRAMS M 18 01 ...

Страница 275: ...e coil Ignition spark advance is achieved by mechanical advance and a vacuum diaphram unit The advance is mechanically controlled according to engine speed by governor weights inside the Distributor body and according to engine load by vacuum control acting directly on the base plate As vacuum advance does not operate at idling speed due to the butterfly plates being closed a correctly retarded sp...

Страница 276: ...n by spiral gears and allow for this when lowering also make sure Timing Adjustment Slot passes over the Fixing Stud Then refit the Mixture Regulator Gaskets must be renewed SETTING THE IGNITION TIMING Fig 4 There are two slots cut into the Crankshaft Pulley indicating No 1 and No 6 Cylinder T D C A Timing Plate 2 is provided on the Timing Cover indicating 0 to 20 advance The engine must be runnin...

Страница 277: ... coil In operation to provide increased coil voltage for starting the engine one half of the ballast resistor is by passed during the engine cranking process to reduce the circuit resistance The coil primary voltage and current will increase thus increasing secondary output voltage C H E C K I N G T H E T R A N S I S T O R I Z E D I G N I T I O N S Y S T E M Preliminary Checks 1 Disconnect plug le...

Страница 278: ... on the oscilloscope and this voltage cannot be altered Only the H T curve can be checked in the same way as for a conventional distributor The dwell angle cannot be read neither can it be adjusted SPECIFICATIONS Distributor Rotation Clockwise Firing Order 1 6 3 5 2 4 Resistor Value Ignition Timing Centrifugal Advance Vacuum Advance Induction Coil Resistance Trigger Stator air gap Coil Primary Win...

Страница 279: ...hicle 1 Remove the nut 1 and washer 2 which secures the Solenoid Terminal 2 Remove the nuts 3 and washers 4 which secures the Solenoid to the starter 3 Withdraw Solenoid 5 from Fixing Bracket 15 4 Remove the Bearing Bosch Cap 6 off the End Plate 9 5 Undo Screw 7 at the end of the Shaft with an impact driver in direction of rotation of the Armature 6 Remove the Long Bolts 8 7 Pull back End Plate 9 ...

Страница 280: ...M 02 02 A Electrical System and Instruments J y pt ...

Страница 281: ...that clearance A between the pinion and stop is 1 5 mm 059 Fig n Turn the fork eccentric pivot pin to adjust if necessary FAULT DIAGNOSIS STARTER NOT WORKING CHECK BATTERY VOLTAGE AND CONDITION OF TERMINALS AND POSTS VOLTAGE CORRECT VOLTAGE POOR TERMINALS AND POSTS CLEAN RECHARGE BATTERY CHECK CHARGING CIRCUIT CHECK IF SOLENOID ACTIVATED WHEN IGNITION SWITCH IS TURNED VOLTAGE AT SOLENOID EXC TERMI...

Страница 282: ... 2 116 1 814 About 15 5 Newtons 3 3 lbs 10 Fig 12 N WR I T WY r WR FROM BATTERY POSITIVE TERMINAL 1 IGNITION START SWITCH 2 STARTER INHIBIT RELAY 3 STARTER 4 NEUTRAL START SWITCH AUTO TRANSMISSION ONLY 1 CIRCUIT OPERATION On turning the ignition key 1 to the starting position current flows through the start inhibit relay 2 and on to ground via the transmission wiring harness completing the circuit...

Страница 283: ...ing Checking the development of centrifugal and vacuum curves Measuring engine R P M Wire Connections A Lambda Electronic Control Unit Orange Frequency Valve Monitor B Feed Wire Purple Battery Feed C T D C Pick Up on Cylinder Block D Earth Yellow wire 4 T D C Signal Pick Up 5 T D C Pick Up Screening 6 Feed WHITE GREY Terminal Allocation 1 T D C Signal Pick Up 2 Diagnostic Socket Earth ground Wire ...

Страница 284: ...t into Bracket NEW PICK UP Fig 16 The pick up 5 has three Lugs which set its position Bring the three Lugs into contact with the Flywheel 6 and tighten Screw 4 REUSING AN OLD PICK UP If the Lugs are worn push the pick up 5 in until it touches the Flywheel 6 Mark its position and withdraw it 1 mm A 040 A Tighten Screw i4 RE FIT ADJUSTING PICK UP The pick up 5 should be set 0 to 1 mm A 020 to 040 A ...

Страница 285: ...be connected to the battery and its negative terminal together with the battery negative terminal connected to earth DUCELLIER BUILT IN REGULATOR CHECKING OUTPUT Connect a voltmeter across the battery posts 1 Read off battery voltage 2 Start engine and accelerate until the voltmeter needle remains steady on the regulated voltage 3 The voltage should read between 13 5 volts and 15 0 volts Check out...

Страница 286: ...r M 04 02 Electrical System and Instruments fo m j pcsm iv V ...

Страница 287: ... S T A T O R 1 Remove the voltage regulator 1 2 Remove the diode carrier 5 3 Mark the relative positions of the slip ring end bracket 6 laminations of stator 7 and drive end bracket 8 4 Place an old fan belt around the pulley 9 and clamp the belt in vice jaws with the pulley as close to the vice as possible The friction and self wrapping action of the belt will provide adequate reaction to looseni...

Страница 288: ...f the belt will provide adequate reaction to loosening the pulley nut 10 5 Remove the assembly from the vice remove the nut spring washer 11 spacer 12 and pulley 9 6 Remove the spacer washer fan 13 washer key 14 and spacer 7 If the bearing remains on the spigot of the rotor assembly 16 use suitable puller for removal of bearing Fig 20 8 If the bearing is in the slip ring end bracket 6 fill the bea...

Страница 289: ...lip ring end bracket 6 and rotor assembly 16 Withdraw the stator 7 from the slip ring end bracket 6 9 With suitable levers remove rotor 16 from slip ring end bracket 6 Fig 19 10 Remove the three bolts 19 and washers securing the bearing retainer to the drive end bracket 8 and press out the bearing 20 REPLACING 1 Pack the new bearing with grease 2 Place the bearing 20 in the drive end bracket 8 wit...

Страница 290: ...ator connector to check If the warning light is illuminated while engine is running there is a charging fault which may be due to 1 Broken alternator belt 2 Broken charging wire 3 Alternator internal fault rotor stator diodes or brushes 4 Regulator fault MOTOROLA ALTERNATOR REMOVING 1 Disconnect battery 2 Disconnect wires to alternator 3 Remove the tension bolt 1 Note position of tensioning bracke...

Страница 291: ...TTING REMOVING THE DIODE CARRIER Fig 24 1 Remove screw 1 washer 2 and holding plastic cover 3 2 Unsolder six winding wires 3 Unsolder regulator feed wire 4 Remove two screws 4 washer 5 spacer 6 and holding bridge 7 to rear housing 5 Remove diode bridge 7 Note Never dismantle the diode bridge REMOVING THE BRUSH CARRIER Fig 24 1 Remove screws 8 and washers 9 from regulator 10 2 Disconnect wires from...

Страница 292: ... clamp the belt in vice jaws with the pulley 25 as close to the vice as possible The friction and self wrapping action of the belt will provide adequate reaction to loosening the pulley nut 23 4 Remove the assembly from the vice Remove the nut 23 washer 24 pulley 25 fan 26 washer 27 key 28 and spacer bush 29 5 Remove four through bolts 17 washers 18 attachment bracket 19 nut 31 washer 32 recessed ...

Страница 293: ...rk the relative position of rear housing 20 stator 21 and front housing 22 3 Place an old fan belt around the pulley 25 and clamp the belt in vice jaws with the pulley 25 as close to the vice as possible The friction and self wrapping action of the belt will provide adequate reaction to loosening the pulley nut 25 4 Remove the assembly from the vice Remove the nut 23 washer 24 pulley 25 fan 26 was...

Страница 294: ...ver battery positive terminal and remove bolt 5 and washer 6 Disconnect cable 7 6 Release battery retaining strap 8 7 Move battery 9 forward to gain access to battery negative terminal and remove plastic protective cover 10 bolt 11 and washer 12 Disconnect cable 13 8 Remove battery 9 REFITTING 1 Place battery 9 at front of battery compartment and connect negative cable black to battery negative te...

Страница 295: ...nd charging problems If new cables are needed sealed terminal cable replacements should be used to retain the reliability of the original maintenance free connection Torque studs to 5 10 lb ft 7 13 Nm With the correct cables property attached and with the battery properly mounted the Freedom Battery never needs any penocttc maintenance attention WARNING All lead acid batteries generate hydrogen ga...

Страница 296: ...vely hot over 125 F 52 C If spewing occurs or temperature exceeds 125 F the charging rate must be reduced or temporarily halted to permit cooling Battery temperature can be estimated by touching or feeling the battery case The battery is sufficiently charged when the green dot in the built in hydrometer is visible No further charging is required Shake or tilt the battery at hourly intervals during...

Страница 297: ...tery is OUT of the vehicle assemble adaptors Fig 30 and connect tester clamps to the adaptors Remove surface charge from all batteries that have just been on charge IF THE GREEN DOT IS VISIBLE This includes batteries in the vehicle having been charged by the vehicle generator Do not remove surface charge from batteries that have been in storage To remove surface charge apply a 300 ampere load acro...

Страница 298: ...ned on 6 Loose or poor battery cable to post connections previous improper charging of a rundown battery or loose hold downs 7 High resistance connections or defects in the cranking system J U M P STARTING IN CASE OF EMERGENCY WITH AUXILIARY BOOSTER BATTERY WARNING ON FREEDOM BATTERIES DO NOT JUMP START IF INDICATOR IS YELLOW Both booster and discharged battery should be treated carefully when usi...

Страница 299: ... care that the clamps from one cable do not inadvertently touch the clamp on the other cable Do not lean over the battery when making connections The ground connection must provide good electrical conductivity and current carrying capacity Avoid moving hot or electrical hazards such as fans manifolds and spark plug terminals 1 Personal injury caused by electrolyte squirting out the battery vent 2 ...

Страница 300: ...Use only the correct value fuse The circuit function of each fuse is indicated on the fuse box cover RELAY COMPARTMENT Fig 31 The relay compartment is situated inside the vehicle behind the passenger seat under the rear deck board To change a relay tilt the passenger seat forward unclip carpet around rear deck board and remove and replace relay affected A defective relay is indicated by the failur...

Страница 301: ...X23C83U43 C3H8C93 L153 JC4D1L10X16J C53L113L172 l c6Hi IT i J Fig 31 ...

Страница 302: ...nter Hazard warning switch horns and buzzer logic box Lambda relay lambda E C U frequency valve fuel pump and control pressure regulator R H tail lamp side lamps front parking lamp license plate lamp cigar lighter lamp instrument panel illumination lamps main light switch lamp and digital clock lamp Heated rear window and electrical mirrors A C mode switch and door lock warning lamp Radio clock ge...

Страница 303: ...and left hand side of the radiator support brackets the high tone horn on the left and low tone on the right If the horns 1 and 2 fail to operate first check the security of the horn terminal 3 and earth fixings 4 The horns are not adjustable and must be renewed if faulty ...

Страница 304: ... fit filler cap 1 REMOVING WINDSHIELD WASHER MOTOR Fig 33 Removing With windshield washer reservoir 8 removed as previously described Unscrew motor 6 from grommet in the reservoir 8 Refitting Screw motor 6 from grommet in reservoir 8 Install the washer reservoir motor assembly as previously described WINDSCREEN WIPER AND MOTOR The windscreen wiper motor and linkage are situated under the dash pane...

Страница 305: ... 1 drive arm Re fit A C U rigid duct L H S and retaining clamp Re fit L H S flexi ducting to A C U rigid duct and L H fascia vent REMOVING MECHANISM Remove wiper motor 1 from support bracket 6 mechanism refer to procedure removing motor Disconnect windshield washer tubing Remove cap 9 nut 10 washer 11 retaining wiper arm 12 Remove arms from spindles Remove seal 13 nut 14 from spindle on support br...

Страница 306: ... 45 and 60 cycles per minute WIPER DELAY CONTROL BOX REMOVING REFITTING Fig 35 Wiper control box is located under L H S of dash panel next to the door logic buzzer box Removing 1 Remove screws 8 and earth wire 9 2 Disconnect two harness plugs 5 3 Withdraw wiper delay control box 10 Refitting REVERSE REMOVAL PROCEDURE S T l ...

Страница 307: ... LIGHT IDENTIFICATION f unlEftOCD V tutt OKL AMBD BPAK 1 LAMBDA WARNING LIGHT 2 OIL PRESSURE WARNING LIGHT 3 IGNITION LIGHT 4 LOW FUEL WARNING LIGHT 5 HAND BRAKE WARNING LIGHT 6 DOOR OPEN WARNING LIGHT 7 SAFETY BELT 8 DIRECTION INDICATORS 9 MAIN BEAM 10 DIP BEAM Fig 36 ...

Страница 308: ...printed circuit 4 is not contaminated with greasy finger marks etc Release screw 5 securing trip re set knob 6 remove knob 6 and spacer sleeve 7 Remove six screws 8 securing front window 9 to instrument casing 10 Release three nuts 11 on rear of casing securing tachometer 12 Remove two screws 13 and rubber washers 14 on rear of casing 10 securing speedometer 15 and remove speedometer 15 Withdraw o...

Страница 309: ...st the position of the light projected by the lamp Note top screws give vertical adjustment Switch to main beam and proceed to similarly adjust REAR CLUSTER A N D BULBS REMOVING REFITTING Fig 39 Removing Withdraw six screws 1 from around light cluster 2 Withdraw light cluster and unplug from connector block 3 Slide printed circuit board 4 to disengage retaining tongue 5 on cluster and withdraw boa...

Страница 310: ...se bulb Refitting REVERSE REMOVAL PROCEDURE FRONT AND REAR SIDE MARKER LIGHT REMOVING REFITTING Fig 42 Removing Release two marker light retaining screws 1 Withdraw light 2 and pull out bulb holder 3 Refitting REVERSE REMOVAL PROCEDURE INTERIOR LIGHTS REMOVING REFITTING Fig 43 Removing Carefully lever light 1 from head lining Release spade terminal connectors 2 Lever off lens 3 Remove festoon bulb...

Страница 311: ...BOX LIGHT REMOVING REFITTING Fig 45 Removing Open the glovebox Locate light on right side of glove box From rightside under glovebox unplug electrical connectors 1 Unscrew bulb holder 2 Remove securing nut 3 Withdraw the lens 4 and washer 5 from inside glove box Unscrew bulb 6 from holder 2 Refitting REVERSE REMOVAL PROCEDURE LUGGAGE COMPARTMENT COVER LIGHT REMOVING REFITTING Fig 46 Removing Open ...

Страница 312: ...gine compartment lid Light is situated on right hand side of the inside of the back fascia panels Remove two screws 1 Remove lens 2 Remove bulb 3 Disconnect wiring connectors 4 Drill out two pop rivets securing light 6 Withdraw light 5 Refitting Locate lamp and secure with 2 pop rivets Reconnect wiring Re fit bulb Re fit lens and secure with two posi drive screws ...

Страница 313: ... 49 For removal of upper and lower shroud on column see IGNITION SWITCH REMOVAL Removing Disconnect the relevant block connectors 1 in the wiring loom under the dash Release cable ties as necessary Remove screws 2 screw 2 and washer 3 holding windshield wiper switch 4 to mounting bracket of signal headlamp flasher horn switch unit 5 Before removing signal headlamp flasher horn switch unit 5 remova...

Страница 314: ... control knobs 2 from fascia panel Remove screw under centre knob and lift out fascia panel and unplug warning lights Place hand behind centre console Disconnect harness plug 3 Push in retaining clips Withdraw switch 1 Press retaining lugs at rear of switch to release bulb holder 4 Pull out bulb 5 Refitting REVERSE REMOVAL PROCEDURE CENTRE CONSOLE MOUNTED SWITCHES ...

Страница 315: ...efitting REVERSE REMOVAL PROCEDURE FAN SPEED SWITCH REMOVING REFITTING Fig 51 Removing Locate switch 8 on centre console Pull off control knobs 2 Remove screw 3 and lift fascia panel 4 and unplug warning lights 5 Pull down switch shaft to release clip Pull out switch 8 Disconnect Refitting REVERSE REMOVAL PROCEDURE PANEL RHEOSTAT REMOVING REFITTING Fig 52 Removing Pull knob 1 off switch 2 Remove t...

Страница 316: ...m and Instruments M 13 03 POWER WINDOW OR DEFROST SWITCHES REMOVING REFITTING Fig 53 Removing Pull switches 1 from console tray Disconnect block connector 2 and remove switches 1 Refitting REVERSE THE REMOVAL PROCEDURE ...

Страница 317: ...e of the glove box Disconnect electrical connections 2 Refitting REVERSE REMOVAL PROCEDURE ENGINE COMPARTMENT SWITCH REMOVING REFITTING Fig 56 Removing Open engine louvre Open engine compartment lid Switch is located far L H S of engine compartment Disconnect electrical connectors 1 Compress retaining clips with fingers and lift switch 2 out of bracket 3 Refitting REVERSE REMOVAL PROCEDURE LUGGAGE...

Страница 318: ...h 1 forward of Luggage Compartment Cover release bracket 2 Disconnect electrical connectors 3 Remove two posidrive screws 4 and remove switch Refitting REVERSE REMOVAL PROCEDURE Note When refitting inertia switch make note of plunger position on switch It should be in the closed position STOP LIGHT SWITCH REMOVING REFITTING Fig 59 Removing Stop light switch is located on the RHS of pedal support b...

Страница 319: ...e one posidrive screw 3 Disconnect harness plug 4 Withdraw logic box Refitting REVERSE REMOVAL PROCEDURE WIPER DELAY CONTROL BOX REMOVING REFITTING Fig 60 SEE WIPER SECTION M 09 03 HANDBRAKE SWITCH REMOVING REFITTING Removing Remove carpet handbrake cover Slide rubber sheath from handbrake lever Apply handbrake Using a 90 angle posidrive screwdriver remove two posidrive securing screws Disconnect ...

Страница 320: ... switch 2 Remove spring clip 3 securing switch 2 in pipe 4 Remove switch 2 Remove and discard grommet 5 Refitting Fit new grommet 5 and refit spring clip 3 Reconnect wiring terminals 1 Top up cooling system to correct level with recommended mixture FUEL TANK SENDER UNIT REMOVAL REFITTING Fig 62 Removal Remove spare wheel from luggage compart ment Remove carpet Remove screws 1 holding panel 2 at re...

Страница 321: ...plug Refitting REVERSE REMOVAL PROCEDURE FRONT FASCIA SPEAKERS REMOVING REFITTING Fig 64 Removing Remove two securing nuts 1 Withdraw the speaker and rubber shroud 2 Disconnect snap connectors 3 Refitting Connect two snap connectors 3 Insert the speaker and shroud 2 Fit the two securing nuts 1 and tighten REAR RADIO SPEAKERS REMOVING REFITTING Fig 65 Removing Locate rear quarter trim panel Partial...

Страница 322: ...M 16 02 Electrical System and Instruments Disconnect electric connections 1 to speaker Loosen off jubilee clip 2 securing speaker to bracket 3 Remove speaker 4 Refitting REVERSE REMOVAL PROCEDURE F i i ...

Страница 323: ...ve two screws 6 holding switch to door Remove switch 5 Refitting REVERSE REMOVAL PROCEDURE WINDOW LIFT MOTOR REMOVING REFITTING Fig 67 Removing Remove window seal support bracket Remove two nuts 1 and washers 2 at top end of drive shaft Remove nut 4 securing drive shaft to bracket on door frame Remove two screws 5 and one screw 6 and nut 7 holding motor bracket 8 to door frame Remove three screws ...

Страница 324: ...vering with a screwdriver Pull out switch 2 and disconnect wiring harness connector 3 Refitting REVERSE REMOVAL PROCEDURE DOOR MIRROR REMOVING REFITTING Fig 69 Remove door trim panel 2 Remove three screws 1 holding mirror to exterior of door Disconnect electrical connection 3 Refitting REVERSE REMOVAL PROCEDURE f ...

Страница 325: ...CK GREEN PINK LIGHT GREEN BROWN ORANGE P PURPLE R RED S SLATE U BLUE W WHITE Y YELLOW STARTING CIRCUIT J FEED LIVE AT ALL TIMES FEED LIVE AT ALL TIMES FROM BATTERY POSITIVE TERMINAL 1 IGNITION START SWITCH 2 STARTER INHIBIT RELAY 3 STARTER MOTOR SOLENOID 4 NEUTRAL START SWITCH AUTO TRANSMISSION ONLY r ...

Страница 326: ...System and Instruments IGNITION SWITCH CIRCUIT FEED LIVE AT ALL TIMES PROM KEY BUZZER GROUNDED WHEN KEY IS FULLY INSERTED TO START INHI8IT RELAY FUSES 9 10 11 13 16 1 3 4 S 1 MAIN RELAY 2 ACCESSORY RELAY 3 IGNITION SWITCH ...

Страница 327: ...stem and Instruments M 18 03 p i COIL CIRCUIT f i UY FEED STARTER MOTOR SOLENOID LIVE WHEN STARTING PWq T WJ f T J w WY FEED MAIN RELAY LIVE WHEN IGNITION IS ON rM WS E C U MODULE 2 2 pF HP 1 COIL 2 IGNITION RESISTOR ...

Страница 328: ...IGNITION CIRCUIT FUSE N 1 X 0 y U y y tj u u i j SCREENED CABLE FEED MAIN RELAY LIVE WHEN IGNITION IS ON FEED STARTER MOTOR SOLENOIO LIVE WHEN STARTING FEED MAIN RELAY LIVE WHEN IGNITION IS ON WY 1 COIL 2 DISTRIBUTOR WS 3 ECU MOOULE 4 IGNITION RESISTOR f ...

Страница 329: ... M 18 05 DIRECTIONAL INDICATOR CIRCUIT ffiytxy J j f f S FEED MAIN RELAY LIVE WHEN IGNITION IS ON LGK TC R H DIRECTIONAL INDICATOR LIGHTS TO L H DIRECTIONAL INDICATOR LIGHTS LGN 1 DI DIP HORN PUSH SWITCH 2 HAZARD SWITCH 3 FLASHER UNIT ...

Страница 330: ...stem and Instruments HAZARD WARNING CIRCUIT PUSE N 6 PEED LIVE AT ALL TIMES LGN i l 4 I TOR H DIRECTIONAL INDICATOR LIGHTS TO L H DIRECTIONAL INDICATOR LIGHTS I LGN 1 DI DIP HORN PUSH SWITCH 2 HAZARD SWITCH 3 PLASHER UNIT f ...

Страница 331: ... 07 DUCELUER ALTERNATOR J IW I FUSE N 5 TO BATTERY POSITIVE TERMINAL VIA STATER SOLENOID FFED MAIN RELAY LIVE WHEN IGNITION IS ON FEED FROM IGNITION RELAY WHEN IGNITION IS ON N 1 STATOR 2 DIOOE CARRIER 3 ROTOR 4 VOLTAGE REGULATOR 5 WARNING LIGHT r ...

Страница 332: ...trical System and Instruments MOTOROLA ALTERNATOR TO BATTERY POSITIVE TERMINAL VIA STATER SOLENOID FEED MAIN RELAY LIVE WHEN IGNITION IS ON 1 STATOR 2 DIOOE CARRIER 3 ROTOR 4 VOLTAGE REGULATOR 5 WARNING LIGHT P Fj ...

Страница 333: ...Electrical System and Instruments M 18 09 HW IDLE SPEED CONTROL CIRCUIT r n r i FEED LIVE WHEN IGNITION IS ON FROM COIL TERMINAL BLG BLG 1 ECU MODULE 2 REGULATOR 3 THERMAL TRIP 4 DIOOE 5 MICRO SWITCH ...

Страница 334: ...IT FROM A C COMPRESSOR FUSE N 5 FEED LIVE AT ALL TIMES FEED MAIN RELAY LIVE WHEN IGNITION IS ON 8 G 3 0 BO 30 V NS s r 3G II 2 2 uF Y BG 80 1 COOLING FANS 2 FAN FAIL MODULE 3 FAN FAIL TELLTALE 4 THERMAL TRIP 5 FAN RELAY 6 DIODE 7 OTTERSTAT 8 A C DIODE 2 2 uF NO ...

Страница 335: ... and Instruments M HEADLAMP CIRCUIT p FEED LIVE AT ALL TIMES I J j r u w P uw 1 MAIN DIP BEAM HEADLIGHTS 2 MAIN BEAM HEADLIGHTS 3 DIP BEAM RELAY 4 MAIN BEAM RELAY 5 LIGHTING SWITCH 6 DIP SWITCH 7 MAiN DIP BEAM INDICATOR LIGHTS r ...

Страница 336: ...LIVE WHEN IGNITION IS ON FEEO LIVE AT ALL TIMES FUSE V F U S N o 1 2 N S 0 h PW lr 1 RH OOOR LIGHTS 2 LH DOOR LIGHTS 3 DOOR SWITCH DIODE A INTERIOR LIGHTS S INTERIOR LIGHT DIODE 6 DIOOE 7 WARNING LIGHT 8 DELAY UNIT 9 LH DOOR SWITCH 10 RH DOOR SWITCH ...

Страница 337: ...Electrical System and Instruments M j1 1 WINDSCREEN WIPER AND WASHER CIRCUIT FEED LIVE WHEN IGNITION IS ON fP fl y i J 1 WIPER MOTOR 2 WIPER CONTROL MODULE 3 WIPER WASHER SWITCH 4 WASHER PUMP ...

Страница 338: ...al System and Instruments DOOR LOCK CIRCUIT PEED LIVE AT ALL TIMES TO INERTIA SWITCH WARNING LIGHT N W NK NK MS J L r N z u s RS RK U 6 n RS RK 1 THERMAL TRIP 2 RELAY 3 LH SWITCH 4 RH SWITCH 5 LH SOLENOIO S RH SOLENOIO ...

Страница 339: ... T Electrical System and Instruments M 18 15 POWER WINDOW CIRCUIT T i i 7 FUSE N 11 LGW SP SG Hri rl M FEED LIVE WHEN IGNITION IS ON LGW 1 LH WINDOW SWITCH 2 RH WINDOW SWITCH SR SU 4 H rl 3 LH MOTOR 4 RH MOTOR r ...

Страница 340: ...M 18 16 Electrical System and Instruments M S FUEL GAUGE CIRCUIT FEED LIVE WHEN IGNITION IS ON FUSE N 5 13 f 3 LGO 1 I GB 1 WARNING LIGHT 2 TANK SENDER UNIT 3 FUEL GAUGE ...

Страница 341: ...i 5r WW Electrical System and Instruments M 18 17 RADIO CIRCUIT pw LGW P L I J FEED MAIN RELAY LIVE WHEN IGNITION IS ON FEED LIVE AT ALL TIMES I 7 RADIO 2 RH SPEAKERS 3 LH SPEAKERS 4 IN LINE FUSES i ...

Страница 342: ...DOOR MIRROR CIRCUIT FUSE N 9 FEED LIVE WHEN IGNITION IS ON 1 9 9 WP WN LGW W WG fT R WR I WN WU U3VV A W LGW AM l 1 MIRROR SWITCH 2 LH MIRROR 3 RH MIRROR 4 MIRROR HEATER IF FITTED ...

Страница 343: ...Electrical System and Instruments M 18 19 AIR CONDITIONING CIRCUIT ALL EARTH CABLES BLACK Y H F J wi to 2 2 uF KLG KG 13 N J N 1 r i i 12 Ls H X zLGW 3_T N h x 16 RO 17 0 1 pF ...

Страница 344: ...M 18 20 Electrical System and Instruments TRUNK LIGHT CIRCUIT FEED LIVE AT ALL TIMES FUSE N 12 JL 2 PW r 1 TRUNK LIGHT 2 SWITCH V j ...

Страница 345: ...Electrical System and Instruments M 18 21 ENGINE COMPARTMENT LIGHT CIRCUIT Pf 5j f wv 1 J fWW FEED LIVE AT ALL TIMES FUSE N 12 t JL PW P W i P W J JIM 1 ENGINE COMPARTMENT LIGHT 2 SWITCH p B ...

Страница 346: ...M 18 22 Electrical System and Instruments HEATED REAR SCREEN CIRCUIT FEED LIVE WHEN IGNITION IS ON FUSE N 9 LGW W8 v I 2 37 1 H R W SWITCH 2 RELAY 3 HEATED REAR SCREEN 4 INOICATOR LIGHT ...

Страница 347: ...Electrical System and Instruments M 18 23 p i MAIN WIRING CIRCUIT jlfaj J vvtfl ffWrft ...

Страница 348: ... p yvv f R r on wo w i ITUEI B W 4 r f 2 6 Labi i f r Mi i j ru w _ J JHil 0 0 0 rSjrfr l 16 10 10 10 aJHS Q 109 4 J 179 n j iliaT 132 nW 107 ssJ 152 r 1 73 J iw a 0 1 0 1 III _ 192 M I X s i Q9 dLr 1 tab 216 02 3 u J 9 V P u P U PU 1 i i i H P i fjq 4 H n s J _ T i i n 1 M I T 24 ...

Страница 349: ... 01 01 SPECIAL TOOLS N 02 01 MAJOR COMPONENTS N 03 01 SAFETY PRECAUTIONS N 04 01 LEAK TESTING N 05 01 PRESSURE CHECKING N 06 01 EVACUATING DEHYDRATING AND CHARGING N 07 01 COMPONENT REMOVAL AND INSTALLATION N 08 01 HEATING AND FAULT DIAGNOSIS N 09 01 COMPRESSOR N 10 01 ...

Страница 350: ...tioning system is of the cycling clutch orifice tube type This uses a pressure sensing switch to prevent evaporative freeze up by cycling the compressor on and off Heating is controlled by the amount of air flow through the heater core and this flow is controlled by the temperature control knob Humidity cleanliness and direction of air flow are all controllable through a system of vacuum operated ...

Страница 351: ...te moulding fixed to the rear of the unit and contains a horizontally pivoted flap which either shuts off the face level vents or closes a bridging duct connecting with the screen vent Fig 2 All flaps with the exception of the temperature flap are vacuum operated via diaphragm activators The temperature flap is cable operated direct from the temperature control knob The heater air conditioning sel...

Страница 352: ... Fig 2 The temperature control should be turned to cold The vacuum supply is sealed off and the switch contacts isolated The flaps assume the positions shown whilst both the compressor and fan speed switch are inoperative Ventilation is provided via the footwells and also to the screen and door vents Fig 2 ...

Страница 353: ...d Air is drawn by the fan from the interior of the car through the re circulation vent and in this way is constantly re circulated through the evaporator thus rapidly pulling down the temperature inside the car A certain amount of fresh air is however drawn through the fresh air vent in order to prevent stale air within the car The refrigerated air is supplied to the door vents and face level vent...

Страница 354: ... control should be returned to full cold Vacuum is supplied to the lower mode flap and the upper mode flap and face level vent flap The compressor and fan speed switch are energised Refrigerated fresh air is supplied to the door vents and face level vents Fig 4 ...

Страница 355: ...y to the upper mode flap and face level vent In this way refrigerated fresh air is supplied predominantly to the door vents and face level vents whilst de humidified warmer air is supplied predominantly to the footwells with a small bleed off to the screen vent Adjustment of the temperature control varies the temperature accordingly Fig 5 The compressor and fan speed switch are energised v r 1 ...

Страница 356: ...rature control should be turned to full cold Vacuum is supplied to the lower mode flap and also the upper mode flap and face level vent The compressor is switched off with only the fan speed switch being energised Fresh air at ambient temperature is supplied to the door vents and face level vents Fig 6 ...

Страница 357: ...d off and current is supplied only to the fan speed switch As the temperature control is turned towards the maximum setting the temperature flap directs an increasing proportion of air through the heater matrix which then flows to the footwells with a small bleed off to the screen and via the bridging duct to the door vents Fig 7 ...

Страница 358: ...l should be turned to maximum heat the fan to speed 4 and the door vents closed off at each door Vacuum is supplied only to the screen flap and the current to the fan speed switch Heated air is supplied to the screen vent with a small bleed off to the footwells and via the bridging duct to the door vents Fig 8 ...

Страница 359: ... and Thermistor Vacuum Gauge Leak Detector Core Removers 2 required Thermometers 2 required PART NO 95301 Fig 9 14950 Fig 10 14650 Fig 11 40859 Fig 12 10735 Fig 13 Compressor Clutch Kit 23 Int Snap Ring Pliers 14163 Fig 14 24 Ext Snap Ring Pliers 14164 Fig 15 Orifice Tube Remover 10960 Fig 16 Broken Orifice Tube Remover Safety Goggles 10962 Fig 17 12008 Fig 18 F p 95301 SERVICE STATION S ...

Страница 360: ...OVER rrmrm Fig 16 HT 10962 BROKEN ORIFICE TUBE REMOVER uiU mrv IUl i Fig 17 14650 CORE REMOVERS Fig 14 Fig 11 40859 THERMOMETERS Fig 12 SNAP RING PLIERS 14163 23 Internal Field Pliers 14164 24 External Field Pliers Fig 15 12008 SAFETY GOGGLES Fig 18 ...

Страница 361: ...Heating and Air Conditioning N 02 03 Fig 13 10735 COMPRESSOR CLUTCH KIT ...

Страница 362: ...VfQ r v Heating and Air Conditioning N 03 01 4 WSf d m MAJOR COMPONENTS P9 EVAPORATOR ACCUMULATOR DRYER J CONDENSER SI COMPRESSOR 75 ...

Страница 363: ...lt into the dash controls or by a cycling switch which senses cooling conditions at the evaporator Orifice Tube Assembly Rg 21 This assembly which replaces the thermostatic expansion valve meters the liquid refrigerant from the condenser to the evaporator It is dependent on pressure differential and subcooling When both the head pressure and subcooling increase at the same time the orifice flow ra...

Страница 364: ...um or steel and mounting provisions Evaporator Fig 24 The evaporator is mounted within the A C box behind the dashboard using the fans to absorb the heat from within the car and transferring it to the liquid gas within the pipes Accumulator Fig 25 The accumulator dehydrator separates the liquid refrigerant from the vapor The liquid will remain in the cylinder while the vapor passes on into the com...

Страница 365: ...t rub them Splash the eyes or the affected area with large quantities of cold water for several minutes If further medication is necessary the affected area should be checked and treated by a physician ALWAYS EXHAUST REFRIGERANT VAPORS AWAY FROM CAR OR THROUGH WALL OR ROOF VENTS While Refrigerant 12 is normally not poisonous if large quantities are discharged in a room with an open flame or sucked...

Страница 366: ...lows the service technician to diagnose any faults on the refrigeration side of the system also to evacuate and dehydrate and recharge the R 1 2 into the system without disconnecting i e allowing air and moisture into the system Note safety precautions when handling R 12 Fig 27 28 Note Reference to colour coded hoses may only apply to DMC Service Tool No 95301 Extreme caution to be observed that c...

Страница 367: ... this point hoses can be connected and service to the air conditioning system performed 6 Reverse procedure to replace Schrader valve cores 7 CAUTION Remove hose connections slowly to allow any refrigerant in hose to escape LEAK TESTING 1 Connect station to car See Section N 06 01 2 Read pressure on gauges if over 60 p s i Start leak check with Leak Detector 14950 To use 14950 switch on instrument...

Страница 368: ...ressor Right hand connection 8 Check static pressure on gauges Suspect leak on system 9 Start engine A C on max cool max fan speed 10 Check clutch is operating 11 Read pressures on station gauges AMBIENT DEGREE F 70 80 90 100 110 120 130 COMPRESSOR OUT PRESSURE PSI 125 150 145 190 170 200 190 230 220 250 245 275 265 300 AD PRESSURE PSI 25 32 25 32 25 32 25 32 26 33 28 35 30 37 12 If pressures corr...

Страница 369: ... to be worn Handle refrigerant with care Well Ventilated Area 1 Valves on D A C closed 2 Connect white hose from left hand valve 2 Fig 33 to liquid connection on bulk supply 3 Crack valve on bulk supply Loosen connection on D A C till slight hissing heard tighten connection This is to purge the hose of any air 4 Open valve 2 Liquid flow into cylinder visible in sight g c s until bulk tank and D A ...

Страница 370: ...ant out tap on the charging cylinder 3 Open the high pressure Red tap and allow 14 lb refrigerant to enter system Close the high pressure Red tap Close outlet valve on D A C A high volume fan can be placed to blow the air over the condenser This will help to keep the refrigerant in a liquid form and therefore cut down the charging time Disconnect and bridge LP switch at accumulator Hand brake on t...

Страница 371: ...refer to N 07 01 2 Drain 10 pints of coolant from cooling system 3 Remove central control console refer to Body Section 4 Remove duct between unit and left hand crash pad 5 Release glove box securing screws unscrew glove box lamp bulbholder and release wires from micro switch Pull out glovebox 6 Release four screws securing re circulation vent flap Disconnect vacuum pipe and remove flap 7 Disconne...

Страница 372: ...umulator mounting bracket from the body if necessary 15 From inside re circulation vent aperture release screws securing fan housing to body 16 Remove bracket securing heater air condition ing unit to tunnel top 17 Withdraw footwell duct from under heater air conditioning unit 18 Disconnect plain black vacuum supply pipe from port 1 of the selector switch plug and disconnect the black and orange w...

Страница 373: ...L ALL DIMENSIONS REFER TO WRENCH SIZES 32 mm HOSE NUT FEMALE THREAD u a n 27 mm INTEGRAL NUT MALE THREAD 22 mm HOSE NUT FEMALE THREAD TO COMPRESSOR I D 3 3 CO Q 3 Q o O 3 a o 3 3 CO J _1 1 J ...

Страница 374: ...h 7 Re fit de mist duct to top of heater air conditioning unit 8 Secure de mist duct with two screws 9 Re fit distribution chamber 10 Secure chamber with four screws 11 Insert glove box in body aperture 12 Secure with screws re fit glove box lamp bulb holder and connect wires to micro switch 13 Connect black ground wire to spade terminal attached to fan casing 14 Connect pink black wire to insulat...

Страница 375: ...re flap to remove heater core INSTALLING HEATER CORE 1 Remove old sealant from around the joint face on both temperature flap carrier and the heater casing 2 Insert heater core into temperature flap carrier and secure with clamp and screw 3 Apply a uniform bead of sealant around joint face of temperature flap carrier and heater casing 4 Insert the carrier into the casing 5 Secure with four screws ...

Страница 376: ... front wheel 4 Pull back protective boot from accumulator low pressure switch and disconnect leads from spade terminals 5 Using two wrenches disconnect compressor hose from bottom of accumulator and cap both connections immediately 6 Release the accumulator mounting bracket from the body 7 Remove access cover at the back of the spare wheel well to gain access to evaporator accumulator top connecti...

Страница 377: ...m carrier h i i 3 With the aid of two spanners tighten the connection INSTALLING TEMPERATURE FLAP To install the flap reverse the removal procedure J 4 Ensure the compressor hose connections are scrupulously clean and coat both connections and new 0 ring with a recommended refrigeration oil NOT ANY OTHER LUBRICANT before connecting to the bottom port on the accumulator 5 With the aid of two spanne...

Страница 378: ...r I Heating and Air Conditioning p7 l f q ...

Страница 379: ...ystem is de pressurized and disconnect condenser hoses using two wrenches of the correct size Cap the ends of the hoses and the condenser connections immediately after disconnection 3 Remove screws securing air duct to body 4 Remove nuts and bolts securing air duct to spoiler 5 Remove the nut washer and rubber buffer securing each radiator lower support bracket to the radiator 6 Remove three bolts...

Страница 380: ...nut to secure bracket to radiator ensuring that rubber buffers are fitted on each side of bracket 7 Repeat to fit left hand bracket Do not overtighten the 17 mm radiator nuts 8 Fit left hand upper support bracket and secure to radiator with nut 9 Fit bolt to secure bracket to chassis 10 Repeat for right hand brackets 11 Fit securing screws to attach air duct to body and spoiler 12 Re connect hoses...

Страница 381: ...Heating and Air Conditioning 3 it Fig 47 ...

Страница 382: ...TS ...

Страница 383: ...rom periphery of evaporator casing 4 Separate the two halves of the casing 5 Remove the evaporator 5 Apply a uniform bead of sealant to the joint face of the evaporator casing 6 Bring the two casing halves together and secure with four screws REMOVING V A C U U M RESERVOIR Fig 50 The Reservoir is located in the LH rear pontoon with access via the charcoal canister aperture p H p i INSTALLING EVAPO...

Страница 384: ...emove the brake master cylinder access cover and fuel filler neck cover 6 Remove the steering column upper universal joint pinch bolt Slacken lower universal joint to column pinch bolt and slide lower column into lower universal joint and off upper steering column refer to Steering Section 7 Remove two nuts securing brake master cylinder to servo and separate Support the master cylinder clear of t...

Страница 385: ...ue red VENT 0 3Qe if S 2 T VAC I VAC I VAC VAC SEAL 1 t IvENT VENT VENT VENT VENT i VAC VAC VAC VAC i i 8 j VAC VENT VAC VENT VACUUM SWITCHING ELECTRICAL CONNECTIONS 1 i 1 I i i CONNECTION SUPPLY COMPRESSOR FAN SPEED SWITCH i WIRE COLOUR 0 r i I SELECTOR POSITION llii lim 2 2 F yLS JL A yL yi yi 9 Sfr fr Sw Sjr i r r _ _ Sw S r T Sw Sw DEFROST HEATER VENT BI LEVEL NORM MAX O F F 1 1 1 ...

Страница 386: ...N 08 16 Heating and Air Conditioning r wj psi t ffg 52 ...

Страница 387: ... body down onto frame checking for entrapment of wires etc 3 Re fit body mounting bolts in front luggage compartment at front and rear either side of centre tunnel above rear spring platforms and inside rear pontoons 4 Re connect compressor hose to accumulator a n d o r condenser ensuring that the connections are scrupulously clean and coating the joints and threads with refrigeration oil NOT ANY ...

Страница 388: ...ds immediately 3 Release condenser hose from evaporator using two wrenches and cap ends immediately 4 Release all hose ties and remove hose from car INSTALLING CONDENSER EVAPORATOR HOSE 1 Feed hose across front of chassis frame as removed 2 Ensuring scrupulous cleanliness of accumulator and hose joint coat new joint 0 ring and connector threads with refrigeration oil NOT ANY OTHER LUBRICANT 3 Ensu...

Страница 389: ...ension by slackening tension screw 3 Roll belt off compressor pulley N 08 19 4 Fit the new belt over the pulleys and tighten the tension screw until the belt may be deflected 6 10 mm V i from the straight line using moderate thumb pressure between crank and upper jockey pulley 5 Tighten tension screw lock nut and adjuster clamp screws and re check belt tension Run the engine briefly switch off and...

Страница 390: ...N 08 20 Heating and Air Conditioning v J l nil zi _ r i CP F p 59 ...

Страница 391: ...p bolt spacers are fitted as shown 4 Tighten the tension adjusting screw until the belt may be deflected 6 10 mm from the straight line using moderate thumb pressure between the crank and upper jockey pulley 5 Tighten tension screw lock nut and adjuster clamp screws and re check belt tension Run the engine briefly switch off and re check belt tension f f F l ...

Страница 392: ...32 38 43 49 55 High Side COMPRESSOR OUT PRESSURE PSI 100 110 125 150 145 190 170 200 190 230 220 250 245 275 265 300 Low Side PRESSURE PSI 20 25 25 32 25 32 25 32 25 32 26 33 28 35 30 37 AC DISCHARGE DEGREE F C 34 38 34 38 34 38 35 39 38 42 40 44 43 47 46 50 1 3 1 1 3 1 3 2 4 3 5 4 7 6 8 8 10 Temperatures and Pressures to be taken when Clutch cuts out r ...

Страница 393: ...vice Manual Check visually for compressor clutch operation ENGAGED OR CYCLING MPRESSOR OFF Proceed to w Continue OFF ALL TIMES Feel liquid tine in front of expansion tube Feel evaporator inlet and outlet pipes Restriction in high side of system Visually check or frost spot to locate restriction Repair evacuate and re charge y INLET PIPE COLDER THAN OUTLET PIPE INLET AND OUTLET PIPES SAME TEMPERATU...

Страница 394: ... AS PER CHART Change blower speed to low observe accumulator and evaporator pipes for frost NO FROST FROST Check accumulator pressure as per chart T LOW Plugged expansion tube Repair or re place Evacuate and re charge NORMAL TO HIGH Check compressor cycling T CYCLES ON AND OFF1 Defective pressure switch Replace ON CONTINUOUSLY I Check for missing expansion tube T hMISSINGI Install expansion tube E...

Страница 395: ...ollowing for open circuits Low pressure switch High pressure switch T O K _L OPEN Replace defective part F Check low charge pressure switch for open circuit T OPEN CLOSED OR O K Look for broken wire or loose connection in clutch circuit Repair as necessary Wiring Diagram I Check refrigerant pressure at high side service fitting T BELOW 50PSIG AT60 F Low charge Leak test and repair Evacuate and re ...

Страница 396: ... Apply external vacuum source to defroster vacuum element Feel for change in airflow CHANGE NOBB CHANGE Check for binding defroster linkage BINDING Adjust or repair defroster linkage NOT BINDING 1 Repair vacuum circuit Install new vacuum element Move temperature lever rapidly back and forth from max cold to max heat Listen for temperature door hitting at each end T HITTING NOT HITTING Adjust or re...

Страница 397: ...Heating and Air Conditioning N 10 01 COMPRESSOR J r i 19 Li ...

Страница 398: ...nose System 1 Check Belt Tension 2 Check Clutch Air Gap Check Clutch Volts Amps J Coil Lead Wire 4 Shaft Turning Smoothness Test m Check Compressor Mounting Components 2 Check Engine Components Check for Intermittent or Slipping Clutch A Check for Proper 2 Refrigerant Charge 5 Check Clutch Bearing 6 Oil Level 7 Shaft Turning Smoothness Test 8 Remove Valve Plate and Inspect 1 Check Air Gap M Replac...

Страница 399: ... of the compressor indicate a leak requiring repair Note A useful device for finding a shaft seal leak while the compressor is installed Bend a 90 angle making about a 3 A leg on a 12 piece of copper tube Insert the straight end into the detector hose The leg can easily be inserted into one of the clutch front plate holes OIL CHECK PROCEDURES Whenever a system component has been replaced or there ...

Страница 400: ... be good reason to suspect an incorrect oil level or it is specified in a diagnosis procedure to check the oil follow these steps Step 1 Run the compressor for 10 minutes at engine idle RPM Step 2 Recover all Refrigerant 12 from the system Be careful not to lose oil Step 3 Proceed with Steps 1 through 7 in Procedure A above SHAFT TURNING SMOOTHNESS TEST Compressor Installed Step 1 Disconnect refri...

Страница 401: ...in Alternator bearing Air pump if any Water pump bearing Engine valves Timing mechanism Loose engine mounting bolts J Refrigerant Charge A 0 5 psig or lower suction pressure due to a low refrigerant charge can cause unusual noise Restore refrigerant to proper level Re test by applying heat to evaporator for higher suction pressure Clutch Bearing See Clutch Test Oil Level Insufficient oil can cause...

Страница 402: ...aft Thumb tighten the three puller bolts into the threaded holes Turn center bolt clockwise with 19 mm socket until front plate is loosened Fig 68 Note Steps 1 and 2 must be performed before servicing either the shaft seal or clutch assembly Step 3 Remove shaft key by lightly tapping it loose with a slot screw driver and hammer Fig 69 Step 4 Remove the internal bearing snap ring by using snap ring...

Страница 403: ...or Puller set over the exposed shaft Fig 72 Align thumb head bolts to puller jaws and finger tighten Fig 73 Turn puller center bolt clockwise using socket until rotor pulley is free Figs 74 75 Step 7 Remove field coil Loosen coil lead wire from clip on top of compressor front housing Earlier models do not use this clip Fig 76 Using snap ring pliers Spread type remove snap ring and field coil Fig 7...

Страница 404: ...Make certain the outer edge rests firmly on the rotor bearing outer race Place the tool set driver into the ring as shown Fig 79 With a hammer tap the end of the driver while guiding the rotor to prevent binding Tap until the rotor bottoms against the compressor front housing hub Listen for a distinct change of sound during the tapping process Fig 80 Step 3 Reinstall internal bearing snap ring wit...

Страница 405: ...accessory sack If the air gap does not meet the specification in Step 7 add or subtract shims by repeating Steps 5 and 6 SHAFT SEAL SERVICE Steps for Shaft Seal Removal Step 1 Repeat Steps 1 and 2 in Clutch Removal Section N 10 09 Step 2 Refer to Figures 85 86 Shaft seal replacement should be done on the bench Never use any old parts of the shaft seal assembly Renew the complete assembly A felt ri...

Страница 406: ... H A F T SEAL R E P L A C E M E N T Step 1 Clean seal cavity thoroughly Clean with R 11 or R 12 Blow out with dry pressurized vapor Clean thoroughly with a lint free or synthetic cloth and clean refrigerant oil Then blow out with dry pressurized vapor M a k e sure all foreign substances are thoroughly removed Step 7 Use the 0 ring hook to remove the shaft seal 0 ring Be careful not to scratch the ...

Страница 407: ...nt oil Place carefully in the seal groove with 0 ring hook Do not scratch surface Fig 91 Step 6 Coat seal retainer with clean refrigerant oil Use tongs to install Press lightly against seal Fig 92 Step 7 Re install snap ring Beveled edge lies outward away from compressor Flat side lies toward compressor It may be necessary to lightly tap the snap ring to securely position it in its groove Fig 93 S...

Страница 408: ...actory operation depends on sufficient lubrication Too much oil decreases cooling efficiency Step 1 Disconnect both hose connections to the compressor Step 2 Remove and discard the Receiver Drier Installation Tips Step 3 Connect the R 1 1 container at the d i s c h a r g e hose c o n n e c t i o n and a l l o w approximately one pound of R 1 1 to enter the discharge side of the condenser Trouble f...

Страница 409: ...Heating and Air Conditioning N 10 13 AIR CONDITIONING WIRING DIAGRAM J f VJ Fig 95 0 1 pF ALL EARTH CABLES BLACK ...

Страница 410: ... 1 N 10 14 Heating and Air Conditioning f WH H D O W LU z cc z Q z LU X r rr n i Fig 96 pr ...

Страница 411: ...ra i CONTENTS GLASS REINFORCED PLASTIC P 01 01 STAINLESS STEEL P 02 01 INTERIOR P 03 01 J Fnff J Ff ...

Страница 412: ...ous strand glass mat and polyester type 5567C 8226 resin The two halfs are bonded together to form an exceptionally strong rigid structure Fig 2 sections of which may be replaced or repaired using conventional fibre glass repair methods The body assembly is drilled to accept riv nuts which provide attachment points for the stainless steel body panels Fig 1 ...

Страница 413: ...d the direction of impact and examine all areas which may have been affected To facilitate a closer examination it may be necessary to remove parts and components to determine the extent of the damage Where the repair of a damaged vehicle calls for replacement sections or panels it is recommended that STANDARD SECTIONAL REPAIR MOULDINGS are used Standard sectional repair mouldings cater for the re...

Страница 414: ...ing chopped strand glass fibre mat of 1 sq ft 450 g m2 weight together with pre accelerated hand lay up polyester resin containing approximately 2 of Trigonox 51 Akzo Chemie Acetyl Acetone Peroxide Catalyst lay up 3 layers of the glass mat wevon wet to the abraided interior joint 6 Stagger the three layers to overlap each side of the joint by 35 mm 55 mm 75 mm respect ively Do not stray onto any u...

Страница 415: ...at and resin then sand to contour CAUTION The Styrene fumes given off due to catalytic action are hazardous to health and also highly flammable Therefore extreme caution should be taken when carrying out any G R P repair Goggles and protective clothing should be used at all times In the event of Resin or catalyst entering the eyes quick medical attention is essential G R P repairs must be carried ...

Страница 416: ...ld in the open position by the use of gas struts The Gull Wing Doors open in less space than conventional doors and gives easier access to the interior to the car The drag coefficient of the car is 0 35 Rear louvres were incorporated to improve the overall aerodynamic drag and conserve fuel The front and rear fascias are made of premoulded impact absorbing polyurethane The fascias blend with the s...

Страница 417: ...l along rear edge of fender Remove two retaining screws 11 Remove three screws securing rear edge of fender to door filler panel 12 Carefully remove finisher seal over top edge of fender inside luggage compartment 13 Remove nine screws securing top edge of fender inside luggage compartment 14 Remove fender Note When performing a fender replacement it is necessary to replace body side mouldings Ins...

Страница 418: ... rear fascia reinforcement brackets to rear body pontoons 4 Ease back end of rear fascia and remove four screws securing rear edge of fender to pontoon bracket 5 Raise car on hoist 6 Remove rearmost six screws securing lower edge of rocker panel to body 7 Remove screw inside wheel opening securing fender to rocker panel 8 Pull back lower edge of rocker panel and remove screws securing fender to po...

Страница 419: ...cates in rear fascia panel groove 3 Install bolt securing fender to valance inside wheel opening 5 4 Install two nuts and bolts securing lower edge of valance to body bracket ROCKER PANEL LEFT OR RIGHT Removal 1 From inside front and rear wheel openings remove one bolt securing fender to rocker panel 2 Remove bolts securing rocker panel to lower edge of body 3 Pull downward to release top edge cli...

Страница 420: ...t A post finishers reveal mouldings 3 Remove windshield header panel Installation Reverse Removal Procedure DOOR SEALS AND STRUTS OUTER DOOR SEAL Remove outer door seal Installation 1 With solvent remove the old adhesive from door seal mounting surface 2 Position and secure new outer door seal with specified adhesive INNER DOOR SEAL Removal and Installation 1 Carefully pull off inner door seal wor...

Страница 421: ...ket 7 While holding torsion bar in position remove the two restraint bracket retaining screws 8 Pull restraint bracket off torsion bar spline and release torque on torsion bar 9 Pull torsion bar out of front door hinge and remove 10 Remove four screws and door wiring harness cover plate from roof channel 11 While assistant supports door disconnect gas strut from door pivot bolt 12 Remove front and...

Страница 422: ...balancing torque counterclockwise for RH door clockwise for LH door to unload the rear restraint bracket 6 Hold torsion bar in balancing position and remove two restraint bracket retaining bolts 7 Remove restraint bracket from torsion bar spiine release balancing torque on torsion bar 8 Remove torsion bar from hinge and roof section 9 If the rear hinge is to be removed with the aid of an assistant...

Страница 423: ...fracture and fail 4 With the aid of an assistant support the door in the fully open position until the torsion bar is removed 5 Use torsion bar pre load tool 3 a tool alien and apply balancing torque counterclockwise for RH door clockwise for LH door To unload the torsion bar restraint bracket bolts are removed and the bracket is withdrawn from the torsion bar splines ...

Страница 424: ...o roof may result in rear window breakage DOOR ALIGNMENT Note Hinge height is adjusted by shims mounted horizontally between hinge and roof while lateral adjustment is by shims mounted vertically between hinge and roof channel Only one hinge should be adjusted at a time 1 Determine which hinge requires adjustment and in which direction 2 Raise and support door with a proper brake while re aligning...

Страница 425: ...e door assembly 5 Pry loose the retaining clips securing the lower edge of the trim panel 6 Pull trim panel away from the door to gain access to the door pull handle mounting bracket Using a long Phillips screwdriver remove two screws securing the door pull handle to its mounting bracket Remove the lower trim panel 7 Peel back inner door plastic water shield to gain access to door latch rods 8 Dis...

Страница 426: ...bellcrank 14 Secure adjustment with control cable lock nut Lift exterior release handle and check front and rear latch release adjustment Note If latches do not open with handle fully raised slowly shorten control cable adjustment to remove any slack Too much adjustment pre load will cause door locks to jam 15 Check door lock adjustment 16 Position and secure interior release handle and locking le...

Страница 427: ...mounting bracket 2 Position and secure interior rear trim panel 3 Position and secure rear quarter panel to filler panel 4 Raise vehicle on hoist 5 Install screws securing rear quarter panel ro underbody 6 Position and secure rocker panel 7 Lower vehicle on hoist 8 Position and secure outer door weather strip with specified adhesive 9 Position and secure striker pin to alignment mark 10 Close door...

Страница 428: ...sition 2 Install nuts to locate each hinge cover but do not tighten fully at this stage 3 Locate struts on cover ball joints and insert retaining clips 4 Lower cover and adjust for alignment tightening hinge bolts when correctly aligned Use previously made reference marks where applicable 5 Reconnect luggage compartment light Install grille 6 Check operation of luggage compartment cover catch and ...

Страница 429: ...ch cover ENGINE COMPARTMENT COVER Removal 1 Open rear window sunshade louvre 2 Open engine compartment cover 3 Remove nuts securing both left and right hinges to cover Remove cover 4 Remove left and right stops from engine cover 5 Remove sunshade louvre and engine compart ment cover striker 6 Remove all engine compartment vents and retaining strips Installation 1 Secure anti rattle strips around a...

Страница 430: ...ounting bracket located in rear of passenger compartment 3 Connect latch to cable and re position latch with alignment mark Secure to rear fascia reinforcement 4 Position and secure cable to rear fascia reinforcement Adjust and tighten cable adjustment lock nut 5 Close engine compartment cover Check alignment Pull release handle and check operation If necessary reset cable adjustment 6 Position an...

Страница 431: ...nshade to hinges 3 Remove sunshade and place on workbench Remove two sunshade grilles latch assembly and both gas strut mounting balls Installation 1 Transfer all parts to replacement sunshade assembly 2 With the aid of an assistant position and secure sunshade to both hinges 3 Connect both gas struts Slowly close sunshade and check alignment and latch operation Adjust as necessary 1 I 1 1 7 ...

Страница 432: ...d reinforcement Installation 1 Install fascia reinforcement and retainer strip into replacement fascia 2 With the aid of an assistant position fascia over headlamps and front end impact absorber Note Front fascia to front end panel assembly fit should be as close as possible To accomplish this some front fender and hood alignment may be necessary It may also be necessary to perform some fascia rew...

Страница 433: ...htened 11 If the end of the fascia extends out past the fender it will be necessary to install a plate over the unused stud on the inside of the fascia at both ends Place long end of plate inside fender flange with the stud protruding through the hole in the plate Place a 6 mm nut on the stud and tighten until fascia is flush with the fender If the fascia will not pull in the front edge of the fen...

Страница 434: ...cense plate lamp assemblies 3 Install nine screws securing top edge of fascia to reinforcement panel 4 Working through tail lamp openings loosely install nuts securing each side of fascia to reinforcement panel Note It may be necessary to place shims between the fascia and reinforcement panel for proper fascia to fender alignment See rear fascia alignment procedures 5 Install seven nuts securing l...

Страница 435: ......

Страница 436: ...ld screw holes 6 Notch fibre glass reinforcement where quarter panel bracket makes contact on both outer ends 7 Allow rear fascia to return to its original position and check for fit 8 Trim edges of fascia at 45 angle with edge no thicker than to fit rear edge of quarter panel 9 If quarter panel has not been secured with a 6mm bolt at the top bracket remove screw and re position quarter panel as n...

Страница 437: ...ower interior door trim panels 2 Partially lower power window to allow access to two nuts securing window regulator arm to window carrier Remove nuts 3 Disengage window carrier from window regulator arm Pull the window assembly off the front and rear guide channels and remove Installation 1 Reverse removal procedure WINDSHIELD REPLACEMENT Removal 1 Cover the car s interior fenders and luggage comp...

Страница 438: ......

Страница 439: ... at least six hours after installation Fill leaks with Betaseal if necessary 6 Let Betaseal dry approximately six hours at a constant room temperature then clean and trim excess with a razor blade knife 7 Position and secure windshield rear view mirror 8 Position and secure cowl screen 9 Position and secure windshield header panel and retainer 10 Position and secure left and right A post finisher ...

Страница 440: ...glass and door assembly This must be done while polyurethane is still wet Let polyurethane dry for approximately six hours at a constant room temperature 5 After polyurethane is dry it can be cleaned and trimmed with a razor blade scraper 6 Position and secure door assembly 7 Raise and lower power window to check alignment Adjust power window inner door guides if necessary 8 Position and secure in...

Страница 441: ... cleaned and trimmed with a razor blade scraper 6 Position and secure rear quarter panel POWER W I N D O W UPPER CHANNEL GUIDE Installation 1 Using glass primer 2 apply a bead 12 7mm Vi wide on both sides of the fixed glass along the perimeter where the power window channel is to be installed Let primer dry approximately 15 minutes 2 Apply poiyurethane adhesive 16411 to the locating edge of the ch...

Страница 442: ... lighter and rocker switch connectors Remove console 10 Place console on work bench and remove four nuts securing upper panel to new console REAR QUARTER TRIM PANEL Removal 1 Remove inner door seal from rear of door opening 2 With the use of heat gun carefully unstick quarter panel trim from around door filler panel flange 3 Carefully unstick carpet from around lower edge of quarter panel 4 Remove...

Страница 443: ...ring lower trim panel mounting bracket to door assembly 3 Pry loose the retaining clips securing the lower edge of the trim panel 4 Pull the trim panel away from the floor to gain access to the door pull handle mounting bracket Using a long Phillips screwdriver remove two screws securing the door pull handle to its mounting bracket Remove the lower trim panel 5 When working on the left door remove...

Страница 444: ...ner into roof panel retaining clips 3 Position and secure both left and right sunvisors 4 Spread an even coat of specified adhesive along roof panel where the headliner material will be secured 5 Pull headliner maferial tight position over roof panel and apply a firm pressure to secure material to adhesive Note Be very careful not to create any wrinkles in headliner material 6 Position and secure ...

Страница 445: ...el where headliner material will be secured Note Be very careful not to create any wrinkles in headliner material 3 Pull headliner material tight position over roof 4 Position and secure left and right inner door panel and apply a firm pressure to secure seals material to adhesive ...

Страница 446: ...CONTENTS GENERAL DESCRIPTION CHASSIS DIMENSIONS CHASSIS FRAME IMPACT TUBE REPLACEMENT R 01 01 R 02 01 R 03 01 J l ...

Страница 447: ...ank is housed behind the front suspension crossmember The centre box section houses the gearchange mechanism and also provides an extremely rigid platform for the G R P body shell Thre rear section of the assembly houses the engine transmission and rear suspension The entire chassis frame is thickly coated with an epoxy coating to protect it from the elements Should the chassis be damaged due to i...

Страница 448: ...Chassis R 02 01 DIMENSIONS L ...

Страница 449: ...R 02 02 Chassis FRAME DIMENSION REFERENCE POINTS J ...

Страница 450: ...Upper Mounting Centres Front Body Mounting to Front Shock Absorber Top Mounting Front to Rear Body Mountings Rear Body Mountings to Rear Top Shock Absorber Mounting Rear Top Wishbone Inner Mounting To Rear Body Mounting Datum Line to Top of Chassis Rear Extension Datum Line to Top of Rear Suspension Tower Centre Line of Rear Damper Top Mounting to Rear of Frame Rear Radius Arm Centre Line to Rear ...

Страница 451: ...r Chassis R 03 01 n IMPACT TUBE REPLACEMENT V I ...

Страница 452: ... T ...

Страница 453: ...ackets and tie rod ends 13 Remove steering rack 14 Using an air chisel high speed rotary grinder or metal saw remove damaged front chassis impact extension Note Do not put into parent metal 15 Grind all surfaces to be welded flush with parent metal allowing approximately inch to 1 inch of clean metal at points to be welded Note Do not use oxyacetylene cutting torch 16 Attach alignment tool jig J 3...

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Delorean DMC, Руководство по ремонту

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